Anaheim Brushless DC MDC151012301Brushless DC Driver Users Guide

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MDC151-012301 Series
12V, 30A Brushless DC 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 
						

							September 2012 L0104052
MDC151-012301 Driver Features
•  Maximum Current Limit Setting from 10.0-30.0 Amps (peak)
•  Internal or External Potentiometer Speed Control
•  0V to 5V External Voltage Speed Control
• 2-Quadrant Operation
•  Hall Sensor Feedback
•  Constant Velocity Mode
•  Short Circuit Protection
•  Requires 10 - 15VDC
• Speed Out
• Fault Out
•  Run/Stop, Freewheel and Direction
•  Selectable Ramp Up
•  TTL-CMOS Compatible Inputs
•  Compact Size (6.25” x 3.28” x 1.65”)
•  Dual Mounting Option
•  Screw Type Terminal Block
General Description
The MDC151-012301 driver is designed to drive DC brushless motors at currents of up to 30A (peak) 
and 15V.  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 
occurs, a fault light is turned on 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 con-
trol the speed of the motor.  An optional external potentiometer (10K) or external voltage (0-5VDC) 
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 profi les from standstill to select from.  The run/stop input 
overrides all inputs into the driver.
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 or external 
current limit potentiometer is produced, an over current latch is activated, shutting off the output.  This 
driver is equipped with a FAULT LED to alert 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 current latch. 
3.  Undervoltage Lockout activation at 9.1VDC for the input voltage and 4.5VDC for Hall Sen-
sor voltage. 
						

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Specifi cations
Control Inputs: (TB1, Pins 1-3)
TTL-CMOS Compatible
Logic “0” = 0-0.8VDC
Logic “1” = OPEN
All three inputs (run/stop, freewheel, and direction) are pulled up through 20k Ohm resistors.
Direction Control: (TB3, Pin 2)
Logic “1” (open) - Clockwise
Logic “0” - Counterclockwise
Freewheel: (TB3, Pin 3)
Logic “1” (open) - Motor is Enabled
Logic “0” - Motor is de-energized and will coast 
Run/Stop: (TB3, Pin 4)
Logic “1” (open) - Motor will not run and if running will come to a hard stop
Logic “0” - Motor will run and will accelerate according to ramp dip switch setting
Vcontrol: (TB1, Pin 4)
To control the speed of the motor with an external DC voltage, INT/EXT SPD switch (SW1-POS1) must 
be switched to the ON position.
0VDC (min) - 5VDC (max)
Control Outputs: (TB3, Pin 1 and 5)
TTL-CMOS Compatible
These outputs are able to sink 50mA
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)
Fault Output: (TB3, Pin 5)
Logic “1” (5V out) - Status good, normal operation.
Logic “0” - One of the three fault conditions listed in the ‘Fault Protection’ section has occurred.  When a 
fault is detected, the Fault Output (pin 5) goes low. 
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 4 and 5)
10VDC (min) - 15VDC (max)
Operating Temperature:
Heat Sink: 0°-70° C 
						

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Hall Sensor Power Output:
6.25V @ 30mA maximum. Typical current draw from hall sensor is 20mA.
All three Hall Sensor inputs are pulled up through 20K ohm resistors.
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, pin 1) must be in the ‘on’ position.
To operate Closed Loop, the O/C LOOP switch (SW2, pin 1) must be in the ‘off’ position and hte 
CLADJ POT (R3) and CLADJ 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 
Close Loop potentiometer and dip switch settings for each motor.  The regulated speed of the motor 
is then controlled by adjusting the internal or external speed pot.  The motor speed can be monitored 
by measuring the pulse rate of PG OUT (TB3 - pin 1).
If using a non-Anaheim Automation DC Motor.
1.  Start with setting the closed loop switches CL1, CL2, and CL3 on the ‘on’ position.
2.  Set CLADJPOT to 0%.
3.  Adjust the internal speed pot or external speed pot to 100% The motor at this time should 
be running at its maximum speed.
4.  Increase the closed loop gain by switching CL1, CL2, and CL3 incrementally one stage 
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 5.
5.   Slowly rotate CLADJPOT toward 100% until the motor speed slightly begins to decrease.  
     At this point, the motor closed loop adjustments are set.
  * If a slower top motor speed is desired, set CLADJPOT to 0%.  Increase the closed 
  loop gain incrementally by setting CL1, CL2, CL3 with respect to the desired top motor 
  speed and re-tune CLADJPOT, as described in step 4 and step 5.
CL1 CL2 CL3 CL Gain
On On On Min
Off On On
On Off On
Off Off On
On On Off
Off On Off
On Off Off
Off Off Off Max 
						

