Anaheim Automation MDC300-120301 Series User manual

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MDC300-120301 Series
120VAC, 30A Brushless Controller
User’s Guide
4985 E. Landon Drive Anaheim, CA 92807
e-mail: [email protected] [phone] fax: [phone] website: www.anaheimautomation.com
ANAHEIM AUTOMATION

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General Description
The MDC300-120301 Driver is designed to drive DC brushless motors at currents of up to 30Apeak and
170VDC. Using hall sensor feedback, a constant velocity mode can be selected. The driver is protected
againstover current (cycle-by-cycle orlatched),hallsensor error and undervoltage. Whenanerror 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
allowedintothemotor and an internal potentiometer to control the speed of the motor. An optional external
potentiometer or voltage input can be used to control the speed voltage input as well. The direction of the
motor can be preset by the direction control input. The speed and direction can also be controlled by the
external voltage speed input when theAuto-Direction mode is chosen. Other inputs to the drive include a
run/stop and a motor freewheel input. An onboard potentiometer sets the ramp up profile from standstill.
The run/stop input overrides all other inputs into the driver.
MDC300-120301 Driver Features
• Peak Current Limit Setting from 10.0 to 30.0 Amps
• Internal/External Potentiometer or Voltage Input Speed Control
• On-board Potentiometer Ramp Up Adjustment
• Single Input Speed and Direction Control (Auto-Direction)
• 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
Electrical Specifications
Item Min Typ Max Units
Input Voltage (Power) 85 120 135 VAC
Input Voltage (Power) 120 170 191 VDC
Phase Output Current 7.1 21.2 A (RMS)
Phase Output Current 10 30 A (Peak)
Input Voltage (Inputs) 3.5 24 VDC
Chopping Frequency 23 25 27 kHz
Operating Temperature 0 70 C
External Speed Voltage -6 6 VDC
Table 1: MDC300-120301 electrical specifications

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Pin Descriptions
The inputs on the MDC300-120301 are optically isolated with the 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 an input, a minimum of 1.0 mA needs to be sourced or synced through the
opto-diode. To enable an input, apply a DC voltage source of +3.5VDC to +24VDC 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 MDC300-120301 are an opto-decoupled open collector output.
Speed Output: (TB1, Pin 1 and 2)
An opto-decoupled open collector output 50% duty cycle square wave 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. Care must be taken not to pass more than 50mA through this transistor.
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)
Motor Direction (TB1 - pins 3 and 4)
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.A high (open) input causes the motor to turn in the CW
direction, while a low at this input causes the motor to turn in the CCW direction.
Motor Freewheel (TB1 - pins 5 and 6)
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 the motor to coast to a stop.
Motor Run/Stop (TB1 - pins 7 and 8)
The motor run/stop feature allows the stopping of a motor by shorting out the bottom drives of the three
phases. Alow 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.
Fault Output: (TB1, Pin 9 and 10)
To use the fault output, FLT LATCH switch (Switch Panel 1, Switch 2) must be in the ON position. 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.
Analog Vin: (TB1, Pin 11 and 12)
To control the speed of the motor with an external DC voltage, INT/EXT SPD switch (Switch Panel 1,
Switch 1) must be on ON Position.

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Function Switch 1 Switch 2 Switch 3 Switch 4 Switch 5
Internal Speed Control (On board speed
potentiometer) Off --- --- --- ---
External Speed Control (TB1 - Pins 11 & 12) On --- --- --- ---
Fault Latching --- On --- --- ---
Fault 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 Panel 1 Settings
Dip Switch Panel 1: Speed Adjustment, Over Current, and Ramp settings
Internal/External Speed Control (Switch Panel 1 - Switch 1)
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 Panel 1- Switch 1) 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 (Switch Panel 1- Swtich 1) to the ‘on’ position.
When INT/EXT SPD switch (Switch Panel 1- Switch 1) 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 - Switch 1) 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
voltagespancay be used to change the speedanddirectionofthe motor (seeAutoDirection(Switch Panel
1 - Switch 4). 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 toTB1 - pin 11, POT(-) to TB1 - pin 12, and POT
(+) to an external +/-5V supply.
Fault Latch (Switch Panel 1 - Switch 2)
Over current protection can be provided by means of a over current latch function by setting the ‘FLT
LATCH’ switch, Switch Panel 1 - Switch 2 to the “on” position. 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 high (logic “1”). This driver is equipped with a FAULT
LED and Fault-out output to alert the user of the following conditions. To reset the MDC300-120301
driver from a latched condition, power down, allow 30 seconds for power to dissipate, then power up.
To diseable the fault latch, set FLT LATCH switch to the “off” position and the driver will have a cycle by
cycle current limiting protection.

