Anaheim Brushless DC MDC300120151 Users Guide

							MDC300-120151 Series
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 MDC300-120151 Driver is designed to drive DC brushless motors at currents of up to 15A peak and 
170VDC.  Using hall sensor feedback, a constant velocity mode can be sel\
ected.  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 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 spee\
d of the motor.  An optional external 
potentiometer or voltage input can be used to control the speed as well.  The direction of the motor can 
be present by the direction control input or controlled by the external voltage speed input.  Other inputs 
to the drive include a run/stop and a motor freewheel input.  An onboard potentiometer sets the ramp up/
down profile from standstill.  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 to the “on” position. The ‘FLT LATCH’ switch is located on Switch Panel 1 toggle 
SW2.   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 and turning the fault output low 
(logic “0”).  This driver is equipped with a FAULT LED and Fault-out output to alert the user of the fol-
lowing conditions.  To reset the MDC300-120151 driver from a latched condition, power down, a\
llow 30 
seconds for power to dissipate, then power up.
MDC300-120151 Driver Features
• Maximum Current Limit Setting from 5.0 to 15.0 Amps peak
• Internal/External Potentiometer or Voltage Input Speed Control
• Onboard Potentiometer Ramp Up/Down Adjustment
• 2-Quadrant Operation
• Hall Sensor Feedback
• Constant Velocity Mode Option
• Short Circuit Protection
• Requires 85-135 VAC
• Speed Out 
• Fault Out 
• Run/Stop, Freewheel and Direction Inputs
• Optically Isolated Inputs and Outputs
• Dual Mounting Option
• Detachable, Screw type Terminal Blocks for the logic inputs and outputs
• Covered, Screw type Barrier Strips for the power input and motor phases
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 9.1VDC for the motor bus voltage and 4.5VDC for Hall Sen-
sor voltage.
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Pin Descriptions
The inputs on the MDC300-120151 are optically isolated with the anode (+) and cathode (-) both broug\
ht 
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 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 isolated external 
Speed Voltage Input must be an analog voltage from 0VDC to +/-5VDC.  The PG Out and Fault output 
on the MDC300-120151 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.
Speed Output: (TB1, Pin 1 and 2)
A signal pulse out is available at a rate of 4 pulses for 1 revolution of an 8-pole motor, 3 pulses for 1 revo-
lution 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)
Hall Sensor Power Output:
5V @ 30mA maximum. Typical current draw from hall sensors is 20mA.
All three Hall Sensors inputs are pulled up through 20K ohm resistors.
ItemMinTy pMaxUnits
Input Voltage (Power) 85120135VA C
Input Voltage (Power) 120170191VDC
Phase Output Current 3.510.7A (RMS)
Phase Output Current 515A (Peak)
Input Voltage (Inputs) 3.524VDC
Chopping Frequency 232527kHz
Operation Temperature 070C
Electrical Specifications
Table 1: MDC300-121051 electrical specifications
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							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.  In Open Loop opera-
tion, typically the greater the load, the speed of the motor decreases. 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 swith must be in the ‘on’ position.
To operate Closed Loop, the O/C LOOP switch (Switch Panel 2, SW1) must be in the ‘off’ position and 
the CLADJ potentiometer (R3) and CLADJ dip switches (Switch Panel 2, SW 2-4) must be set to optimize 
the driver for each motor and 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 tables shown on the next page are the Closed Loop potentiometer and dip switch settings for each 
motor.  These settings are valid for the listed motor rated voltage. These adjustments will set the maxi-
mum running speed of the internal/external speed potentiometer or the 5VDC voltage set to the motors 
maximum running speed.  Motor operation at slower speeds may also be attained.  For the slower speed, 
the pulse width of the duty cycle can be increasedby adjusting the CLPOT toward 100% and switching 
‘off’ CL3, CL2, and CL1 one after another, until the desired motor speed is achieved.  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 Motor. 1. Start by making sure the open loop setting is toggled ‘on’, Switch\
 Panel 2, SW1.
2.  Set the closed loop switches CL1, CL2, and CL3 on the ‘on’ position.
3.  Set CLADJ POT to 0%.
4.  Adjust the internal speed pot or external speed pot to 100% The motor at this time should 
be running at its maximum speed.
