Anaheim Brushless DC MDC150120151 Brushless DC Controller Users Guide

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MDC150-120151
120VAC, 15A 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 
						

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General Description
The MDC150-120151 driver is designed to drive DC brushless motors at currents of up to 15A (peak) and
170V. 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 and output is turned on to notify the user. Included on the driver is an internal potentiom-
eter 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) can be used to control the speed as well.
The direction of the motor can be preset by the direction control input. Other 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 freewheel input overrides all other inputs into the driver. If the motor stalls, run/
stop must be toggled to have the motor run again.
Fault Protection
Over current protection can be provided by means of an over current latch function by setting the ‘FLT
LATCH’ dip switch. If a motor current level exceeding the current limit set by the internal current limit
potentiometer is produced, an over current latch is activated, shutting off the output. This driver is
equipped with a FAULT LED and Fault-out output to alert the user of the following conditions. To reset
the MDC150-120151 driver from a latched condition, power down, allow 30 seconds for power to dissi-
pate, then power up.
1. Invalid Sensor Input code
2. Over Current. The driver is equipped with cycle-by-cycle current limiting or over current latch.
3. Undervoltage Lockout activation at 9.1VDC for the motor bus voltage and 4.5VDC for Hall
    Sensor voltage.
MDC150-120151  Driver Features
• Maximum Current Limit Setting from 5.0 to 15.0 Amps (peak)
• Internal or External Potentiometer Speed Control
• 2-Quadrant Operation
• Hall Sensor Feedback
• Constant Velocity Mode
• Short Circuit Protection
• Requires 85 - 135 VAC
• Speed Out
• Fault Out
• Run/Stop, Freewheel and Direction Inputs
• Selectable Ramp Up
• Optically Isolated Inputs and Outputs
• Dual Mounting Option
• Detachable, Screw type Terminal Blocks for the logic inputs, outputs and motor phases
• Covered, Screw type Barrier Strips for the power input
Speed Adjust Setting
There are two ways to set the speed on this drive. One is to use the on board potentiometer.  To use the on
board potentiometer, set INT/EXT SPD switch (SW1, pin 1) to the ‘off ‘position (default). The speed is then
adjusted by setting R46. The second is to use an external 10K potentiometer. To use the external potenti-
ometer, set the INT/EXT SPD switch to the ‘on’ position.  If an external potentimeter is used to control the
speed of the motor, connect the pot to TB5. 
						

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Specifications
Pin Descriptions
The inputs on the MDC150-120151 are optically isolated with the anode (+) and cathode (-) both brought
out to the user.  With no current going through the Direction, Freewheel, and Run/Stop opto-diodes, the
input is considered high. To enable the motor to Run, current must go through the Run/Stop input opto-
diode. To Freewheel (remove energy from the motor) the motor, current must go through the Freewheel
input opto-diode.To enable the input a minimum of 1.0 mA needs to be sourced or sinked through the opto-
diode. This is done simply by placing a voltage of +5 to +24 VDC across the two inputs of the opto-diode.
If sourcing current into the inputs, then all three cathodes (-) should be tied together and grounded. If
sinking current, then all three anodes (+) should be tied together to the +voltage. The PG Out and Fault
output on the MDC150-120151 are an opto-decoupled open collector output. When normal operation oc-
curs, this output will conduct current into the emitter. Care must be taken not to pass more than 50mA
through these transistor.
m e t In i Mp y Tx a Ms t i n U
) r e w o P ( e g a t l o V t u p n I5 802 153 1CA V
t n e r r u C t u p t u O e s a h P551)k a e P ( A
t n e r r u C t u p t u O e s a h P5 . 25. 7)s u o u n i t n o C ( A
) s t u p n I ( e g a t l o V t u p n I5 . 342CD V
y c n e u q e r F g n i p p o h C3 25272zH k
e r u t a r e p m e T n o i t a r e p O007C
Hall Sensor Power Output:
6.25V @30mA maximum. Typical current draw from hall sensors is 20mA.
All three Hall Sensor inputs are pulled up through 20K ohm resistors.
The external speed control potentiometer must be 10K ohms.
Motor Freewheel
The motor freewheel feature allows the de-energizing of the motor phases. A high (open) 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 operation
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.
Heating Considerations
The temperature of the heat sink should never be allowed to rise above 70 degrees Celsius. If necessary,
mount the unit to an additional heat sink or air should be blown across the heat sink to maintain suitable
temperatures. 
						