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Motor Ramp Up (Switch panel 1 - Switch 3)
Ramp Set on Switch Panel 1 - Switch 3 set to 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 Set on Switch Panel 1 - Switch 3 set to the OFF position, the motor will have the following zero
RPM to max open loop speed ramp times:
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
Ramp Profile 1
Auto Direction (Switch Panel 1 - Switch 4)
When AUTO DIRECTION switch (Switch Panel 1, Switch 4) in the OFF Position (default):
Ahigh (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, Switch 4) in the ON Position:
A0 to +5V speed voltage signal at TB1 - pins 11 & 12 causes the motor to turn in the CW direction, while
a 0 to -5V speed voltage causes the motor to turn in the CCW direction. With Switch Panel 1 Switch 4 in
the ON position, the Direction inputs TB1-pin 3 (Direction +) should be left openANDTB1-pin 4 (Direction
-) should be tied to TB1-pin 12 (Analog VIN -). INT/EXT SPD switch (Switch Panel 1 - Switch 1) needs to
be set to the ON Position.
Hall Sensor Spacing (Switch Panel 1 - Switch 5)
60° Hall Sensor Spacing when Switch Panel 1 - Switch 5 is set to the OFF position.
120° Hall Sensor Spacing when Switch Panel 1 - Switch 5 is set to the ON position.
Dip Switch Panel 2 Settings (Closed loop settings)
Function Switch 1 Switch 2 Switch 3 Switch 4
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) On Off Off Off
Dip Switch Panel 2: Open Loop and Closed Loop. If Closed Loop selected, Closed
Loop compensation switches must be set according to motor speed desired.

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Open Loop/Closed Loop Constant Velocity Mode (Switch Panel 2 - Switch 1-4)
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, the greater the load, typically 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 switch must be in the ‘on’ position.
To operate Closed Loop, the O/C LOOP switch (Switch Panel 2, Switch 1) must be in the ‘off’ position
and the CLADJ potentiometer (R3) and CLADJ dip switches (Switch Panel 2, Switch 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 repect to the required motor speed.
The tables shown on the next page are the Closed Loop potentiometer and dip switch settings for each
motor. Thesesettingarecalidfor the rated motor voltage listed on thefollowingtables. Theseadjustments
will set the maximum 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 increased by adjusting the CL POT towards 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/Closed loop (Switch Panel 2, Switch 1) setting is toggled ‘on’.
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/Closed loop setting Dip Switch Panel 2, Switch 1 ‘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 CL2 CL3 Duty Cycle
Setting
On On On Max
Off On On
On Off On
Off Off On
On On Off
Off On Off
On Off Off
Off Off Off Min
Table 2: CLgain adjust decremented settings

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Motor CL1 CL2 CL3 CL POT MAX SPD
(RPM) MIN SPD (RPM)
BLWS235D-160V-3000
BLWS235S-160V-3000 Off Off On 80% 3000 270
Motor CL1 CL2 CL3 CL POT MAX SPD
(RPM) MIN SPD (RPM)
BLY342D-160V-3000
BLY342S-160V-3000 Off On On 50% 3000 250
BLY343D-160V-3000
BLY343S-160V-3000 Off On On 50% 3000 250
BLY344D-160V-3000
BLY344S-160V-3000 Off On On 50% 3000 250
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
123456
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
Commutation Sequence
Step
123456
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
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
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
120° Hall Spacing Sequence Reverse120° 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 sensor wires 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, closed loop setting (if closed loop is used) 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..
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.

