Solo Uno v2 Slu0722 5832 Usermanual

SOLO UNO_v2 User Manual
Part Numbers: SLU0722_5832 , SLU0722_5845
Product Description Power Range
SOLO UNO_v2 is a member of the SOLO Supply Voltage Range: 8- 58 VDC

motor controllers family of devices capable of
driving and controlling various types of Continuous DC Current: 32 ADC / 45 ADC
electrical motors like DC brushed, BLDC, Continuous AC Current: 22.5 Arms / 32 Arms
PMSM, AC Induction and EC coreless motors
in a single platform.They are made to be easy
to use with state of art technologies and Dual
Core parallel processing architecture on top of
FOC control methods.
They offer both sensor-based and sensor-less
options for Speed, Torque and Position
controlling plus other options like full digital
and analog controls and active safety
measures to keep the applications safe from
unforeseen behaviours, SOLO UNO comes
with two versions of 32A and 45A.
Features
● Easy to use ● Field Oriented Controls with Nested

● Drives and Controls DC, BLDC, PMSM, Position-Speed-Torque loops
EC coreless and ACIM motors ● Dual Core with Parallel Processing
● Closed-loop and Open-loop controls Architecture
● Speed, Torque and Position control ● Reverse Polarity, Bus over-voltage, Bus
● Sensor-based and Sensor-less control under-voltage, over-current and
● Four Quadrant Regenerative operation over-temperature protections
● Automatic parameter Identification ● Active Brake Chopper circuitry
and self-tuning ● Full Digital and Analogue Control
Modes of Operation Commands and feedback Source
● Analogue or Digital commanding ● 0-5V Analogue/ PWM inputs for Speed or

● Torque Control Torque control
● Speed Control ● Quadrature Encoder input (RS422)
● Position Control ● Hall sensors input
● UART, USB, CANopen
Applications
● Industrial Automation
● Robotics and Traction Units
● Drones
www.solomotorcontrollers.com
May 2024 - Revision V_1.0.10 Copyright © 2022, All right Reversed. SOLO motor controllers.
1
Revision History:
Revision Date Changes Firmware version
V1.0.6 10/02/2021 - First Release 0x000B006
V1.0.7 15/04/2021 - Updating the document for Firmware version 0x000B007

0x000B007
- Introduction of Dual-core
- Sensor connection and calibration enhanced
- The performance of the system updated
V1.0.8 06/09/2021 - Updating the document for Firmware version 0x000B009

0x000B009
- Introduction of new graphics for wiring
- Introduction of CANopen wirings
V1.0.9 15/05/2022 - SOLO UNO_v2 updates added 0x00BB00A
V1.0.10 10/05/2024 - Adding the 45A version specs. 0x0000B020

- P/F pin description changed
- Certification Table updated
- Temperature ratings update per UL61800-5-1
- Matings and connector refernces added
2
Table of Contents
Power Specifications for 32A version: 5
Power Specifications for 45A version: 5
Control and Timings specifications: 6
Thermal Specifications: 7
Mechanical Specifications: 7
Mechanical Dimensions: 8
Absolute Maximum Voltage Ratings: 9
Standards and Conformities: 10
Overview of the product 11
Functional Block Diagram: 12
Theory of Operation: 13
FOC control Architecture in SOLO UNO_v2 for 3-phase Motors: 14
Cascade control Architecture in SOLO UNO_v2 for DC Motors: 15
SOLO’s Interactional Sections: 16
Connectors and Sections: 17
Section 1 - Motor Output 17
Section 2 - Supply Input 18
Section 3 - Analogue Inputs and +5V External Supply 19
Section 4 and 5 - Speed Controller Gains 24
Section 6 - Piano Switch Settings 25
Section 7 - USB Connection 28
Section 8 - Encode/Hall connector 29
Section 9 - Communication Port 31
Section 10 and 11 - Functionality LEDs 33
Section 12 - Power Up LED 34
Section 13 -CAN BUS / UART PINOUT 35
Section 14 - Active Brake Chopper 36
Section 15 - Brake Activation LED 37
Connectors and their Matings Part Number: 38
Analogue versus Digital Control in SOLO UNO_v2 39
Minimum Required Wirings in Analogue Mode: 40
Wiring Legend: 40
BLDC, PMSM Motors _ Sensorless Closed-loop Mode: 41
BLDC, PMSM or ACIM Motors _ Sensorless Open-loop Mode: 42
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AC Induction Motors_ Closed_loop Sensorless Mode: 43

DC brushed Motors_ Open-loop Sensorless Mode: 44
DC brushed Motors_ Closed-loop Sensorless Mode: 45
Standalone Wiring Example (No External Modules): 46
Essential Wiring Example (SOLO UNO_v2 + Arduino UNO) 47
Minimum Required Wirings in Digital Mode: 48
USB Interface Wiring 48
UART Interface Wiring 49
CANopen Interface Wiring 50
Wiring with Incremental Encoders: 51
Wiring with HALL Sensors: 52
Wiring and Setup of Active Brake Chopper: 53
4
Power Specifications for 32A version:

Description Units Values
DC Supply Voltage Range (continuous) VDC 8 to 58
DC Bus Overvoltage Limit VDC 60
DC Bus Undervoltage Limit VDC 8
Maximum Peak Output Current ADC 32
Maximum Continuous Output Current ADC 32
Maximum Continuous Output Current Arms 22.5
Maximum Continuous Output Power W 800
Maximum Peak Output Power W 1500
Internal Bus Capacitance µF 2000
Switching Frequency (output PWM frequency) kHz 8 to 80
Power Specifications for 45A version:

DC Supply Voltage Range (continuous) VDC 8 to 58
DC Bus Overvoltage Limit VDC 60
DC Bus Undervoltage Limit VDC 8
Maximum Peak Output Current ADC 50
Maximum Continuous Output Current ADC 45
Maximum Continuous Output Current Arms 32
Maximum Continuous Output Power W 1200
Maximum Peak Output Power W 1800
Internal Bus Capacitance µF 2000
Switching Frequency (output PWM frequency) kHz 8 to 80
5
Control and Timings specifications:

Analogue Speed or Torque Commands VDC 0-5V Analogue voltages or PWM inputs with
frequency above 5kHz
Digital Direction Control VDC 0 - 3.3/5V
Modes of Operation - Torque - Speed- Position
Motors supported - DC - BLDC - PMSM - EC Coreless- ACIM
Hardware Protections - Reverse Polarity, Bus over-voltage Bus

under-voltage, over-current and over
temperature
Current (Torque) Loop sampling time µs Synched to PWM frequency ( Min 7 µs)
Current (Torque) Loop execution time µs 7
Speed controller Loop sampling time µs 500
Speed controller Loop execution time µs 75
Position controller Loop sampling time µs 500
Position controller Loop execution time µs 75
Maximum Encoder Frequency MHz 18 (Pre-Quad)
6
Thermal Specifications:

Board Temperature Range °C -20 to +120
Heatsink (base) Temperature Range °C -20 to +85
Cooling system - Natural Convection
Mechanical Specifications:

Size (H x W x D) mm 37.17 x 87.15 x 67.10
Weight (with heatsink) gr 99
Form Factor - Wall Mount
7
Mechanical Dimensions:
- All the measurements are in millimetres.

- Download the 3D step model from here.
8
Absolute Maximum Voltage Ratings:

- All The sections are referred to in Figure 3 below
- The +3.3V parts are NOT +5V tolerant, and in case of applying more than 3.3V, the device might get
permanently Damaged.
- The users should refer to “Typical Max” for the maximum voltage allowed on each pin, the “Absolute
Max” is just for very short times considering the effect of spikes and fast harmonics.
Section PIN/Connector name Input / Output Units Min Typical Absolute
Max Max
2 Supply Input Input VDC +8 +58 +63
3 S/T (speed/torque) Input VDC 0 +5.0 +5.5
3 P/F (power/flux) Input VDC 0 +5.0 +5.5
3 DIR (Direction control) Input VDC 0 +5.0 +5.5
3 +5V (External supply) Output VDC +4.95 +5.0 +5.2
8 CHA(Encoder)/HALL_A Input VDC 0 +5.0 +5.5
8 CHB(Encoder)/HALL_B Input VDC 0 +5.0 +5.5
8 Index(Encoder)/ HALL_C Input VDC 0 +5.0 +5.5
9 UART_RX Input VDC 0 +5 +5.5
9 UART_TX Output VDC 0 +3.3 +3.6
9 CAN_RX Input VDC 0 +3.3 +3.6
9 CAN_TX Output VDC 0 +3.3 +3.6
9 +3.3V(External supply) Output VDC +3.25 +3.3 +3.56
13 CANH - VDC -2 - +7
13 CANL - VDC -2 - +7
9
Standards and Conformities:
Standard Code Class
UL 61800-5-1 / CSA C22.2 No. 274 File Number E535351 DVC A
Radiated emissions – enclosure port CISPR 16-2-3 EN 55016-2-3 B*
Enclosure ports – Electrostatic discharges IEC / EN 61000-4-2 B*
Enclosure ports – Radio-frequency IEC / EN 61000-4-3 B*

electromagnetic field (AM)
I/O DC power ports – Fast transients IEC / EN 61000-4-4 B*
I/O DC power ports – Surges IEC / EN 61000-4-5 B*
I/O DC power ports – Radio-frequency IEC / EN 61000-4-6 B*

common mode
Enclosure ports – Power-frequency magnetic IEC / EN 61000-4-8 B*

field
ROHS 2011/65/EU -
* : Without using any external Filters.
10
Overview of the product

SOLO UNO_v2 is the latest version of SOLO UNO controllers with enhanced performance and
some extra features compared to previous versions, it serves the purpose of being universal and
easy to use for a wide range of users from different backgrounds. This product is designed to
support various types of electrical motors like DC brushed, Brushless DC, Brushless AC or
Permanent Magnet Synchronous Motors as well as AC Induction motors up to 58V with the
supply voltage and continuous current of up to 32 or 45 Amps, this will enable SOLO UNO_v2 to
be utilized in a wide range of products and projects and eventually speeding up the developments
and time to market for its users.
SOLO UNO_v2 can be commanded in two different ways, either by sending Analogue voltages or
PWM pulses which is called Analogue Mode, or totally by sending Digital data packets through
UART, USB or the CAN bus with CANopen software layer which is called Digital Mode Control.
This will give high flexibility in terms of system setup to the users and they can choose the best
way to wire up their systems using SOLO, The main features of SOLO UNO_v2 are listed below:
● Wide input voltage supply range from 8V to 58V

