Anaheim Brushless DC MDC150050301 Brushless DC Driver Users Guide

							MDC150-050301
50V, 30A Brushless Controller 
User’s Guide
910 East Orangefair Lane, Anaheim, CA 92801
e-mail: [email protected](714) 992-6990  fax: (714) 992-0471
website: www.anaheimautomation.com
ANAHEIM AUTOMATION
April 2012L010356  
						

							General Description
The MDC150-050301 driver is designed to drive DC brushless motors at currents of up to 30A (peak) 
and 50V.  Using hall sensor feedback, a constant velocity mode can be selected.  The driver is protected 
against over current (cycle-by-cycle or latched), hall sensor error and under voltage.  When an error oc-
curs, a fault light notifies the user.  If the fault latch is enabled and an error occurs, the fault output goes 
low to notify the user.  Included on the driver is an internal potentiometer to control the maximum phase 
current allowed into the motor and an internal potentiometer to control the speed of the motor.  An optional 
external potentiometer (10K) or external voltage (1-4VDC) can be used to control the speed as well.  The 
direction of the motor can be preset by the direction control input.  Ot\
her inputs to the drive include a run/
stop and a motor freewheel input.  When using the run/stop input, there are three ramp up profiles from 
standstill to select from.  The run/stop input overrides all other inputs into the driver. 
Fault Protection
Over current protection can be provided by means of a over current latch\
 function by setting the ‘FLT 
LATCH’ dip switch on.  If a motor current level exceeding the current limit set by the internal or external 
current limit potentiometer is produced, an over current latch is activa\
ted, shutting off the output and 
turning the fault output low (logic “0”).  When a fault is detec\
ted, the driver turns off the motor current, 
the red FAULT LED alerts the user a fault occurred and the Fault Output (TB3 - Pin 5\
) goes low.  The 
Fault Output is disabled, logic ‘1’ output, when the ‘FLT LATCH’ dip switch is in the off position and dis-
abled.  This Fault protection alerts the user of the following conditions. 1. Invalid Sensor Input Code
2.  Over Current.  The driver is equipped with cycle-by-cycle current limiting or over curr\
ent    
   latch.
3.  Undervoltage Lockout activation at 9.1 VDC for the input voltage and 4.5\
 VDC for the    
    Hall Sensor voltage.
MDC150-050301 Driver Features
• Maximum Current Limit Setting from 10.0-30.0 Amps (peak)
• Internal or External Potentiometer Speed Control
• 2-Quadrant Operation
• Hall Sensor Feedback
• Constant Velocity Mode
• Short Circuit Protection
• Requires 20-50 VDC
• Speed Out          • TTL-CMOS Compatible Inputs
• Fault Out           • Compact Size (5.25” x 3.06” x 1.65”)
• Brake, Disable and Direction Inputs   • Dual Mounting Option
• Selectable Ramp Up/Down      • Detachable, Screw Type Terminal Block
Ordering Information
Part #Description
MDC150-050301 Featured BLDC driver 30A, 50V
PSA24V2.7A DC Power Supply 24VDC at 2.7 Amps
PSA40V4A DC Power Supply 40VDC at 4 Amps
PSA40V8A DC Power Supply 40VDC at 8 Amps
CBL-AA5420 Cable, 3 Pins 12in. Long, For External Pot
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							Specifications
Control Inputs: (TB3, Pins 2-4)
TTL-CMOS Compatible
Logic “0” = 0-0.8VDC
Logic “1” = OPEN
All three inputs (run/stop, freewheel and direction) are pulled up to \
through 20k ohm resistors.
Freewheel: (TB3, Pin 3)
Logic “1” (open) - Motor is Enabled
Logic “0” - Motor is de-energized and will coast
Direction Control: (TB3, Pin 2)
Logic “1” (open) - Clockwise
Logic “0” - Counterclockwise
Run/Stop: (TB3, Pin 4)
Logic “1” (open) - Motor will not run and if running will come t\
o a hard stop
Logic “0” - Motor will run and will accelerate according to ramp d\
ip switch setting
Fault Output: (TB3, Pin 5)
Enabled when fault latch is enabled.
Logic “1” (5V out) - Status good, normal operation.
Logic “0” - One of the three fault conditions listed in the ‘Fa\
ult Protection’ section has occurred.
Speed Output: (TB3, Pin 1)
A 5V signal pulse out is available at a rate of 4 pulses for 1 revolution of an 8-pole motor, 3 pulses for 1 
revolution of a 6-pole motor, and 2 pulses for 1 revolution of a 4-pole motor.
