Anaheim Brushless DC MDC151050601 Users Guide

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MDC151-050601
50V @ 60 Input 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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MDC151-050601 Driver Features
•	Maximum Current Limit Setting from 20 - 60Amps (peak) up to 1000W Powe\
r Output
•	 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 20-50 VDC
•	 Speed Out
•	 Fault Out
•	 Brake, Disable and Direction Inputs
•	 Selectable Ramp Up
•	 TTL-CMOS Compatible Inputs
•	 Dual Mounting Option
•	 Detachable, Screw type Terminal Blocks
General Description
The MDC151-050601 driver is designed to drive DC Brushless motors at currents of up to 60A (peak) 
and 50V.  Using hall sensor feedback, a constant velocity mode can be selected.  The driver is pro-
tected against over current (cycle-by-cycle or latched), hall sensor error and under voltage.  When an 
error	 occurs,	 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 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	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 an over current latch function by setting the 
‘FLT LATCH’ dip switch.  If a motor current level exceeding the current limit set by the current limit 
potentiometer is produced, an over current latch is activated, shutting off the output and turning the 
fautl output low (logic “0”).  This driver is equipped with a FAULT LED and a fault output 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 S\
en-
sor voltage.
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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 th\
rough 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 t\
o a hard stop
Logic “0” - Motor will run and will accelerate according to ramp d\
ip switch setting
V Control: (TB3, Pin 6)
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)
Controls Outputs: (TB3, Pins 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 pulse 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)
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 ‘Fault Protection’ section has occurred.  When a 
fault is detected, the Fault Output (pin 5) goes low.
Output Current Rating:
Adjustable 20.0 - 60.0 amperes per phase maximum operating peak current
 
      (10.0 - 30.0 amperes per phase maximum operating continuous curre\
nt)
Power Requirements: (TB2, Pins 4 and 5)
20VDC (min) - 50VDC (max)
Operating Temperature:
Heat Sink: 0°-70° C
Specifications
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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.
Open Loop/Closed Loop (Constant Velocity Mode)
The driver can either be set for Open Loop or Closed Loop operation.  Op\
en 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 (SW1 - pos1) 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 the CLADJ 
POT 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 Brushless motor:
1. Start with setting the closed loop switches CL1, CL2, and CL3 on the ‘\
on’ position.
2.  Set CLADJ POT 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 posi-
tion before the motor dips below the maximum speed and proceed to step 5\
.
5.  Slowly rotate CLADJ POT 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 CLADJ 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 CLADJ POT, 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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MotorCL1CL2CL3 CL 
POT MAX SPD
(RPM) MIN 
SPD 
(RPM)
BLWR110S-15V-8000 OnOnOn80% 8000 500
BLWR111S-24V-10000 OnOnOn50% 10050 825
BLWR112S-24V-3700 OnOffOn100% 3735 450
BLWR231D-36V-4000 OnOffOn65% 4010 550
BLWR232D-36V-4000 OnOffOn65% 4010 550
BLWR233D-36V-4000 OnOffOn65% 4010 550
BLWR234D-36V-4000 OnOffOn65% 4010 550
BLWR235D-36V-4000 OnOffOn65% 4010 550
BLWR232S-24V-1350 OffOffOff0% 1600 200
BLWS231D-36V-4000
BLWS231S-36V-4000 On
OffOn65% 4010 550
BLWS232D-36V-4000
BLWS232S-36V-4000 On
OffOn65% 4010 550
BLWS233S-36V-4000 OnOffOn65% 4010 550
BLWS234D-36V-4000
BLWS234S-36V-4000 On
OffOn65% 4010 550
BLWS235-36V-4000 OnOffOn65% 4010 550
4-Pole Motors
Motor CL1CL2CL3 CL 
POT MAX SPD
(RPM) MIN 
SPD 
(RPM)
BLY171S-17V-8000 OnOnOn0% 7500 500
BLY172S-17V-9500 OnOnOn0% 9000 500
BLY171S-24V-4000 OnOnOn80% 4000 250
BLY172D-24V-4000
BLY172S-24V-4000 On
OnOn80% 4000 250
BLY173D-24V-4000 OnOnOn80% 4000 250
BLY174D-24V-4000
BLY174S-24V-4000 On
OnOn80% 4000 250
BLY341D-48V-3200
BLY341S-48V-3200 Off
On On40% 3200 250
BLY342D-24V-3000 OffOn On40% 3000 250
BLY342D-30V-3000
BLY342D-30V-3000 Off
On On40% 3000 250
BLY342D-48V-3200
BLY342S-48V-3200 Off
On On30% 3200 250
BLY343D-48V-3200
BLY343S-48V-3200 Off
On On30% 3200 250
BLY343S-30V-3000 OffOn On40% 3000 250
BLY344D-48V-3200
BLY344S-48V-3200 Off
On On30% 3200 250
BLZ362S-36V-3500 OffOn On10% 3500 330
BLZ362S-160V-3500 OffOn On10% 3500 330
BLZ482S-160V-3500 OffOn On10% 3500 330
BLZ242S-24V-3500 OffOn On10% 3500 330
8-Pole Motors
Anaheim Automation Motor Closed Loop Settings
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Step
1 234 56
Phase A +Z --Z +
Phase B Z++Z --
Phase C --Z ++Z
Hall A 1100 01
Hall B 0111 00
Hall C 0001 11Step
1 234 56
Phase A -Z ++Z -
Phase B Z--Z ++
Phase C ++Z --Z
Hall A 1100 01
Hall B 0111 00
Hall C 0001 11
Step
1 234 56
Phase A +Z --Z +
Phase B Z++Z --
Phase C --Z ++Z
Hall A 1110 00
Hall B 0111 00
Hall C 0011 10Step
1 234 56
Phase A -Z ++Z -
Phase B Z--Z ++
Phase C ++Z --Z
Hall A 1110 00
Hall B 0111 00
Hall C 0011 10
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	 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 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 ar\
e 
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 GroundPin # Description
1 Phase A
2 Phase B
3 Phase C
4 VIN
5 GND
TB1: Motor Hall Terminals
TB2: Power and Motor 
Phase Terminals
TB3: Control Inputs 
and Outputs
Pin #Description
1 PG OUT
2 Direction
3 Freewheel
4 Run/Stop
5 Fault/Stop
6 V Control
7 GND
SW # Description
1 INT/EXT SPEED
2 FLT LATCH
3 RAMP 1
4 RAMP 2
5 60/120
SW1: Dip Switch
Dip Switch Settings
Function SW1SW2SW3SW4SW5
Internal Speed Control (R46) Off------------
External Speed Control (TB3 - Pin 6) 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
Standard Product (Ready to Ship) OffOffOffOffOn
SW1: Speed Adjustment, Over Current, and Ramp settings
SW #Description
1 O/C LOOP
2 CL1
3 CL2
4 CL3
SW2: Dip Switch
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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 dire\
ction.
Speed Adjust Setting
There are three ways to set the speed on this drive.  One is to use the onboard.  The others is to 
use an external voltage.  To use the onboard potentiometer, set INT/EXT SPD switch to the off posi-
tion (default).  To use the external potentiometer or external 0V to 5V voltage speed sett\
ing, set INT/
EXT SPE 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 V Control (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 V Control (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 V Control 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 V Control input.
Dip Switch Settings (cont.)
FunctionSW1SW2SW3SW4
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) OnOffOffOff
SW2: Open Loop and Closed Loop.  If Closed Loop selected, 
Closed Loop compensation switches must be set according to the 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.
# PolesRPM
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
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