● The continuous output current of 32A or 45A
● Capable of controlling DC, BLDC, PMSM and ACIM motors
● Dual Core with parallel processing architecture
● CANopen, USB and UART Communications
● Active Brake chopper circuitry with selectable activation voltage
● Extremely fast F.O.C loop-rate up to 140kHz (7µs complete execution time)
● Over-current, Over-voltage, Over-Temperature, Under-voltage and Reverse Polarity
Protection
● Selectable output PWM switching frequency from 8kHz to 80kHz
● Automatic self-tuning and identification of Motor parameters
● Open-loop or Closed-loop Control modes
● Torque, Speed or Position control
● Advanced Sensor-less and Sensor-based Control
● Advanced Field Oriented Control
● PWM and Analogue voltage input for Controlling Speed and Torque
● SVPWM modulation
● Encoder and Hall Sensor Input with +5V supply
● +5V/1A (5W) output to supply external modules
● Updatable Firmware
● Heatsink mounted on the back of the board to enhance the thermal behaviour
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● 2000µF onboard BUS capacitance
Functional Block Diagram:
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Theory of Operation:
SOLO UNO_v2 is designed to operate in a closed-loop fashion with nested Torque, Speed and
Position controlling loops, this type of topology gives the possibility of controlling each of these
phenomenons (Torque, Speed, Position) separately and almost independently, resulting in very
robust and smooth control for systems with variable dynamics and loads, for 3-phase motors like
Brushless DC, PMSM and AC Induction motors this topology is known as Field Oriented Control
or Vector Control, it worth mentioning that SOLO UNO_v2 can operate in Open-loop mode as well
which can be used for simple applications.
In general, we can divide the whole control architecture of SOLO for two different types of
Motors, the 3-phase motors that can be seen in Figure 1 and the Brushed DC motors that can be
seen in Figure 2 below, as can be seen in these figures, the main foundation of the architecture of
motor controlling in SOLO is based on four fundamental controllers:
1. The Torque Controller: This is the closest controller to the motor and the fastest one, it
will only control the Torque of the Motor which is generated by the injection of Current
into the stator, that’s why this controller is known as Current Controller too, this controller
will try to stabilize the required torque (current) in the motor to make the whole system
capable of overcoming the dynamics changes in the load.
2. The Speed Controller: The Speed Controller comes behind the Torque Controller, it is
slower than the Torque controller (at least around tenfold) and it basically tries to fix the
Speed on a desired value, this controller will keep the rotational speed fixed regardless of
the load variation and it will adjust the torque accordingly. One might ask why the Speed
controller comes after the Torque controller, this is a big topic, but to simplify it drastically ,
in principle an Electrical Motor is a Torque Generation machine, even the Speed is
controlled finally by controlling the Torque, so the Speed commands to the Torque
Controller to increase or decrease the Torque on the Motor to stabilize the motor on a
specific desired Speed based on the effect of the load on the shaft.
3. The Position Controller: This is the last controller coming behind the speed controller, it
basically tries to set the exact position of the Motor on a specific value, so to make this loop
functional, the user needs to make sure the Torque and Speed loops are firstly tuned and
ready.
4. The Magnetizing Current Controller: This controller is useful at the moment to control
the amount of magnetizing current for only AC induction motors, the magnetizing current
will help to generate flux for controlling the AC induction Motor, for Brushless motors, this
loop will stabilize the Id ( direct current) at zero which is necessary for FOC.
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FOC control Architecture in SOLO UNO_v2 for 3-phase Motors:
Figure 1 - FOC Control Architecture of SOLO UNO_v2 for 3-phase Motors
As can be seen in Figure 1, to control any of the Torque, Speed and even position of a 3-phase
motor in FOC fashion, there is a need to have at least 4 different feedbacks:
1. Current Feedback: This feedback is necessary to control the current inside of the motor
and for Torque Controlling and it’s measured internally by SOLO, the accuracy of current
measurement is 16mA in SOLO UNO_v2.
2. Speed Feedback: This feedback is either measured using the sensors mounted on the
motor ( Encoders, Halls, …) or it’s estimated by the Nonlinear observer in sensorless
modes, and it’s used for Speed Controlling purposes.
3. Position Feedback: This feedback comes from external sensors like Encoders, and it
enables the Servo-Driving Capabilities of SOLO
4. Motor Electrical Angle: This feedback is essential for any types of closed-loop or
open-loop control on SOLO, this feedback is either Estimated or Measured by SOLO
internally.
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Cascade control Architecture in SOLO UNO_v2 for DC Motors:
Figure 2 - Control Architecture of SOLO UNO_v2 for DC Brushed Motors
As can be seen in Figure 2, the main architecture of Motor Controlling for DC brushed motors in
SOLO follows a very similar pattern to 3-phase Motors Controlling with FOC, however the
architecture is generally simple with only one cascade loop of Torque, Speed and Position.
Similar to 3-phase motors, for DC brushed Motors, SOLO offers both Sensorless and Sensor-based
controls as well as Servo-Driving in case an Incremental Encoder is attached to the Motor, so the
whole control strategy and tunings are identical to the 3-phase motors with minor differences on
the processing methods.
15
SOLO’s Interactional Sections:

SOLO UNO_v2 can be decomposed into 14 main interactional sections as shown in Figure 3, all the
sections are explained in detail and their electrical and maximum ratings are mentioned later in
this user manual, the user has to make sure they don’t exceed those maximum ratings to avoid
damaging themselves or the SOLO UNO_v2 unit.
Figure 3 - SOLO UNO_v2’s interactional sections
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Connectors and Sections:
Section 1 - Motor Output

PIN Name Descriptions / Notes I/O
1 A Motor Output 1 -
2 B Motor Output 2 -
3 C Motor Output 3 -
Description
This connector of SOLO should be connected to the Motors’ wires. You can find out more about
how to connect them by looking at the “Minimum Required Wirings” part, but in general, for 3
phase motors the A,B,C pins should get connected to the 3-phase wires of the motor and for DC
brushed motors only B and C pins are required to be connected to the motor.
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Section 2 - Supply Input

1 ++ Positive Voltage Input -
2 -- Negative Voltage Input ( Ground ) -
Description
This is the Power Supply input of SOLO and it can be supplied with any input voltages from 8 to
58 volts in continuous mode, depending on the voltage rating of the Motor Connected at the
output. The max rating for supply input is 59V in transient mode, meaning that SOLO UNO_v2
will go into over-voltage protection mode in case the supply or BUS voltage rises above almost
60.0 volts, the Brake Chopper circuit will get activated at approximately 59.5V in default mode,
to know more please check Section 14 below.
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Section 3 - Analogue Inputs and +5V External Supply

1 GND Analogue Ground of SOLO -
2 DIR The direction of rotation of the motor control I
3 P/F Power or Flux reference I
4 S/T Speed or Torque reference I
5 +5V Supply output for external modules O
Description
This is the Analogue commanding port of SOLO,it’s useful when SOLO is in “Analogue Command
Mode” and using that you can control the Speed or Torque of your motor by sending Analogic
commands using PWM pulses with any frequency above 5kHz or by sending pure Analogue
voltages rated from 0V to 5V ( see the Minimum Required Wirings Section) This part is
composed out of 5 pins:
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“GND” PIN:
This is the Ground or Return Path, in other words, the 0V Analogue input reference of SOLO, so
if you want to send Analogue commands to SOLO, you need to make sure the Ground of the
commanding unit ( PLC, Arduino, Raspberry Pi , … ) is shared and connected with SOLO at this
point.
“+5V” PIN:
This is a 5V/1A output to supply external peripherals or controllers with maximum of 5W.
“DIR” PIN:
This is the Direction control pin which is a digital pin, accepting voltage levels of 0V or 3.3V/ 5V,
by giving each of these values, the connected Motor to SOLO, will either rotate in C.W. direction
or C.C.W. direction.
“P/F” PIN:
This is a pin can be either used as a “Power” input once in Open-loop mode or as a
general-purpose Analogue input.
Mode of Operation Functionality
Inthe Open-Loop mode of It will act as increasing or decreasing the injected power into
3-phase motors the Motor, so by applying 0V of Analogue voltage or 0% duty
cycle of PWM, there will be no power injected inside the Motor,
and at 5V or 100% duty cycle of PWM, it will apply the
maximum deliverable power into the Motor.
“S/T” PIN:
This is the input for controlling the Speed or Torque of the Motor connected to SOLO depending
on the selected Mode on the Piano switch mentioned in section 6, the Analogue voltage or the
duty cycle of PWM pulse applied at this input will be treated as a desired reference or set-point
based on table below, this pin can also be used as a general-purpose Analogue input.
Mode of Operation Functionality
In Closed_loop Torque if you apply an Analogue 5V or in case of using PWM inputs, a