5.  Turn the open loop setting off by setting Switch Panel 2, SW1 ‘off’.
6.  Decrease 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 7.
7.   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 CL2CL3 Duty 
Cycle 
Setting
On OnOnMax
Off OnOn
On OffOn
Off OffOn
On OnOff
Off OnOff
On OffOff
Off OffOffMin
Table 2: CL gain adjust decremented settings
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							MotorCL1CL2CL3CL POT MAX SPD 
(RPM) MIN SPD
(RPM)
BLWR1103-15V-8000 OnOnOn 80% 8000 500
BLWR111S-24V-10000 OnOnOn 50% 10050 825
BLWR112S-24V-3700 OnOffOn100% 3735 450
BLWR231D-36V-4000 OnOffOn 65% 4010 550
BLWR232D-36V-4000 OnOffOn 65% 4010 550
BLWR233D-36V-4000 OnOffOn 65% 4010 550
BLWR234D-36V-4000 OnOffOn 65% 4010 550
BLWR235D-36V-4000 OnOffOn 65% 4010 550
BLWR232S-24V-1350 OffOffOff 0% 1600 200
BLWS231D-36V-4000
BLWS231S-36V-4000 On
OffOn 65% 4010 550
BLWS232D-36V-4000
BLWS232S-36V-4000 On
OffOn 65% 4010 550
BLWS233S-36V-4000 OnOffOn 65% 4010 550
BLWS234D-36V-4000
BLWS234S-36V-4000 On
OffOn 65% 4010 550
BLWS235S-36V-4000 OnOffOn 65% 4010 550
Motor CL1CL2CL3CL POT MAX SPD 
(RPM) MIN SPD
(RPM)
BLY171S-17V-8000 OnOnOn 0% 7500 500
BLY172S-17V-9500 OnOnOn 0% 9000 500
BLY171S-24V-4000 OnOnOn 80% 4000 250
BLY172D-24V-4000
BLY172S-24V-4000 On
OnOn 80% 4000 250
BLY173D-24V-4000 OnOnOn 80% 4000 250
BLY174D-24V-4000
BLY174S-24V-4000 On
OnOn 80% 4000 250
BLY341D-48V-3200
BLY341S-48V-3200 Off
On On 40% 3200 250
BLY342D-24V-3000 OffOn On 40% 3000 250
BLY342D-30V-3000
BLY342S-30V-3000 Off
On On 40% 3000 250
BLY342D-48V-3200
BLY342S-48V-3200 Off
On On 30% 3200 250
BLY343D-48V-3200
BLY343S-48V-3200 Off
On On 30% 3200 250
BLY343S-30V-3000 OffOn On 40% 3000 250
BLY343D-160V-3000 OffOn On 50% 3000 250
BLY344D-48V-3200
BLY344S-48V-3200 Off
On On 30% 3200 250
BLZ362S-36V-3500 OffOn On 10% 3500 330
BLZ362S-160-3500 OffOn On 10% 3500 330
BLZ482S-160V-3500 OffOn On 10% 3500 330
BLZ242S-24V-3500 OffOn On 10% 3500 330
Table 4: Closed Loop Operation Motor Settings @ rated motor voltages
Table 3: Closed Loop Operation Motor Settings @ rated motor voltages
4-pole motors
8-pole motors
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							Step
1 23456
Phase A +Z --Z +
Phase B Z++Z --
Phase C --Z ++Z
Hall A 110001
Hall B 011100
Hall C 000111
Commutation Sequence
Step
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 Reverse
120° Hall Spacing Sequence Forward
60° Hall Spacing Sequence Forward
60° Hall Spacing Sequence Reverse
+ = 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 connection a motor for the first time, 
connect the hall sensor wires (5 of them) to the driver.  DO NOT CONNECT THE PHASE WIRES YET.