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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 Reference
Pin # Description
1 AC Hot
2 AC Neutral
3EARTH 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
Switch# Description
1 INT/EXT SPEED
2 FLT LATCH
3 RAMP
4 AUTO DIRECTION
5 60/120
Switch# Description
1 O/C LOOP
2 CL1
3 CL2
4 CL3
Switch Panel 1: Dip Switch Switch Panel 2: Dip Switch
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.
Fault Protection
The MDC300-120301 is equipped with a FAULT LED and Fault-out output to alert the user of the follow-
ing conditions. :
- Invalid Hall Sensor Input Code
- Over Current. The driver is equipped with cycle-by-cycle current limiting or over current latch.
- Undervoltage Lockoutactivationat 9.1VDC forthemotor bus voltageand4.5VDC for HallSensorvoltage.
A Fault latch function is available by setting the ‘FLT LATCH’ dip switch (Switch Panel 1, SW2) to the
“on” position. If Fault latchis selected and a fault occurs, the driver shuts off the output and turns the
fault output open (logic “1”). To reset the MDC300-120301 driver from a latched condition, power down,
allow 30 seconds for power to dissipate, then power up.

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Typical Hookup Drawing
Figure 1: Hookup for current sinking inputs with external DAC
Figure 2: Hookup for current sourcing inputs with external DAC

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Dimensions
Weight = 4.5lbs

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Troubleshooting
Problem Suggested Things to Test
Red Fault LED on at Power Up Verify if Motor Halls, Power, and GND are not either disconnected or miswired.
Verify if Motor Phases are not either disconnected or miswired.
Verify that the Hall Sensor Spacing switch (SW1 - POS. 5) is properly set for the motor
used.
If a heavy load is present at power up, verify current limit setting is set appropriately
and current latch (SW2 - POS. 2) is not set to the ON position.
Verify the Motor Hall Power is not overloaded. This occurs when other external
circuitry other than the motor halls is using this voltage reference for power, i.e. motor
encoder.
Verify the Freewheel input is not sinking or sourcing any current through the opto-
diode.
Motor does not run Check if Red Fault LED is on.
Verify if Motor Halls, Power, and GND are not either disconnected or miswired.
Verify if Motor Phases are not either disconnected or miswired.
Verify the Run/Stop input is sinking or sourcing current through the opto-diode.
Verify the on-board/external speed setting is correct on SW1, pin 1 is correct.
Verify on-board or external speed adjustment not at 0VDC or 0%
If a Closed-Loop operation is required, verify the Closed-Loop settings are correct for
the motor used.
Motor runs erratic, at high tem-
perature (above 70°C), or incorrect
speed Verify if Motor Halls, Power, and GND are not either disconnected or miswired.
Verify Motor Phases are not either disconnected or miswired.
Verify the on-board/external speed setting is correct on SW1, pin 1 is correct.
Verify the Freewheel input is not intermittently sinking or sourcing any current through
the opto-diode.
Verify the Run/Stop input is not intermittently losing any current sinking or sourcing
through the opto-diode.
Verify that nothing is connected to the Direction inputs when the Auto Direction mode is
selected.
If a Closed-Loop operation is required, verify the Closed-Loop settings are correct for
the motor used.
Verify there are no large variations in the motor bus voltage by monitoring the voltage
input when open-loop operation is used.
Verify the motor is not damaged by trying another motor with the driver.

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ANAHEIM AUTOMATION
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transmitted, transcribed, stored in a retrieval system, or translated into any language, in any form or by
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written permission of Anaheim Automation, 4985 E Landon Drive, Anaheim, CA 92807.
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.
AnaheimAutomation’sgeneralpolicydoesnotrecommendthe useof its’productsinlife supportapplications
whereina failure ormalfunctionofthe product maydirectlythreaten life or injury. PerAnaheimAutomation’s
Terms and Conditions, the user of Anaheim Automation products in life support applications assumes all
risks of such use and indemnifies Anaheim Automation against all damages.
LIMITED WARRANTY
AllAnaheimAutomationproductsarewarrantedagainstdefects inworkmanship, materialsandconstruction,
when used under Normal Operating Conditions and when used in accordance with specifications. 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 first. Warranty provisions may be voided if products
are subjected to physical modifications, damage, abuse, or misuse.
AnaheimAutomation will repair or replace at its’option, any product which has been found to be defective
andiswithinthewarrantyperiod, providedthat theitem isshippedfreightprepaid,withpreviousauthorization
(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.