mode 100% duty cycle to this pin, without having a current limit,
SOLO will try to inject 32A of current inside your motor , given
this, the amount of Torque for motors generally can be
calculated:
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Applied Motor Torque = Current acting in torque generation *

Motor Torque Constant
The “Current acting in torque generation” for DC motors is
shown with “IM” for 3 phase motors (BLDC , PMSM or ACIM) is
shown by “Iq” or namely the “Quadrature current”.
So the amount of active current in torque generation injected to
your motor based on the amount of voltage or duty cycle you
apply to S/T pin can be calculated as:
In case of using PWM:
The torque generation Current = ((100 - duty cycle of PWM at
S/T input)/100) * 32.0
In case of using Analogue Voltages:
The torque generation Current = ((5.0 - the voltage at S/T
input)/5.0) * 32.0
In Closed_loop Speed if you apply an Analogue 0V or in case of using PWM inputs, a

mode: 0% duty cycle to this pin , it will keep your motor’s speed at 0
RPM, and at the same time by applying 100% duty cycle or 5V
Analogue input, SOLO will force your motor to go to the
maximum speed based on the Motor’s type selected by the
Piano Switch divided by ASRDC coefficient ( Analogue Speed
Resolution Division Coefficient), to learn more about ASRDC
coefficient please refer to our UART, USB or CANopen user
manuals, the default value of ASRDC is set at one, and it
basically allows you to increase the resolution at S/T input for
low speed motors.
Motor Motor Name Maximum Speed in Closed-loop
code mode
0 DC brushed Depends on BEMF constant of the

Motor, but it will go to nominal speed
at 5V or 100% input duty-cycle
1 Normal Brushless 8000RPM/ASRDC at 5V or 100%

Motors (BLDC, PWM input duty-cycle
PMSM)
2 AC Induction 4000RPM/ASRDC at 5V or 100%

Motors (ACIM) input duty-cycle
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3 Ultra Fast Brushless 30000 RPM/ASRDC at 5V or 100%

Motors (BLDC, PWM input duty-cycle
PMSM)
For instance, if we take Normal Brushless motors as an example,

and in case of applying Analogue voltages, the speed of the
motor can be found based on the following formula:
The Normal BLDC motor speed [RPM] = ((5.0 - the voltage at
S/T input)/5.0) * (8000/ASRDC)
- To have accurate motors speed measurements for 3

phase motors, you need to set the number of Poles of
your motor using the SOLO Motion Terminal or by using
USB or UART or CANopen interfaces, the default value
for the number of poles in SOLO is set at 8.
“S/T” and “P/F” PINs in Open_loop Mode:
In Open-loop Mode to control the speed of 3 phase Motors, you need to set both “S/T” and “P/F”
voltage values to apply the desired speed and power respectively, and for each of them you can
find the explanation below:
The speed of the motors in RPM can be derived from the following formulas based on the motor
type selected on Piano Switch shown in Section 6:
Number of Motor Pole Pairs = Number of Motor Poles / 2
In case of using Analogue Voltages on “S/T”:

● Normal Brushless Motor = (voltage applied at “S/T”)/(5.0* Number of Pole pairs)*8000
● Ultrafast Brushless Motor = (voltage applied at “S/T”)/(5.0* Number of Pole
pairs)*30000
● AC induction Motors = (voltage applied at “S/T”)/(5.0* Number of Pole pairs)*4000
In case of using PWM inputs on “S/T”:

● Normal Brushless Motor = (PWM duty-cycle Percentage at “S/T”)/(100%* Number of
Pole pairs)*8000
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● Ultrafast Brushless Motor = (PWM duty-cycle Percentage at “S/T”)/(100%* Number of

Pole pairs)*30000
● AC induction Motors = (PWM duty-cycle Percentage at “S/T”)/(100%* Number of Pole
pairs)*4000
Three phase Motors “Power” Notation in Open-loop Mode:

The “P/F” input in open loop mode of 3 phase motors acts as the output voltage adjuster, so by
going all the way up from 0V of Analogue voltage or 0% duty-cycle of PWM inputs at this pin to
+5V or 100%, you will increase the peak 3 phase voltage resulted by SVPWM modulation on
SOLO to the motor linearly from 0V to Vbus/sqrt(3) or equivalently to Vbus*0.577 at
maximum, Vbus here refers to the DC supply input voltage ( or battery voltage ), the action of
increasing the output voltage peak, will result in higher consumption by the motor depending
on their phase resistance and finally having more power for their rotation.
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Section 4 and 5 - Speed Controller Gains

section Name Descriptions / Notes I/O
4 Kp Proportional Gain of speed controller -
5 Ki Integral Gain of speed controller -
Description
These are two potentiometers, defining the speed controller gains in closed-loop Analogue
mode(pure Analogue control) , You can increase their values by rotating them in Counter
ClockWise direction, subsequently by rotating them in Clockwise direction their value reduces
until they get blocked in that direction which means a value of ZERO, to work with SOLO, in
Analogue closed-loop speed mode you need to tune these two potentiometers, their simple
definitions can be given as following , you can by pass these gains by putting SOLO in “Analogue
Mode with Digital Gains” through Motion Terminal.
Kp Potentiometer :
This potentiometer defines for you how fast your motor should react and reach the speed you
asked, so if you increase this value, your motor will be more reactive, but too much of this gain
might cause vibrations, so you need to tune it carefully. Also another effect of this gain will be
how “harshly” the controller ( here SOLO ) should react to the variation of the load on the shaft
of the motor to keep the speed constant. It's not always good to increase this gain randomly,
since it might cause instability and it totally depends on your system.
Ki Potentiometer :
This potentiometer defines how good your motor during time should reach the goal and stay in
steady state, so by increasing this value your motor might reach the set-point slower but more
consistently. Also by increasing this gain too much your motor might get unstable. So you need
to tune this similarly to Kp gain with patience and accuracy, to have zero error at steady state
this gain must be anything greater than zero, and zero error in steady state means, the
controller reaches to desired speed and remains there with zero error in theory ( in practice
with minimum possible error)
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Section 6 - Piano Switch Settings