8-pole motor RPM = 15 * PG OUT (in Hz)
6-pole motor RPM = 20 * PG OUT (in Hz)
4-pole motor RPM = 30 * PG OUT (in Hz)
Output Current Rating:
Adjustable 10.0 - 30.0 amperes per phase maximum operating peak current
 (5.0 - 15.0 amperes per phase maximum operating continuous current)
Power Requirements: (TB2, Pins 1 and 2)
20VDC (min) - 50VDC (max)
Operating Temperature
Heat Sink: 0°-70° C
Hall Sensor Power Output:
6.25V @30mA maximum.  Typical current draw from hall sensors in 20mA.
All three Hall Sensor inputs are pulled up through 20K ohm resistors.
The external speed control potentiometer must be 10K Ohms.
Heating Considerations
The temperature of the heat sink should never be allowed to rise above 70° C.  If necessary, mount the unit 
to an additional heat sink or air should be blown across the heat sink t\
o maintain suitable temperatures.
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							Commutation Sequence
+ = Top Transistor ON, Bottom Transistor OFF, Current flows into this wire
- = Top Transistor OFF,  Bottom Transistor ON, Current flows out of this wire
Z = Top Transistor OFF, Bottom Transistor OFF,  No current into or out of this wire (High Impedance)
Motor Connection
Refer to the hookup diagram for typical driver applications.  When connecting a motor for the first time, 
connect the hall sensor wires (5 of them) to the driver.  DO NOT CONNECT THE PHASES YET.  Turn 
on power and rotate the motor by hand.  If the RED FAULT LED comes on, the hall phases are incor -
rectly wired.  If the RED FAULT LED does not come on then the hall wires are connected correctly.  
Power the unit down and proceed to connect the motor phases.  If the motor does not run or runs 
erratically, power down and check the speed potentiometer and make sure the phases \
are connected 
correctly.  There are six different ways to connect the phase wires, and normally only two will allow\
 the 
motor to rotate, but only one is correct.  If the direction of the motor is changed and the no-load current 
of the motor is approximately the same and the motor runs smoothly in bo\
th directions then the phase 
wires are correct.
The wiring of the motor phases should be separated from the hall and inp\
ut connections to not allow a 
possible source of interference.
Step
1 23456
Phase A +Z --Z +
Phase B Z++Z --
Phase C --Z ++Z
Hall A 110001
Hall B 011100
Hall C 000111Step
1 23456
Phase A -Z ++Z -
Phase B Z--Z ++
Phase C ++Z --Z
Hall A 110001
Hall B 011100
Hall C 000111
Step
1 23456
Phase A +Z --Z +
Phase B Z++Z --
Phase C --Z ++Z
Hall A 111000
Hall B 011100
Hall C 001110Step
1 23456
Phase A -Z ++Z -
Phase B Z--Z ++
Phase C ++Z --Z
Hall A 111000
Hall B 011100
Hall C 001110
120° Hall Spacing Sequence Forward 120° Hall Spacing Sequence Reverse
60° Hall Spacing Sequence Forward 60° Hall Spacing Sequence Reverse
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							Dip Switch and Jumper Settings
Terminal and Dip Switch Descriptions
TB1: Motor Hall Terminals
Pin #
Description
1 Hall Sensor Power
2 Hall Sensor A
3 Hall Sensor B
4 Hall Sensor C
5 Hall Sensor Ground
Function SW1SW2SW3 SW4 SW5 JP2
Constant Speed Mode (Closed Looped) Off------ --- ------
Voltage Controlled Speed Mode (Open Loop) On------ --- ------
Over Current Latching ---On ------ ------
Over Current Cycle by Cycle ---Off ------ ------
Ramp Profile 1 (4 Sec) ------Off Off ------
Ramp Profile 2 (2 Sec) ------Off On ------
Ramp Profile 3 (1 Sec) ------On Off ------
Ramp Profile 4 (500mSec) ------On On ------
60° Hall Sensor Spacing --------- ---Off ---
120° Hall Sensor Spacing --------- ---On ---
Internal Speed Control (JP2) --------- --- ---1-2
External Speed Control (JP2) --------- --- ---2-3
Standard Product (Ready to Ship) OffOffOff Off On1-2
Pin # Description
1 Power In (20-50VDC)
2 Ground
3 Phase C
4 Phase B
5 Phase APin # Description
1 PG OUT
2 Direction
3 Freewheel
q Run/Stop
5 Fault Out
6 GND
TB2: Power and Motor 
Phase Terminals TB3: Control Inputs and 
Outputs
P1: 10K External Pot
Pin # Description
1 +4.0V (Pot Top)
2 Pot Wiper
3 +1.0V (Pot Bottom)
SW: Dip Switch
SW # Description
1 O/C LOOP
2 FLT LATCH
3 RAMP 1
4 RAMP 2
5 60/120
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							Motor Freewheel
The motor freewheel feature allows the de-energizing of the motor phases.  A high (open) input at this input 
causes the motor to run at the given speed, while a low at this input causes the motor to coast to a stop.