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Speed Output
The PG OUT  terminal (TB1 - pin 1 and 2)  is used to determine the speed of the motor shaft. An opto-
decoupled open collector output is shown 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. Care must be taken not to
pass more than 50mA through this transistor.
s e l o P #M P R
8)z H n i ( T U O G P * 5 1
6)z H n i ( T U O G P * 0 2
4)z H n i ( T U O G P * 0 3
# n i Pn o i t p i r c s e D
1)r o t c e l l o c ( T U O G P
2)r e t t i m e ( T U O G P
3)+ ( n o i t c e r i D
4)- ( n o i t c e r i D
5)+ ( l e e h w e e r F
6)- ( l e e h w e e r F
7)+ ( p o t S / n u R
8)- ( p o t S / n u R
9)r o t c e l l o c ( t u O t l u a F
0 1)r e t t i m e ( t u O t l u a F
Terminal and Dip Switch Descriptions
# n i Pn o i t p i r c s e D
1re w o P r o s n e S l l a H
2Ar o s n e S l l a H
3Br o s n e S l l a H
4Cr o s n e S l l a H
5ec n e r e f e R r o s n e S l l a H
# n i Pn o i t p i r c s e D
1Ae s a h P
2Be s a h P
3Ce s a h P
# n i Pn o i t p i r c s e D
1)C A V 5 3 1 - 5 8 ( N I V
2DN G
3DN G H T R A E
# n i Pn o i t p i r c s e D
1)+ ( t o P x E
2)w ( t o P x E
3)- ( t o P x E
# W Sn o i t p i r c s e D
1DE E P S T X E / T N I
2HC T A L T L F
31P M A R
42P M A R
502 1 / 0 6
# W Sn o i t p i r c s e D
1PO O L C / O
21L C
32L C
43L C
TB1: Opto-isolated Control
Inputs and OutputsTB2: Motor Hall Terminals TB3: Motor Phase
Terminals
TB4: AC  Voltage  In
TerminalsTB5: 10K External Pot
(optional)
SW1: Dip Switch SW2: Dip Switch 
						

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Dip Switch and Jumper Settings
n o i t c n u F1 W S2 W S3 W S4 W S5 W S
) 6 4 R ( l o r t n o C d e e p S l a n r e t n Iff O-- --- --- --- -
) 5 B T ( l o r t n o C d e e p S l a n r e t x EnO-- --- --- --- -
g n i h c t a L t n e r r u C r e v O-- -nO-- --- --- -
e l c y C y b e l c y C t n e r r u C r e v O-- -ff O-- --- --- -
) c e S 4 ( 1 e l i f o r P p m a R-- --- -ff Off O-- -
) c e S 2 ( 2 e l i f o r P p m a R-- --- -ff OnO-- -
) c e S 1 ( 3 e l i f o r P p m a R-- --- -nOff O-- -
) c e S m 0 0 5 ( 4 e l i f o r P p m a R-- --- -nOnO-- -
g n i c a p S r o s n e S l l a H ° 0 6-- --- --- --- -ff O
g n i c a p S r o s n e S l l a H ° 0 2 1-- --- --- --- -nO
) p i h S o t y d a e R ( t c u d o r P d r a d n a t Sff Off Off Off OnO
SW1: Speed Adjustment, Over Current, and Ramp settings
n o i t c n u F1 W S2 W S3 W S4 W S
) d e p o o L d e s o l C ( e d o M d e e p S t n a t s n o Cff O-- --- --- -
) p o o L n e p O ( e d o M d e e p S d e l l o r t n o C e g a t l o VnO-- --- --- -
1 n o i t a s n e p m o C p o o L d e s o l C-- --- --- --- -
2 n o i t a s n e p m o C p o o L d e s o l C-- --- --- --- -
3 n o i t a s n e p m o C p o o L d e s o l C-- --- --- --- -
_ p i h S o t y d a e R ( y c u d o r P d r a d a n t SnOff Off Off O
SW2: Open Loop and Closed Loop. If Closed Loop selected, Closed Loop
compensation switches must be set according to motor speed desired.
Switch and Terminal Block Locations 
						