1 Motor Select-1 Selects the Type of the Motor -
2 Motor Select-2 Selects the Type of the Motor -
3 DFU Mode Puts the device into Firmware Upgrade Mode -
4 Speed / Torque Speed or Torque control -
5 Open / Closed loop Open-loop or Closed-loop selection, Motor Identification -
Description
The piano switch in SOLO is used for the Analogue mode settings and for the convenience of
those who want to use SOLO with minimum possible external modules and wirings.
The main roles of the Piano switch as can be seen are as following:
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Pin number 5, Defining the Control Mode - Motor Identification:
By putting this pin in the UP position we are in open-loop mode, and if this pin is in DOWN
position we are in closed-loop mode, this is the only functionality shared between Analogue and
Digital control in SOLO UNO_v2.
- If you go from open-loop to closed-loop mode, while SOLO is powered ON, it will cause
identification of your motor parameters right after this transition, which is necessary for
closed-loop controls only once. You can also Identify the motor parameters by sending a
Motor ID. command through UART, USB or CANopen, the Identified Motor parameters
will reside inthe NVM memory of SOLO, so there will be no need to re-do this process
unless the motor has been changed.
Pin number 4, Defining The Type of the control- Speed or Torque:

This pin once it’s UP it means we want SOLO to operate in Analogue Torque mode, and once it’s
DOWN it means SOLO should go to Analogue Speed control mode.
Pin number 3, Defining the DFU mode for upgrading the firmware:
This pin should never be DOWN except the moments you want to upgrade the firmware of
SOLO, in case of the desire to upgrade the device firmware, you need to do the followings:
- Turn OFF SOLO
- Put the pin number 3 in DOWN position
- Turn ON SOLO
- Upgrade the Firmware
- Put back the pin number 3 in UP position
- Turn OFF / Turn ON SOLO ( recycle the Power with 5 seconds of delay in
between)
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Pin number 1 and 2 , Defining the Motor type:

using these two pins you can define the type of the electrical motor you are using in Analogue
mode with specific features mentioned in following table:
Pin 1 Pin 2 Motor Name Motor Default Max Speed Speed /

code Switching with +5V at Position
Frequency “S/T” in Controller
Closed-Loop Sampling
Rate
UP UP Brushless 3 80kHz 30000/ASRDC 2kHz

RPM
(ultra-fast / Low
inductance)
UP DOWN AC Induction 2 20kHz 4000/ASRDC RPM 2kHz
DOWN UP Brushless 1 20kHz 8000/ASRDC RPM 2kHz

(normal)
DOWN DOWN DC brushed 0 20kHz Nominal Speed of 2kHz

the motor
- By selecting each motor type, the switching frequency of SOLO at the output will be
adapted to what has been mentioned in the table above. These are default values and
you can overwrite them using Digital commanding like by USB, UART or CANopen, by
setting them digitally to any value from 8kHz to 80kHz with incremental steps of 1kHz.
- As a rule of thumb for Low inductance motors you should select higher switching
frequencies at the output of SOLO, default 20kHz can be low for some types of motors
mainly with phase inductance lower than 200µH, and in case you are using Brushless or
PMSM motors, you can select the motor type number 3, which by default has 80kHz of
switching at the output, you can also change these values to your desired value as
mentioned above for any type of motor selected.
27
Section 7 - USB Connection

- USB Virtual COM port or Device Firmware upgrader -
Description
This is the micro_USB 2 connector of SOLO which is used for sending and receiving digital
packets and commands as well as upgrading the firmware, in Commanding mode, this USB will
be a virtual COM port (VCP) capable of putting SOLO into digital control mode and functioning
in standalone fashion with only 1 USB cable and the Motor connected at the output. You can
download the latest drivers from our website.
28
Section 8 - Encode/Hall connector

1 +5V/500mA Encoder +5V external supply O
2 Encoder CHA/HALL_A Channel A of the Encoder or Hall position sensors I
3 Encoder CHB/HALL_B Channel B of the Encoder or Hall position sensors I
4 Encoder Index/ HALL_C Index Input of the Encoder or Channel C of Hall position Sensors I
5 Encoder Strobe Encoder Strobe (not needed) I
6 GND SOLO’s Ground -
Description
This port is the Quadrature Encoders or Hall sensors input, it accepts single-ended signals
leveled at +5V (RS422) while providing a +5V/500mA supply for powering up the sensors. All
the sensor inputs are internally pulled up to +5V with 1kΩ resistance to provide 5mA current for
open drain/collector configurations.
29
PIN NO# FUNCTIONALITY
1 +5V (500mA)
2 Encoder_CHA / HALL_A
3 Encoder_CHB / HALL_B
4 Encoder_Index/ HALL_C
5 NC
6 GND
- The use of Index pulse for 3 phase Motors is mandatory as it’s required for Encoder
Calibration process, for DC brushed motors, the presence ofan Index pulse is not
needed.
- To learn about how to Setup and calibrate your Incremental Encoders for SOLO UNO_v2
please visit this page on our website.
- To learn about how to Setup and calibrate your HALL sensors for SOLO UNO_v2 please
visit this page on our website.
30
Section 9 - Communication Port

