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Anaheim Brushless DC MDC151012601 Users Guide

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    							September 2012 L0104781
    MDC151-012601 Series
    12V @ 60A 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 L0104782
    MDC151-012601 Driver Features
    •  Maximum Current Limit Setting from 20.0 - 60.0 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 12VDC
    • Speed Out
    • Fault Out
    •  Run/Stop, Freewheel and Direction
    •  Selectable Ramp Up
    •  TTL-CMOS Compatible Inputs
    •  Compact Size (7.5” x 6.9” x 5.2”)
    •  Works great with 24VDC-36VDC brushless motors
    • 48VDC Bus
    •  Detachable, Screw type Terminal Blocks
    General Description
    The MDC151-012601 driver is designed to drive DC brushless motors at currents of up to 60A (peak) 
    and 12V.  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 and a fault output are 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 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 
    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.  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 Sen-
    sor voltage. 
    						
    							September 2012 L0104783
    Specifi cations
    Control Inputs: (TB1, 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 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 20.0 - 60.0 amperes per phase maximum operating peak current
      (10.0 - 30.0 amperes per phase maximum operating continuous current)
    Power Requirements: (TB2, Pins 4 and 5)
    9VDC (min) - 15VDC (max)
    Operating Temperature:
    Heat Sink: 0°-70° C 
    						
    							September 2012 L0104784
    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.
    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.  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 the 
    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 
    						
    							September 2012 L0104785
    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 
    						
    							September 2012 L0104786
    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 L0104787
    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 (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 
    						
    							September 2012 L0104788
    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. 
    						
    							September 2012 L0104789
    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 
    						
    							September 2012 L01047810
    Dimensions 
    						
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