Anaheim Brushless DC MDCKB1120081 Users Guide

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MDCKB1-120081
110VAC, 8A 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 L0106742
MDCKB1-120081 Driver Features
•  Maximum Current Limit from 1.0-8.0 Amps (peak)
•  External 5K Potentiometer Speed Control
•  Internal Max and Base Speed Adjustment
• 2-Quadrant Operation
•  Hall Sensor Feedback
•  Constant Velocity Mode
•  Short Circuit Protection
•  Requires 90-120 VAC
•  Brake, Disable and Direction Inputs
•  TTL-CMOS Compatible Inputs
•  Compact Size (4.3”x4.09”x1.77”)
•  Dual Mounting Option
•  Optically Isolated Analog Voltage Speed Control (optional)
General Description
The MDCKB1-120081 driver is designed to drive DC Brushless motor at currents of up to 8A (peak) 
and 160V.  Using hall sensor feedback, a constant velocity mode can be selected.  The driver is 
protected against over current (cycle-by-cycle), hall sensor error and under voltage.  When an error 
occurs, a fault light is turned on to notify the user.  Included on the driver are internal potentiometers 
to control the maximum phase current allowed into the motor, the maximum speed of the motor, the 
base speed of the motor and closed loop compensation.  An external potentiometer (5K) is 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 enable input.  When using the run/stop input, 
it overrides all other inputs into the driver. 
Fault Protection
This driver is equipped with a FAULT LED to alert the user of the following conditions.
1.  Invalid Hall Sensor Input code
2.  Over Current.  The driver is equipped with cycle-by-cycle current limiting
3.  Undervoltage Lockout activation at 30VAC for the input voltage and 4.5VDC for Hall 
Sensor power output voltage.
 Caution: The MDCKB1-120081 driver does not have an internal fuse.  To protect the driver 
from major motor failures, an external fuse greater than the application maximum load current is 
needed. The MDCKB1-120081 driver is not line isolated. Use only mechanical switches for the control 
inputs. The terminals of motor connector contains high voltage. Do not probe any part of the driver 
with power on, this could damage the drive or result in body injury.
Ordering Information
Part # Description
MDCKB-120081 110VAC DC Brushless Driver at 8A
MDCKB1-120081-01 110VAC Open Loop Only DC Brushless Driver at 8A
PWR-10EMC1 Dual Stage RF | Power Line Filter. 
						

							September 2012 L0106743
Specifi cations
Control Inputs: (QD12, QD13, QD16-QD19)
External Switch Compatible
Note: The MDCKB1-120081 driver is not line isolated. Use only mechanical switches for the control inputs. The 
terminals of motor connector contains high voltage. Do not probe any part of the driver with power on, this could 
damage the drive or result in body injury.
Run/Stop: I1 and I2 (QD12 and QD13)
Switch Open - Motor will not run and if running will decelerate rapidly
Switch Closed - Motor will run
Direction Control: D1 and D2 (QD16 and QD17)
Switch Open - Clockwise
Switch Closed - Counterclockwise
Enable Control: E1 and E2 (QD18 and QD19)
Switch Open - Motor is Enabled
Switch Closed - Motor is de-energized and will coast
Speed Adjustment Control: P1-P3 (QD9-QD11)
The external speed control potentiometer must be 5K Ohms.
P3 (QD9) - Pot (+)
P2 (QD10) - Pot Wiper
P1 (QD11) - Pot (-)
Output Current Rating:
Adjustable 2.0 - 8.0 amperes per phase maximum operating peak current
  (1.0 - 4.0 amperes per phase maximum operating continuous current)
Power Requirements: L1 and L2 (QD14 and QD15)
90VAC (min) - 135VAC (max)
 Caution: The MDCKB1-120081 driver does not have an internal fuse.  To protect the driver 
from major motor failures, an external fuse greater than the application maximum load current is 
needed.
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.
Only the Motor Hall Power wire should be tied here. 
						

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Commutation Sequence
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
123456
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
+ = 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 turns on, the hall phases 
are incorrectly wired.  If the RED FAULT LED does not turn 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 only 6 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.  If the motor still runs erratically, adjust the close loop 
compensation potentiometer R11.
The wiring of the motor phases should be separated from the hall and input connections to not allow 
a possible source of interface.120° Hall Spacing Sequence Forward 120° Hall Spacing Sequence Reverse
60° Hall Spacing Sequence Forward 60° Hall Spacing Sequence Reverse
Note: The MDCKB1-120081 driver is not line isolated. Use only mechanical switches for the control inputs. The 
terminals of motor connector contains high voltage. Do not probe any part of the driver with power on, this could 
damage the drive or result in body injury. 
						

