Anaheim Brushless DC MDC200048051 Brushless DC Controller Users Guide

							September 2012 L0104041
MDC200-048051
110VAC 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 
						

							September 2012 L0104042
MDC200-048051 Driver Features
•  Maximum Current Limit Setting from 1 - 5Amps (peak) up to 100W Power Output
•  Internal or External Potentiometer Speed Control
•  48VDC Motor Voltage Bus
• 2-Quadrant Operation
•  Hall Sensor Feedback
•  Constant Velocity Mode
•  Short Circuit Protection
•  Requires 85 - 135 VAC Power Input
• Speed Out
• Fault Out
•  Brake, Disable and Direction Inputs
•  Selectable Ramp Up/Down
•  Optically Isolated Inputs and Outputs
•  Compact Size (6.25” x 4.35” x 1.93”)
•  Dual Mounting Option
•  Detachable, Screw type Terminal Blocks
General Description
The MDC200-048051 driver is a velocity control driver designed to drive DC Brushless Motors from 
a supply of 120VAC.  With a motor bus voltage of 48V, maximum phase current of 5A (peak) and 
power output of 100W, this driver eliminates the need for an external power supply.  Using hall sen-
sor 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 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 freewheel input.  When using the run/stop input, there are three ramp up/down profi les from 
standstill to select from.  The run/stop input overrides all other inputs into the driver.
Pin Descriptions
The inputs on the MDC200-048051 are optically isolated with an 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 +7 VDC across 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 MDC200-048051 are an opto-decoupled open collector output.  
When normal operation occurs, this output will conduct current into the emitter.  Care must be taken 
not to pass more than 50mA through this transistor. 
						

							September 2012 L0104043 Output Current Rating:
Adjustable 1.0 - 5.0 amperes per phase maximum operating peak current.
  (0.5 - 2.5 amperes per phase maximum operating continuous current)
Power Requirements: (TB4, Pins 1 and 2)
85VAC (min) - 135VAC (max)
Operating Temperature:
Heat Sink: 0° - 70° C
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.
Optically Isolated Inputs and Output
The following inputs and output to the MDC200-048051 are Optically Isolated.
Item Pin #
PG Out 1 & 2
Direction 3 & 4
Freewheel 5 & 6
Run Stop 7 & 8
Fault Out 9 & 10
To enable an input, apply a DC voltage source of +5VDC to +7VDC across the inputs.  The Anodes 
(+) are pins 3, 5, and 7 and the Cathodes (-) are pins 4, 6, and 8.
Absolute Maximum Ratings
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 (SW1 - pos1) must be in the ‘on’ position.
To operate Closed Loop, the O/C LOOP switch must be in the ‘off’ position and the CLADJ poten-
tiometer (R3) and CLADJ dip switches (SW1 - pos2-4) must be set to optimize the driver for each 
application.  The Closed Loop adjustments are needed for faster and slower motor operation, within 
the restrictions of the motor rated speed.  The adjustments provide a direct duty cycle to the driver 
with respect to the required motor speed.
The following tables show Closed Loop potentiometer and dip switch settings for each motor.  These 
adjustments will set the maximum setting of the internal/external speed potentiometer to the motors 
maximum running speed.  If operation at slower speeds is needed for the application, CL POT can 
be adjusted toward 100% until desired motor speed is achieved.  The motor speed can be monitored 
by measuring the pulse rate of PG OUT (TB2 - pin 1 & 2) 
						

							September 2012 L0104044
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 
						

							September 2012 L0104045
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. 
						

							September 2012 L0104046
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 PG OUT (collector)
2 PG OUT (emitter)
3 Direction (+)
4 Direction (-)
5 Freewheel (+)
6 Freewheel (-)
7 Run/Stop (+)
8 Run/Stop (-)
9 Fault Out (collector)
10 Fault Out (emitter)
TB1: Motor Hall Terminals
TB2: Opto-isolated Control 
Inputs and OutputsTB3: AC  Voltage  In 
Terminals
Pin # Description
1 AC Hot
2 AC Neutral
3EARTH GND (must 
be connected)
Pin #  Description
1 Phase A
2 Phase B
3 Phase C
SW # Description
1 O/C LOOP
2 CL1
3 CL2
4 CL3
TB4: Motor Phase 
Terminals
SW1: Dip Switch
Dip Switch Settings
Function SW1 SW2 SW3 SW4 SW5
Internal Speed Control (R46) Off --- --- --- ---
External Speed Control (TB3 - Pin 6) 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
SW # Description
1 INT/EXT SPEED
2 FLT LATCH
3 RAMP 1
4 RAMP 2
5 60/120
SW2: Dip SwitchP1: 10K External Pot
TB# Pin # Description
1 1 Pot (+) Top
3 6 Pot Wiper
3 7 Pot (-) Bottom 
						

							September 2012 L0104047
Motor Freewheel
The motor freewheel feature allows the de-energizing of the motor phases. Zero current into this input 
causes the motor to run at the given speed, while ~1mA into 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.  Zero current into this input causes the motor to turn in the CW 
direction, while ~1mA into 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 onboard or external potentiometer.  
To use the onboard potentiometer, set INT/EXT SPD Switch to the off position (default).  To use the 
external 10K potentiometer, set INT/EXT SPD switch to the on position.  If an external potentiometer 
is used to control the speed of the motor, connect the pot wiper to P1 - pin ‘W’, the positive end of 
the potentiometer to P1 - pin ‘H’ and the negative end to P1 - pin ‘L’.
Fault Protection and Fault Output
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.  Under-voltage Lockout activation at 9.1VDC for the input voltage and 4.5VDC for Hall Sen-
sor voltage.
The fault output on the MDC200-048051 is an opto-deocoupled open collector output.  When a 
latched fault condition occurs, no current conducts into the emitter.  When normal operation occurs, 
this output will conduct current into the emitter.  Care must be taken not to pass more than 50mA 
through this transistor.
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
SW1: Open Loop and Closed Loop.  If Closed Loop selected, 
Closed Loop compensation switches must be set according to the motor speed 
desired. 
						

							September 2012 L0104048
Speed Output
The PG OUT terminal (TB2 - 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.
# 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.
Dimensions 
						

							September 2012 L0104049
Typical Wiring Diagram 
						

							September 2012 L01040410
ANAHEIM AUTOMATION
COPYRIGHT 
Copyright 2012 by Anaheim Automation. All rights reserved. No part of this publication may be reproduced, 
transmitted, transcribed, stored in a retrieval system, or translated into 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 consequential 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 indemnifi es 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 specifi cations.  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 fi rst. Warranty provisions may be voided if products 
are subjected to physical modifi cations, 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.