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Anaheim Automation Motor Closed Loop Settings
Motor CL1 CL2 CL3CL 
POTMAX SPD
(RPM)MIN 
SPD 
(RPM)
BLWR110S-15V-8000 On On On 80% 8000 500
BLWR111S-24V-10000 On On On 50% 10050 825
BLWR112S-24V-3700 On Off On 100% 3735 450
BLWR231D-36V-4000 On Off On 65% 4010 550
BLWR232D-36V-4000 On Off On 65% 4010 550
BLWR233D-36V-4000 On Off On 65% 4010 550
BLWR234D-36V-4000 On Off On 65% 4010 550
BLWR235D-36V-4000 On Off On 65% 4010 550
BLWR232S-24V-1350 Off Off Off 0% 1600 200
BLWS231D-36V-4000
BLWS231S-36V-4000On Off On 65% 4010 550
BLWS232D-36V-4000
BLWS232S-36V-4000On Off On 65% 4010 550
BLWS233S-36V-4000 On Off On 65% 4010 550
BLWS234D-36V-4000
BLWS234S-36V-4000On Off On 65% 4010 550
BLWS235-36V-4000 On Off On 65% 4010 550
4-Pole Motors
Motor CL1 CL2 CL3CL 
POTMAX SPD
(RPM)MIN 
SPD 
(RPM)
BLY171S-17V-8000 On On On 0% 7500 500
BLY172S-17V-9500 On On On 0% 9000 500
BLY171S-24V-4000 On On On 80% 4000 250
BLY172D-24V-4000
BLY172S-24V-4000On On On 80% 4000 250
BLY173D-24V-4000 On On On 80% 4000 250
BLY174D-24V-4000
BLY174S-24V-4000On On On 80% 4000 250
BLY341D-48V-3200
BLY341S-48V-3200Off On On 40% 3200 250
BLY342D-24V-3000 Off On On 40% 3000 250
BLY342D-30V-3000
BLY342D-30V-3000Off On On 40% 3000 250
BLY342D-48V-3200
BLY342S-48V-3200Off On On 30% 3200 250
BLY343D-48V-3200
BLY343S-48V-3200Off On On 30% 3200 250
BLY343S-30V-3000 Off On On 40% 3000 250
BLY344D-48V-3200
BLY344S-48V-3200Off On On 30% 3200 250
BLZ362S-36V-3500 Off On On 10% 3500 330
BLZ362S-160V-3500 Off On On 10% 3500 330
BLZ482S-160V-3500 Off On On 10% 3500 330
BLZ242S-24V-3500 Off On On 10% 3500 330
8-Pole Motors 
						

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Step
1 2 3456
Phase A + Z - - Z +
Phase B Z + + Z - -
Phase C - - Z + + Z
Hall A 1 1 0 0 0 1
Hall B 0 1 1 1 0 0
Hall C 0 0 0 1 1 1
Step
1 2 3456
Phase A - Z + + Z -
Phase B Z - - Z + +
Phase C + + Z - - Z
Hall A 1 1 0 0 0 1
Hall B 0 1 1 1 0 0
Hall C 0 0 0 1 1 1
Step
1 2 3456
Phase A + Z - - Z +
Phase B Z + + Z - -
Phase C - - Z + + Z
Hall A 1 1 1 0 0 0
Hall B 0 1 1 1 0 0
Hall C 0 0 1 1 1 0
Step
1 2 3456
Phase A - Z + + Z -
Phase B Z - - Z + +
Phase C + + Z - - Z
Hall A 1 1 1 0 0 0
Hall B 0 1 1 1 0 0
Hall C 0 0 1 1 1 0
120° Hall Spacing Sequence Forward 120° Hall Spacing Sequence Reverse
60° Hall Spacing Sequence Forward 60° Hall Spacing Sequence Reverse
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 fi rst 
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 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. 
						