  
Turn  on  power  and  rotate  the  motor  by  hand.    If  the  RED  FAULT  LED  comes  on,  the  hall  sensors  are 
incorrectly wired.  If the RED FAULT LED does not come on then the hall sensor wires are connected cor-
rectly.  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, the closed loop settings,  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 Block Descriptions
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)
11 Speed Voltage (+)
12 Speed Voltage (-)Pin # Description
1 Hall Sensor Power
2 Hall  Sensor A
3 Hall Sensor B
4 Hall Sensor C
5 Hall Sensor ReferencePin # Description
1 AC Hot
2 AC Neutral
3 EARTH GND
(must be connected)
Pin #
Description
1 Phase A
2 Phase B
3 Phase C
TB1: Opto-isolated
Control Inputs and  Outputs TB3: Motor Phase Terminals
TB2: Motor Hall Terminals
TB4:AC Voltage In Terminals
Dip Switch Descriptions
SW#
Description
1 INT/EXT SPEED
2 FLT LATCH
3 RAMP
4 AUTO DIRECTION
5 60/120SW# Description
1 O/C LOOP
2 CL1
3 CL2
4 CL3
Switch Panel 1: Dip Switch Switch Panel 2: Dip Switch
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							FunctionSW1SW2SW3 SW4 SW5
Internal Speed Control (Onboard Speed 
Potentiometer) Off
------ --- ---
External Speed Control (TB1 - Pins 11 & 12) On------ --- ---
Over Current Latching ---On --- --- ---
Over Current Cycle by Cycle ---Off --- --- ---
Ramp 1 profile 1 (set by Ramp Pot) ------On --- ---
Ramp 1 profile 2 (set by Ramp Pot) ------Off --- ---
Direction control via Direction Opto-input --------- Off ---
Direction Control via Speed Voltage polarity --------- On ---
60° Hall Sensor Spacing --------- --- Off
120° Hall Sensor Spacing --------- --- On
Dip Switch and Jumper Settings
SW1: Speed Adjustment, Over Current, and Ramp settings
Function SW1SW2SW3 SW4
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 Producy (Ready to Ship) OnOffOff Off
SW2: Open Loop and Closed Loop.  If Closed Loop selected, Closed Loop 
compensation switches must be set according to motor speed desired.
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 th\
e 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 Ramp Up/Down
With Switch 3 on Dip Switch Panel 1 on the ON position, the motor will have the following zero RPM to 
max open loop speed ramp times:
RAMP POT % Ramp up/down time
100 3.2 sec
75 2.4 sec
50 1.6 sec
25 0.8 sec
0 0 sec
Ramp Profile 1
RAMP POT %Ramp up/down time
100 1.6 sec
75 1.2 sec
50 0.8 sec
25 0.4 sec
0 0 sec
Ramp Profile 2
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							Motor Direction
The motor direction feature allows the changing of the rotation of the motor.  This input should not be 
changed while maximum speed is in progress.  The direction can be controlled two different ways.  
When AUTO DIRECTION switch (Switch Panel 1, SW3) in the OFF Position:
A high (open) input causes the motor to turn in the CW direction, while\
 a low at this input causes the mo-
tor to turn in the CCW direction.
When AUTO DIRECTION switch (Switch Panel 1, SW3) in the ON Position:
A 0 to +5V speed voltage signal at TB1 - pins 11 & 12 causes the motor to turn in the CW direction, whilea 
0 to -5V speed voltage causes the motor to turn in the CCW direction.  With SW1-position 3 in the ON 
position, the Direction inputs TB1-pin 3 should be left open AND TB1-pin 4 should be tied to TB1-pin 12.
Speed Adjust Setting
There are two ways to set the speed on this drive: 
 1. Use the on board potentiometer. To use the on board potentiometer, 
      set INT/EXT SPD switch (Switch Panel1, SW1) to the ‘off’ position (default). The speed is 
      adjusted by setting the onboard speed potentiometer. 
  2. The second way is to use an external source.To use an external 10K potentiometer or 
      external voltage set INT/EXT SPD switch to the ‘on’ position. 
When INT/EXT SPD switch (Switch Panel 1, SW1) in the OFF Position:
The onboard speed potentiometer is used to control the speed of the motor. The motor speed increases 
as the potentiometer is set from 0% - 100%.
When INT/EXT SPD switch (Switch Panel 1, SW1) in the ON Position:
Either an external speed analog voltage or an external potentiometer can\
 be used to set the motor speed.  
For an external voltage, apply a +/- voltage on TB1 - pin 11 and the return on TB1 - pin 12.  The motor 
speed increases as the voltage is set from 0.1VDC to +5VDC or -0.1VDC to -5VDC.  A -5VDC to +5VDC 
voltage span cay be used to change the speed and direction of the motor (see Motor Direction above). 
The motor will be stopped with an external speed analog voltage from -0.\
1VDC to 0.1VDC. 
For an external potentiometer, connect the POT WIPER to TB1 - pin 11, POT (-) to TB1 - pin 12, and POT 
(+) to an external +/-5V supply.
Speed Output
The PG OUT Terminal (TB1 - pin 1 and 2)  is used to determine the speed of the motor shaft.  An optode -
coupled 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 pulse for 1 revolution of a 4-pole motor.  Care must be taken not 
to pass more than 30V and 50mA through this transistor.
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 suitable tem-
peratures.
# 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
Figure 1: Hook up for current sinking inputs
Figure 2: Hook up for current sourcing inputs
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