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Closed Loop Compensation and Rated Motor Speed Range Adjustment:
1.  Start with setting the external speed potentiometer to 50%, closed loop adjustment poten-
tiometer R11 at 50%, minimum motor speed potentiometer R25 at 50%, maximum motor 
speed potentiometer R17 at 50%, and current limit potentiometer at 100%.  The motor might 
be cogging at fi rst.
2.  If the motor is cogging, slowly lower closed loop adjustment potentiometer R11 until the motor 
stops cogging and operates smoothly.  The motor should not be stalled, running maximum 
open loop speed, or cogging.  R11 must be set where the motor should be running smoothly.  
If the motor is not cogging, proceed to step 3.
3.  Set the external speed potentiometer to 50%.  Set the minimum motor speed by adjusting 
potentiometer R25 according to user application.  The minimum running speed should be 
set to a speed higher than 0RPM.  The run/stop switch should be used to brake the motor 
for 0RPM.  
4.  Slowly raise the external speed potentiometer to 100%.  The motor may be operating at 
maximum open loop speed.
5.  Set the maximum rated motor speed by adjusting potentiometer R17 according to user ap-
plication.  If R17 is set to the maximum setting and a slower speed is required, adjust R11 
for slower maximum motor speed.
  Note: A different speed range, maximum speed, or minimum speed can be attained by 
further adjusting R11, R17, and R25. 
POT # Description Setting
R11 CLADJ 50%
R14 RAMP 50%
R17 Max Speed 50%
R25 Min Speed 50%
Open Loop Only Driver (MDCKB1-120081-01) Rated Motor Speed Range 
Adjustment:
1.  Set the external speed potentiometer to 50%.  Set the minimum motor speed by adjusting 
potentiometer R25 according to user application.  The minimum running speed should be 
set to a speed higher than 0RPM.  The run/stop switch should be used to brake the motor 
for 0RPM.  
2.  Slowly raise the external speed potentiometer to 100%
3.  Set the maximum rated motor speed by adjusting potentiometer R17 according to user ap-
plication.  If R17 is set to the maximum setting and a slower speed is required, adjust R11 
for slower maximum motor speed.
Note: A different speed range, maximum speed, or minimum speed can be attained by further 
adjusting R17, and R25.
Note: The MDCKB1-120081 driver is not line isolated. Use only mechanical switches for the control inputs. The 
terminals of motor connector contains high voltage. Do not probe any part of the driver with power on, this could 
damage the drive or result in body injury. 
						

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Speed Adjust Setting
The maximum speed of the motor is set by adjusting R17.  The minimum speed of the motor is set 
by adjusting R25.  An external 5Kohm potentiometer is used to adjust the motor speed between 
the set minimum and maximum speed.
Motor Run/Stop
The motor run/stop feature allows the stopping of a motor by shorting out the bottom drives of the 
three phases.  Shorting QD12 and QD13 together allows the motor to run, while an 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.  Shorting QD16 and Q17 together causes the motor 
to turn in the CW direction, while an open between QD16 and QD17 causes the motor to turn in 
the CCW direction.
Note: Avoid changing the direction of rotation when the motor is already running in any one direction.
The following instructions must be followed to prevent permanent drive failure due to over-current conditions that exist is dynamic 
direction reversals of the motor:
1.  Stop the motor by releasing the short on the Run/Stop input
2.  Wait for at least 500mS
3.  Change the direction with the DIRECTION input
4.  Run the motor by shorting the Run/Stop input
Heating Considerations
The temperature of the heat sink should never be allowed to rise above 70 degrees Celsius.  This 
may occur with motor currents higher than 6A.  If necessary, mount the unit to an additional heat 
sink or air should be blown across the heat sink to maintain suitable temperatures.
Motor Enable
The motor enable feature allows the de-energizing of the motor phases.  This input can be 
changed while motion is in progress.  Shorting QD18 and QD19 together causes the motor to 
de-energize, while an open between QD18 and QD19 causes the motor to run at the given speed.  
To run motor again. 
Note: The MDCKB1-120081 driver is not line isolated. Use only mechanical switches for the control inputs. The 
terminals of motor connector contains high voltage. Do not probe any part of the driver with power on, this could 
damage the drive or result in body injury.
Note: The MDCKB1-120081 driver is not line isolated. Use only mechanical switches for the control inputs. The 
terminals of motor connector contains high voltage. Do not probe any part of the driver with power on, this could 
damage the drive or result in body injury. 
						

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QD#Board 
DesignatorDescription
1 HP Hall Sensor (+)
2 HA Hall Sensor A
3 HB Hall Sensor B
4 HC Hall Sensor C
5 HG Hall Sensor (-)
6 PA Phase A
7 PB Phase B
8 PC Phase C
Terminal Descriptions
Quick Disconnect Mating Connectors
Quick Disconnect/Potentiometer Location
QD#Board 
DesignatorDescription
12 I1 Brake 1
13 I2 Brake 2
14 L1 Line HOT
15 L2 Line Neutral
16 D1 Direction 1
17 D2 Direction 2
18 E1 Enable 1
19 E2 Enable 2
QD# Description
9 +4.0V (Pot Top)
10 Pot Wiper
11 GND (Pot Bottom)
For QD1-QD5, QD9-QD11, QD12-QD13, QD16-QD19:
Panduit # DNF18-110-M.  Female Disconnect, nylon barrel insulated, funnel entry, 22 - 18 AWG, 
.110 x .032 tab size.
For QD6-QD8, QD14-QD15:
Panduit # DNF14-250FIB-3K.  Female disconnect, (standard receptacle housings), nylon fully 
insulated, funnel entry with insulation support and internal wire stop.  16 - 14 AWG wire range, 
.250 x .032 in. (6.3 x 0.8mm) tab size.
POT# Description
R11 CLADJ
R14 RAMP
R17 Max Speed
R23 Current Limit
R25 Min Speed
Note: The MDCKB1-120081 driver is not line isolated. Use only mechanical switches for the control inputs. The 
terminals of motor connector contains high voltage. Do not probe any part of the driver with power on, this could 
damage the drive or result in body injury. 
						

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Wiring Diagram
Dimensions
Note: The MDCKB1-120081 driver is not line isolated. Use only mechanical switches for the control inputs. The 
terminals of motor connector contains high voltage. Do not probe any part of the driver with power on, this could 
damage the drive or result in body injury. 
						

							September 2012 L0106749
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.
Note: The MDCKB1-120081 driver is not line isolated. Use only mechanical switches for the control inputs. The 
terminals of motor connector contains high voltage. Do not probe any part of the driver with power on, this could 
damage the drive or result in body injury.