Motor Run/Stop
The motor run/stop feature allows the stopping of a motor by shorting out the bottom drives of the three 
phases.  A low at this input allows the motor to run,  while a high (open) input does not allow motor opera-
tion and if operating causes rapid deceleration.
Motor Direction
The motor direction feature allows the changing of the rotation of the motor.  This input should not be 
changed while motion is in progress.  A high (open) input causes the motor to turn in the CW direction, 
while a low at this input causes the motor to turn in the CCW direction.\
Speed Adjust Setting
There are two ways to set the speed on this drive.  One is to use the on\
 board potentiometer.  The other 
is to use an external 10K potentiometer.   To use the on board potentiometer, set jumper JP2 to position 
1-2 (default).  To use the external 10K potentiometer or external 1V to 4V voltage speed setting, remove 
cover and set jumper JP2 to position 2-3.  A voltage of 1V-4V to control the speed of the motor can be tied 
to the Pot Wiper connection of P1 with 0V tied to pin 6 of TB3 (GND).  The maximum voltage that can be 
placed on the pot wiper with respect to ground is 6V.
The mating connector for the external 10K potentiometer is Molex part nu\
mber 3-640440-3.
Speed Output
The PG OUT terminal (TB3 - pin 1) is used to determine the speed of the motor shaft.  A 5V signal pulse 
out is shown at a rate of 4 pulses for 1 revolution of an 8-pole motor, 3 pulse for 1 revolution of a 6-pole 
motor, and 2 pulses for 1 revolution of a 4-pole motor.
Fault Output
The Fault Output is only active when the Fault Latch is enabled, setting the ‘FLT LATCH’ dip switch on.  
The TTL level Fault Output indicates an over current or failure in the motor/driver operation.  The Fault 
Output is normally at a TTL logic level 1.  If a fault occurs, the Fault Output will go to a TTL logic level 0.
# Poles RPM
8 15 * PG OUT (in Hz)
6 20 * PG OUT (in Hz)
4 30 * PG OUT (in Hz)
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							Typical Hookup Drawing
Dimensions
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							ANAHEIM AUTOMATION
COPYRIGHT 
Copyright 2007 by Anaheim Automation. All rights reserved. No part of this publication may be reproduced, 
transmitted, transcribed, stored in a retrieval system, or translated in\
to any language, in any form or by 
any means, electronic, mechanical, magnetic, optical, chemical, manual, or otherwise, without the prior 
written permission of Anaheim Automation, 910 E. Orangefair Lane, Anaheim, CA 92801. 
DISCLAIMER
Though every effort has been made to supply complete and accurate information in this manual, the 
contents are subject to change without notice or obligation to inform the buyer. In no event will Anaheim 
Automation be liable for direct, indirect, special, incidental, or conse\
quential damages arising out 
of the use or inability to use the product or documentation.   
Anaheim Automation’s general policy does not recommend the use of its’ products in life support applications 
wherein a failure or malfunction of the product may directly threaten life or injury.  Per Anaheim Automation’s 
Terms and Conditions, the user of Anaheim Automation products in life support applications assumes all 
risks of such use and indemnifies Anaheim Automation against all damages.
LIMITED WARRANTY
All Anaheim Automation products are warranted against defects in workmanship, materials and construction, 
when used under Normal Operating Conditions and when used in accordance with specifications. This 
warranty shall be in effect for a period of twelve months from the date of purchase or eighteen months 
from the date of manufacture, whichever comes first.  Warranty provisions may be voided if products 
are subjected to physical modifications, damage, abuse, or misuse.
Anaheim Automation will repair or replace at its’ option, any product which has been found to be defective 
and is within the warranty period, provided that the item is shipped freight prepaid, with previous authorization 
(RMA#) to Anaheim Automation’s plant in Anaheim, California. 
TECHNICAL SUPPORT
If you should require technical support or if you have problems using any of the equipment covered by this 
manual, please read the manual completely to see if it will answer the questions you have. If you need 
assistance beyond what this manual can provide, contact your Local Distributor where you purchased the 
unit, or contact the factory direct.
April 2012L010356