1 +3.3V / 100mA +3.3V external supply O
2 +5V/500mA +5V external supply O
5 +5V/500mA +5V external supply O
9 CANL CAN Low Bus Output (ISO 11898) -
11 CANH CAN High Bus Output (ISO 11898) -
13 CAN_RX CAN protocol receiver input I
15 CAN_TX CAN protocol transmitter output O
17 UART_TX UART protocol transmitter output O
19 UART_RX UART protocol transmitter input I
Description
This is an Auxiliary port that gives you the access to UART and CAN bus communication pins in
order to send/receive fully digital commands in the form of data packets.
Notice that, The CAN_TX and CAN_RX are strictly leveled at 3.3V and they are NOT 5V
tolerant, applying 5V leveled signals to these pins will cause permanent damage to the main
controller unit.
31
CAN_TX and CAN_RX are not useful for CANbus CANopen networks as they are coming out of
the DSP directly without any CAN transceiver in between, to use CANbus for CANopen
networks the user must use the CANH and CANL pins provided in Section 13 below.
The communication port provides you two supply voltages of 3.3V and 5V with the main Ground
( reference) of SOLO, so you can use them to feed external modules with the mentioned current
limit, the communication port on SOLO UNO might be from right-angle or the vertical type, the
pin numbering for each shown in images below:
32
Section 10 and 11 - Functionality LEDs

10 E2 Normal Activity LED -
11 E1 Error Indicator LED -
Description
There are two LEDs on the bottom right side of SOLO, which are named as “E1” and “E2” and
each of them has a functionality as below:
- E2 : This is the status or heart-beat indicator, after the device startup, in case of
having a safe boot up with no errors like over-current, over-voltage etc., it will
start blinking and remains in the blinking state as long as no error occurs.
- E1: This is the Error indicator, and in case of an error, it will start blinking, to
know the exact reason of the blinking, please check the Error Register (get
connected to Motion Terminal and read it.)
33
Section 12 - Power Up LED

12 A1 Power Up LED -
Description
This LED will start glowing once SOLO is correctly powered up with a voltage from 8 to 58V.
34
Section 13 -CAN BUS / UART PINOUT

1 UART_RX UART protocol transmitter input I
2 CANL CAN Low Bus Output (ISO 11898) -
3 UART_TX UART protocol transmitter output O
4 CANH CAN High Bus Output (ISO 11898) -
Description
This section provides easy access to both of the CANopen and UART interfaces; these pins can
also be found on the “Communication Port” on section 9 with the same functionality.
The UART interface from this port on SOLO UNO_v2can be wired as:
The CANopen interface from this port on SOLO UNO_v2 can be wired as:
35
Section 14 - Active Brake Chopper

1 BRO- Brake chopper negative output O
2 BRO+ Brake chopper positive output O
7 BRA1 Brake voltage activation external resistor input 1 I
8 BRA2 Brake voltage activation external resistor input 2 I
Description
This section provides a compact Active ‌Brake Chopper circuitry to protect the device from
over-voltage conditions caused by powered fed back from the motor to the DC-Bus due to
regeneration by dissipating the power on a high-power resistor through BRO+ and BRO- output
with tunable activation voltage using an external resistor through BRA1 and BRA2 inputs from
59.5V down to 10.0V.
The default activation voltage for this circuitry on SOLO UNO_v2 (SLU0722_5832 ) is set at
59.5V, however, this voltage can be changed to any desired voltage using the below formula
mentioned in Active Brake Chopper wirings.
The general wiring for the brake chopper section can be as below, to find out more about brake
chopper please refer to Active Brake Chopper wirings later in this document.
36
Section 15 - Brake Activation LED

15 B1 Brake Activation LED -
Description
This LED will turn on once the Brake circuitry is actively dissipating Energy on the RC power resistor.
37
Connectors and their Matings Part Number:
Section Manufacturer Mating Part Number

[8] Molex 510210600
[9] JST Sales America Inc. SHDR-20V-S-B
[13] Amphenol ICC (FCI) 87606-303LF
[14] Amphenol ICC (FCI) 87606-304LF
38
Analogue versus Digital Control in SOLO UNO_v2

By notion of “Analogue” in SOLO we mean any interface that can be done using Analogue voltages
or mechanically at hardware level to SOLO, for instance in SOLO UNO_v2 you can do the following
actions completely at hardware level:
1. Set the Speed or Torque Reference through “S/T” input

2. Set the Magnetizing current through “P/F” input
3. Tune the Speed controller Kp and Ki gains through two potentiometers mechanically
4. Set the Motor type through Piano switch (4 types)
5. Set the Control Mode of Torque or Speed through Piano switch
6. Set the Open-loop or Closed-loop type of control through Piano switch
7. Put SOLO into DFU mode through Piano switch
For SOLO, once you are in “Analogue Mode”, these settings have the highest priority over all the
settings from the same nature in Digital mode, for example, if you are in Analogue Mode, you can
only select the motor type from the Piano switch, and if you set it using Motion Terminal or you
send the data packet through UART or CAN bus it will not change the Motor type unless you go to
“Digital Mode” before.
The main reason that “Analogue Mode” exists on SOLO is to eliminate the need for the users to set
a special parameter through a software and to minimize the interfacing effort to SOLO for simple
applications.
However, there are tons of settings that you can’t do them at hardware Level, like setting the
motor numbers’ of poles for 3 phase motors, or setting the output switching frequency, … so for all
of these parameters, regardless of what mode you are in ( Analogue or Digital ) you can only set
them digitally using Motion Terminal or with UART , USB or CANopen commands.
So if you go from “Analogue Mode” to “Digital Mode”, again for most of the Mentioned
functionalities listed above you need to set them digitally like Motor type, speed or torque
references and so on.
The only two functionalities that can be done only at Hardware level on SOLO UNO_v2 are
“Closed-loop” or “Open-loop” selection as well as putting SOLO into DFU mode using the Piano
switch, this means you will need to do this setup at hardware level regardless of the fact that you
are in “Analogue Mode” or “Digital Mode”.
39
Minimum Required Wirings in Analogue Mode:

The minimum required wirings to run SOLO in Analogue control mode, by applying Analogue or
PWM voltages depending on the type of the electrical motors connected are shown later in this
chapter.
Wiring Legend:
Shape Description
Input Positive of the DC supply
Input Negative or Return of the DC supply
Fuse, the value can be selected based on the system

requirements
Line carrying pulses with PWM (fixed frequency above 5kHz)
Line carrying Pure Analogue voltage
Line carrying ON / OFF type of signals (low frequency)
Line with signal inputting to the circuit
Line with signal outputting from the circuit
40
BLDC, PMSM Motors _ Sensorless Closed-loop Mode:
- To put SOLO in Closed-loop Mode, the Pin Number 5 of the Piano switch must be Down.
- In sensorless closed-loop mode, the order of the connection of Motor wires to A,B,C
output is not important and it will only affect the Direction of rotation which you can set
using “DIR” input.
41
BLDC, PMSM or ACIM Motors _ Sensorless Open-loop Mode:
- To put SOLO in Open-loop Mode, the Pin Number 5 of the Piano switch must be UP.
- In sensorless or open-loop mode, the order of the connection of Motor wires to A,B,C
42
AC Induction Motors_ Closed_loop Sensorless Mode:
- In sensorless closed-loop mode, the order of the connection of Motor wires to A,B,C
43
DC brushed Motors_ Open-loop Sensorless Mode:
- To put SOLO in Open-loop Mode, the Pin Number 5 of the Piano switch must be UP.
44
DC brushed Motors_ Closed-loop Sensorless Mode:
45
Standalone Wiring Example (No External Modules):

Here you can see an example of how to wire SOLO without having any external modules, just by
using a potentiometer and a switch. In this example, you can see the wiring of a Brushless Motor in
Closed-Loop Mode, Please Note that:
- “DIR” pin in SOLO UNO_v2 is +5V tolerant, you can also apply +3.3V on this pin.
- To set the Current Limit during the operation you can use Motion Terminal.
- In the case of using Potentiometers or resistors, the user has to make sure the minimum
resistance of the Potentiometer at any position is not below 1kOhm (residual resistance),
applying lower resistance at the input might cause damage to the internal circuitry.
46
Essential Wiring Example (SOLO UNO_v2 + Arduino UNO)

Here is an example of wiring SOLO with an Arduino uno, as can be seen:
- Arduino has been directly powered up by SOLO, depending on the Arduino models, the user can
commit the USB of the Arduino at the same time, the most important point in connection is to make
sure the GND pin of SOLO has been connected to the GND of your Arduino or other modules at
least in a single point.
- “DIR” pin in SOLO UNO_v2 is +5V tolerant, you can also apply +3.3V on this pin.
- In Case of using SOLO UNO in closed-loop mode, the Power pin connection is not necessary
47
Minimum Required Wirings in Digital Mode:

All of the functionalities of SOLO UNO_v2 can be controlled fully digitally by sending data packets
through UART, USB or CAN bus with the CANopen software layer, below there are three main
examples of possible wirings of SOLO in Digital Mode for Brushless Motors ( the same pattern of
wiring applies for other types of motors)
USB Interface Wiring

By using USB connection, you have access to the simplest form of wiring of SOLO to be
commanded using only the USB cable thanks to the digital control that it offers, in this mode the
only thing you will need is a Micro USB cable that makes SOLO able to communicate with a local
PC or controller through USB communication as a Virtual COM Port, in such a setup SOLO offers
full control over every possible and existing feature that it supports.
- Operation in Closed-loop or Open-loop is controlled by Piano Switch PIN Number 5 both

in Analogue and Digital modes, so to put SOLO in Closed-loop Mode, the Pin Number 5 of
the Piano switch must be Down, subsequently for operating in Open-loop Pin Number 5 of
the Piano switch must be UP.
48
UART Interface Wiring

The UART line of SOLO is accessible both through the “Communication Port” or through the “CAN
BUS / UART PINOUT” which makes it easier and faster to access these lines for testing purposes,
in SOLO UNO_v2 model the UART_RX and UART_TX lines are +5V tolerant and they can be fed
both by signals levelled at +3.3V or +5V.

49
CANopen Interface Wiring

SOLO UNO_v2 can be commanded in a CAN network by CANopen standard, using CANopen all of
the functionalities of SOLO can be controlled digitally using data packets sent within CAN bus. To
know more please refer to SOLO UNO_v2 CANopen user Manual here. CANopen can be accessed
both through “Communication Port” or the “CAN BUS / UART PINOUT” using CANH and CANL
pins.
- Operation in Closed-loop or Open-loop is controlled by Piano Switch PIN Number 5 both in

Analogue and Digital modes, so to put SOLO in Closed-loop Mode, the Pin Number 5 of the Piano
switch must be Down, subsequently for operating in Open-loop Pin Number 5 of the Piano switch
must be UP.
- CAN_TX and CAN_RX pins are CAN outputs coming right off the DSP and they are only +3.3V
leveled signals with no CAN Transciever on the path, they are brought out just for special use, these
pins should not be used instead of CANH and CANL pins, by doing so the damage to the DSP is
imminent.
50
Wiring with Incremental Encoders:

By using Incremental Encoders you can turn SOLO into a servo drive controlling Torque, Speed
and Position of your Motor, once using Incremental Encoders you need to make sure you apply the
correct setup followed by one-time calibration of the system, to learn about the process please
visit this page on our website.

51
Wiring with HALL Sensors:

Using HALL sensors mounted on BLDC or PMSM motors, you can increase the accuracy of Speed
and Torque controlling. Once using HALL sensors you need to make sure you apply the correct
setup followed by one-time calibration of the system, to learn about the process please visit this
page on our website.