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1 L C2 L C3 L Cn i a G L C
n OnOnOni M
f f OnOnO
n Off OnO
f f Off OnO
n OnOff O
f f OnOff O
n Off Off O
f f Off Off Oxa M
Open Loop/ Closed Loop (Constant Velocity Mode)
The driver can either be set for Open Loop or Closed Loop operation. Open Loop operation is used for
applications where the speed of the motor needs to change according to the load. Closed Loop operation
is used for applications where speed regulation is needed. Under closed loop operation, the speed is
regulated despite changes to the load and the power supply voltage.
To operate Open Loop, the O/C LOOP switch (SW2, pin1) must be in the ‘on’ position.
To operate Closed Loop, the O/C LOOP switch (SW2, pin1) must be in the ‘off’ position and the CL ADJ
POT (R3) and CL ADJ dip switches (SW2, pin 2-4) must be set to optimize the driver for each application.
*   If using an Anaheim Automation DC Brushless motor: the tables shown on the next page are
    the Closed Loop potentiometer and dip switch settings for each motor.  The regulated speed of
    the motor is then controlled by adjusting the internal (R46) or external speed pot. The motor
    speed can be monitored by measuring the pulse rate of PG OUT (TB1 - pin 1 and 2).
*   If using a non-Anaheim Automation DC Brushless motor:
     1) Set the O/C LOOP switch (SW2, pin1) in the ‘off’ position
     2) Set the closed loop switches CL1, CL2, and CL3 on the ‘on’ position.
     3) Set CL ADJ POT to 0%.
     4) Adjust the internal speed pot (R46)  or external speed pot to 100% The motor at this time
         should be running at its maximum speed.
     5) Increase the closed loop gain by switching CL1, CL2, and CL3 incrementally one stage
         according to the following table until the motor speed dips below the maximum speed. Set
         the switches up one stage to the position before the motor dips below the maximum speed
         and proceed to step 6. Decreasing the gain will increase the motor speed.
     6) Slowly rotate CL POT toward 100% until the motor speed slightly begins to decreases. At this
         point, the motor closed loop adjustments are set.
*  If a slower top motor speed is desired, set CL ADJ POT to 0%. Increase the closed loop
   gain incrementally by setting CL1, CL2, CL3 with respect to the desired top motor speed
   and re-tune CL ADJ POT, as described in step 4 and step 5. 
						