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Terminal and Dip Switch Descriptions
Pin # Description
1 Hall Sensor Power
2 Hall Sensor A
3 Hall Sensor B
4 Hall Sensor C
5 Hall Sensor Ground
Pin # Description
1 Phase A
2 Phase B
3 Phase C
4 VIN
5 GND
TB1: Motor Hall TerminalsTB2: Power and Motor 
Phase Terminals
TB3: Control Inputs and 
Outputs
Pin # Description
1 PG OUT
2 Direction
3 Freewheel
4 Run/Stop
5 Fault Out
6 VControl
7 GND
SW # Description
1 INT/EXT SPEED
2 FLT LATCH
3 RAMP 1
4 RAMP 2
5 60/120
SW # Description
1 O/C LOOP
2 CL1
3 CL2
4 CL3
SW1: Dip SwitchSW2: Dip Switch
Dip Switch Settings
Function SW1 SW2 SW3 SW4 SW5
Internal Speed Control (R46) Off --- --- --- ---
External Speed Control (P1) On --- --- --- ---
Over Current Latching --- On --- --- ---
Over Current Cycle-by-Cycle --- Off --- --- ---
Ramp Profi le 1 (4 Sec) --- --- Off Off ---
Ramp Profi le 2 (2 Sec) --- --- Off On ---
Ramp Profi le 3 (1 Sec) --- --- On Off ---
Ramp Profi le 4 (500mSec) --- --- On On ---
60° Hall Sensor Spacing --- --- --- --- Off
120° Hall Sensor Spacing --- --- --- --- On
Standard Product (Ready to Ship) Off Off Off Off On
SW1: Speed Adjustment, Over Current, and Ramp settings 
						

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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 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 direc-
tion, while a low at this input causes the motor to turn in the CCW direction.
Speed Adjust Setting
There are three ways to set the speed on this drive.  One is to use the on-board or external poten-
tiometer.  To others is to use an external voltage.  To use the on-board potentiometer, set INT/EXT 
SPD switch to the off position (default).  To use the external 10K potentiometer or external 0V to 5V 
voltage speed setting, set INT/EXT SPD switch to the on position.  If a voltage is used to control the 
speed of the motor, the 0V to 5V voltage can be tied on Vcontrol (TB3 - pin 6) with respect to GND 
(TB3 - pin 7).  If an external potentiometer is used to control the speed of the motor, connect the pot 
wiper to Vcontrol (TB3 - pin 6), the positive end of the potentiometer to Hall Power (TB1 - pin 1) and 
the negative end to GND (TB3 - pin 7).
The maximum voltage that can be placed on Vcontrol is 15V.  A voltage exceeding 15V may cause 
damage to the driver.  If a voltage other than 0V to 5V is needed to control the speed of the motor, 
contact Anaheim Automation for custom tuning of the Vcontrol input.
Dip Switch Settings (cont.)
Function SW1 SW2 SW3 SW4 SW5
Constant Speed Mode (Closed Loop) Off --- --- --- ---
Voltage Controlled Speed Mode (Open Loop) On --- --- --- ---
Closed Loop Compensation 1 --- --- --- --- ---
Closed Loop Compensation 2 --- --- --- --- ---
Closed Loop Compensation 3 --- --- --- --- ---
Standard Product (Ready to Ship) On Off Off Off Off
SW2: Open Loop and Closed Loop.  If Closed Loop selected, Closed Loop 
compensation switches must be set according to motor speed desired. 
						

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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 pulses for 1 revolution 
of a 6-pole motor, and 2 pulses for 1 revolution of a 4-pole motor.
# Poles RPM
8 15 * PG OUT (in Hz)
6 20 * PG OUT (in Hz)
4 30 * PG OUT (in Hz)
Heating Considerations
The temperature of the heat sink should never be allowed to rise above 70° Celsius.  If necessary, 
mount the unit to an additional heat sink or air should be blown across the heat sink to maintain suit-
able temperatures.
Typical Wiring Diagram 
						

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Dimensions