52
Wiring and Setup of Active Brake Chopper:

This circuit provides a compact Active ‌Brake Chopper circuitry to protect the device from
over-voltage conditions caused by powered fed back from the motor to the DC-Bus due to
regeneration by dissipating of the power on a high-power resistor through BRO+ and BRO-
outputs with tunable activation voltage using an external resistor through BRA1 and BRA2 inputs.
The default activation voltage for this circuitry on SOLO UNO_v2 (SLU0722_5832 ) is set
approximately at 59.5V, however this voltage can be changed to any desired voltage using the
formula mentioned later in this part.
The general principle of this circuit is whenever the BUS voltage goes above the activation voltage
limit, the circuit shorts the BRO+ to BRO- thus by placing a high power resistor with minimum
value of 68Ω 10Watts, the extra power will be dissipated in the “RC” resistor shown below in the
wiring.
- Do not use power resistors with resistance below 68Ω for “RC” resistor, since by doing so,
the brake circuitry might get damaged due to excessive power dissipation.
Whenever the brake circuit turns on, the “B1” LED will turn ON too.
The Activation voltage limit can be tuned using the “RBA” resistor based on below formula, by
leaving pin 8 and 7 open the default activation voltage of 59.5V will be applied.
X= ((((Desired Brake Activation Voltage) / 5.6) * 10200 ) - 10200 )

RBA [Ω] = (X * 97600 / (97600 - X )
Table1 below shows some sample activation voltages based on the nominal DC bus voltage,
however any arbitrary voltage down to 10V can be achieved using this formula for various
systems.
53
The brake activation voltage should be always above the nominal applied DC bus voltage to the
system to avoid power dissipations on “RC” resistor once not necessary, it’s always better to test
the activation voltage by looking at “B1” LED and verify if the LED turns on at the desired value
before committing the Motor to the controller.
Table 1: Examples of “RBA” resistance selection based on desired brake activation voltage
Nominal DC bus voltage Possible Desired Brake “RBA” resistance value [kΩ]
based on the Motor Activation Voltage (approximately)
(approximately)
58V 59.5V ∞ (open)
48V 49V 415
36V 37V 138
24 25V 55
12 13V 16
The resistor values for “RBA” should be chosen as close as possible to the theoretically calculated
values to have the highest resolution possible in Brake activtion, some candidates for power
resistor “RC” are listed in below table 2:
Table 2: Some candidates for “RC” power resistor

Candidate Part Number for “RC” resistor Resistance and Power
THS1075RJ 75Ω 10W
THS2568RJ 68Ω 25W
THS1568RJ 68Ω 15W
RHA05068R00FE02 68Ω 50W
HSC100-100R 100Ω 100W
54

Solo Uno v2 Slu0722 5832 Usermanual

Uploaded by

Solo Uno v2 Slu0722 5832 Usermanual

Uploaded by

SOLO UNO_v2 User Manual

Part Numbers: SLU0722_5832 , SLU0722_5845

Product Description Power Range

SOLO UNO_v2 is a member of the SOLO Supply Voltage Range: 8- 58 VDC

● Easy to use ● Field Oriented Controls with Nested

Modes of Operation Commands and feedback Source

● Analogue or Digital commanding ● 0-5V Analogue/ PWM inputs for Speed or

V1.0.7 15/04/2021 - Updating the document for Firmware version 0x000B007

V1.0.8 06/09/2021 - Updating the document for Firmware version 0x000B009

V1.0.9 15/05/2022 - SOLO UNO_v2 updates added 0x00BB00A

V1.0.10 10/05/2024 - Adding the 45A version specs. 0x0000B020

AC Induction Motors_ Closed_loop Sensorless Mode: 43

Power Specifications for 32A version:

DC Bus Overvoltage Limit VDC 60

DC Bus Undervoltage Limit VDC 8

Maximum Peak Output Current ADC 32

Maximum Continuous Output Current ADC 32

Maximum Continuous Output Current Arms 22.5

Maximum Continuous Output Power W 800

Maximum Peak Output Power W 1500

Internal Bus Capacitance µF 2000

Switching Frequency (output PWM frequency) kHz 8 to 80

Power Specifications for 45A version:

DC Bus Overvoltage Limit VDC 60

DC Bus Undervoltage Limit VDC 8

Maximum Peak Output Current ADC 50

Maximum Continuous Output Current ADC 45

Maximum Continuous Output Current Arms 32

Maximum Continuous Output Power W 1200

Maximum Peak Output Power W 1800

Internal Bus Capacitance µF 2000

Switching Frequency (output PWM frequency) kHz 8 to 80

Control and Timings specifications:

Description Units Values

Digital Direction Control VDC 0 - 3.3/5V

Modes of Operation - Torque - Speed- Position

Motors supported - DC - BLDC - PMSM - EC Coreless- ACIM

Hardware Protections - Reverse Polarity, Bus over-voltage Bus

Current (Torque) Loop execution time µs 7

Speed controller Loop sampling time µs 500

Speed controller Loop execution time µs 75

Position controller Loop sampling time µs 500

Position controller Loop execution time µs 75

Maximum Encoder Frequency MHz 18 (Pre-Quad)

Description Units Values

Heatsink (base) Temperature Range °C -20 to +85

Cooling system - Natural Convection

Description Units Values

Weight (with heatsink) gr 99

Form Factor - Wall Mount

- All the measurements are in millimetres.

Absolute Maximum Voltage Ratings:

2 Supply Input Input VDC +8 +58 +63

3 S/T (speed/torque) Input VDC 0 +5.0 +5.5

3 P/F (power/flux) Input VDC 0 +5.0 +5.5

3 DIR (Direction control) Input VDC 0 +5.0 +5.5

3 +5V (External supply) Output VDC +4.95 +5.0 +5.2

8 CHA(Encoder)/HALL_A Input VDC 0 +5.0 +5.5

8 CHB(Encoder)/HALL_B Input VDC 0 +5.0 +5.5

8 Index(Encoder)/ HALL_C Input VDC 0 +5.0 +5.5

9 UART_RX Input VDC 0 +5 +5.5

9 UART_TX Output VDC 0 +3.3 +3.6

9 CAN_RX Input VDC 0 +3.3 +3.6

9 CAN_TX Output VDC 0 +3.3 +3.6

9 +3.3V(External supply) Output VDC +3.25 +3.3 +3.56

Standards and Conformities:

Standard Code Class

UL 61800-5-1 / CSA C22.2 No. 274 File Number E535351 DVC A

Radiated emissions – enclosure port CISPR 16-2-3 EN 55016-2-3 B*

Enclosure ports – Electrostatic discharges IEC / EN 61000-4-2 B*

Enclosure ports – Radio-frequency IEC / EN 61000-4-3 B*

I/O DC power ports – Fast transients IEC / EN 61000-4-4 B*

I/O DC power ports – Surges IEC / EN 61000-4-5 B*

I/O DC power ports – Radio-frequency IEC / EN 61000-4-6 B*

Enclosure ports – Power-frequency magnetic IEC / EN 61000-4-8 B*

Overview of the product