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r o t o M1 L C2 L C3 L CL C
T O PD P S X A M
) M P R (D P S N I M
) M P R (
0 0 0 8 - V 5 1 - S 0 1 1 R W L BnOnOnO%0 800 0 800 5
0 0 0 0 1 - V 4 2 - S 1 1 1 R W L BnOnOnO%0 505 0 0 152 8
0 0 7 3 - V 4 2 - S 2 1 1 R W L BnOff OnO%0 0 153 7 305 4
0 0 0 4 - V 6 3 - D 1 3 2 R W L BnOff OnO%5 601 0 405 5
0 0 0 4 - V 6 3 - D 2 3 2 R W L BnOff OnO%5 601 0 405 5
0 0 0 4 - V 6 3 - D 3 3 2 R W L BnOff OnO%5 601 0 405 5
0 0 0 4 - V 6 3 - D 4 3 2 R W L BnOff OnO%5 601 0 405 5
0 0 0 4 - V 6 3 - D 5 3 2 R W L BnOff OnO%5 601 0 405 5
0 5 3 1 - V 4 2 - S 2 3 2 R W L Bff Off Off O%000 6 100 2
0 0 0 4 - V 6 3 - D 1 3 2 S W L B
0 0 0 4 - V 6 3 - S 1 3 2 S W L Bn Off OnO%5 601 0 405 5
0 0 0 4 - V 6 3 - D 2 3 2 S W L B
0 0 0 4 - V 6 3 - S 2 3 2 S W L Bn Off OnO%5 601 0 405 5
0 0 0 4 - V 6 3 - S 3 3 2 S W L BnOff OnO%5 601 0 405 5
0 0 0 4 - V 6 3 - D 4 3 2 S W L B
0 0 0 4 - V 6 3 - S 4 3 2 S W L Bn Off OnO%5 601 0 405 5
0 0 0 4 - V 6 3 - S 5 3 2 S W L BnOff OnO%5 601 0 405 5
r o t o M1 L C2 L C3 L CL C
T O PD P S X A M
) M P R (D P S N I M
) M P R (
0 0 0 8 - V 7 1 - S 1 7 1 Y L BnOnOnO%000 5 700 5
0 0 5 9 - V 7 1 - S 2 7 1 Y L BnOnOnO%000 0 900 5
0 0 0 4 - V 4 2 - S 1 7 1 Y L BnOnOnO%0 800 0 405 2
0 0 0 4 - V 4 2 - D 2 7 1 Y L B
0 0 0 4 - V 4 2 - S 2 7 1 Y L Bn OnOnO%0 800 0 405 2
0 0 0 4 - V 4 2 - D 3 7 1 Y L BnOnOnO%0 800 0 405 2
0 0 0 4 - V 4 2 - D 4 7 1 Y L B
0 0 0 4 - V 4 2 - S 4 7 1 Y L Bn OnOnO%0 800 0 405 2
0 0 2 3 - V 8 4 - D 1 4 3 Y L B
0 0 2 3 - V 8 4 - S 1 4 3 Y L Bf f OnOnO%0 400 2 305 2
0 0 0 3 - V 4 2 - D 2 4 3 Y L Bff OnOnO%0 400 0 305 2
0 0 0 3 - V 0 3 - D 2 4 3 Y L B
0 0 0 3 - V 0 3 - S 2 4 3 Y L Bf f OnOnO%0 400 0 305 2
0 0 2 3 - V 8 4 - D 2 4 3 Y L B
0 0 2 3 - V 8 4 - S 2 4 3 Y L Bf f OnOnO%0 300 2 305 2
0 0 2 3 - V 8 4 - D 3 4 3 Y L B
0 0 2 3 - V 8 4 - S 3 4 3 Y L Bf f OnOnO%0 300 2 305 2
0 0 0 3 - V 0 3 - S 3 4 3 Y L Bff OnOnO%0 400 0 305 2
0 0 2 3 - V 8 4 - D 4 4 3 Y L B
0 0 2 3 - V 8 4 - S 4 4 3 Y L Bf f OnOnO%0 300 2 305 2
0 0 5 3 - V 6 3 - S 2 6 3 Z L Bff OnOnO%0 100 5 303 3
0 0 5 3 - V 0 6 1 - S 2 6 3 Z L Bff OnOnO%0 100 5 303 3
0 0 5 3 - V 0 6 1 - S 2 8 4 Z L Bff OnOnO%0 100 5 303 3
0 0 5 3 - V 4 2 - S 2 4 2 Z L Bff OnOnO%0 100 5 303 3
4-pole motors
8-pole motors
Anaheim Automation Motor Closed Loop Settings 
						

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+ = 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 AND DO
NOT HOOKUP ANYTHING BUT THE HALL WIRES TO THE HALL CONNECTIONS. Turn on power
and rotate the motor by hand. If the RED FAULT LED comes on, the hall phases are incorrectly 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 both directions then the phase wires are correct.
The wiring of the motor phases should be separated from the hall and input connections to not allow a
possible source of interference.
Commutation Sequence
p e t S
123456
A e s a h P+Z--Z+
B e s a h PZ++Z--
C e s a h P--Z++Z
A l l a H 11000 1
B l l a H 0 11100
C l l a H 000 111
p e t S
123456
A e s a h P-Z++Z-
B e s a h PZ--Z++
C e s a h P++Z--Z
A l l a H 11000 1
B l l a H 0 11100
C l l a H 000 111
p e t S
123456
A e s a h P+Z--Z+
B e s a h PZ++Z--
C e s a h P--Z++Z
A l l a H 111000
B l l a H 0 11100
C l l a H 00 1110
p e t S
123456
A e s a h P-Z++Z-
B e s a h PZ--Z++
C e s a h P++Z--Z
A l l a H 111000
B l l a H 0 11100
C l l a H 00 1110
120° Hall Spacing Sequence Forward120° Hall Spacing Sequence Reverse
60° Hall Spacing Sequence Forward 60° Hall Spacing Sequence Reverse 
						

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Typical Hookup Drawing
Figure 2: Hook up for current sinking inputs
Figure 3: Hook up for current sourcing inputs 
						

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Dimensions