Nidec GreenDrive Dynamo User manual

Dynamo Brushless DC Motor
and GreenDriveTM Manual
This manual was developed as a guide for use by FIRST
Robotics Teams using Controller Part Number 840205-000
in conjunction with the Nidec Dynamo BLDC Motor.

Nidec Motor Company, 2009
Printed in United States of America
Information furnished by Nidec Motor Company is believed to be accurate and reliable. Nidec
Motor Company reserves the right to change the design or operation of the equipment described
herein and any associated motion products without notice.
Part Number: TDE840205-000
Revision: 1
Date: November 13, 2017
Nidec Motor Company, 2017
Read this Operator’s Manual
carefully before using this
device. Failure to understand
and follow the contents of
this manual may result in
electrical shock, fire and/or
serious personal injury.

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This document has been prepared to conform to the current released version of the product.
Because of our extensive development efforts and our desire to further improve and enhance
the product, inconsistencies may exist between the product and documentation in some
instances. Call your customer support representative if you encounter an inconsistency.
CUSTOMER SUPPORT
Nidec Motor Company
1551 East Broadway Street
Princeton, Indiana 47670
U.S.A.
Telephone: [phone]
It is Nidec Motor Company’s goal to ensure your greatest possible satisfaction with the
operation of our products. We are dedicated to providing fast, friendly, and accurate assistance.
We offer you many ways to get the support you need. Our wide range of services include:
FAX [phone]
You can FAX questions and comments to Nidec Motor Company. Just send a FAX to the number
listed above.
Website www.hurst-motors.com
If you have Internet capabilities, you also have access to technical support using our website.
The website includes technical notes, frequently asked questions, release notes, and other
technical documentation.
Customer Service (Sales) [phone]
Email: [email protected]

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Nidec Motor Company
Brushless DC Motor and GreenDrive
TM
Manual
TABLE OF CONTENTS
Customer Support ................................................................................ 3 
Table of Contents................................................................................ 4 
List of Figures ................................................................................... 6 
List of Tables .................................................................................... 6 
Safety Symbols.......................................................................................................................................7 
General Safety Rules .............................................................................................................................8 
Safety Precautions...........................................................................................................................................8 
Qualified Person................................................................................................................................................8 
Setup, Commissioning and Maintenance.....................................................................................................8 
Safety of Machinery .......................................................................................................................................9 
Specific Safety Information ...............................................................................................................9 
Introduction .....................................................................................10 
Features..................................................................................................................................................10 
Product Description..............................................................................................................................10 
Getting Started .................................................................................11 
Mounting Recommendations.....................................................................12 
Dynamo Motor Size 17.........................................................................................................................12 
Axial & Radial Loading Recommendations................................................................................................12 
Axial & Radial Loading Recommendations...................................Error! Bookmark not defined. 
Choosing a Power Supply........................................................................13 
Motor Power Supply.......................................................................................................................................13 
Connecting inputs and outputs...........................................................................................................14 
Motor Power Supply Connections...............................................................................................................14 
Control Connections..............................................................................................................................15 
Inputs/Outputs .....................................................................................................................................17 
Tachometer (Pin 1) .........................................................................................................................................17 

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Externally Supplied Voltage Command Input...................................................................................17 
PWM (Pin 3)......................................................................................................................................................17 
Direction (Pin 6) ..............................................................................................................................................18 
PWM & Direction (Pin 7)...............................................................................................................................18 
Enable (Pin 8)....................................................................................................................................................18 
GND (Pin 9).......................................................................................................................................................19 
+5 Vdc (Pin 10) (Input) ..................................................................................................................................19 
PWM & Direction................................................................................20 
Mechanical Specifications ...........................................................................................................................21 
Dimensional Outline Drawings............................................................................................................21 
Dynamo Size 17 Motor..................................................................................................................................21 
Cables & Mating Connectors....................................................................21 

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LIST OF FIGURES
FIGURE 1 – DYNAMO SIZE 17 MOTOR......................................................................................................12 
FIGURE 2 – POWER SUPPLY CONNECTIONS (C1) .................................................................................14 
FIGURE 3 – CONTROL CONNECTIONS (C2)............................................................................................15 
FIGURE 4 – TACHOMETER AND DIRECTION INDICATION OUTPUTS......................................18 
FIGURE 5 – PWM & DIRECTION CONTROL METHOD W/O INTERNAL 5 VDC SUPPLY
(TYPICAL CONNECTIONS)...................................................................................................................... 20

FIGURE 6 – DYNAMO SIZE 17 MOTOR .....................................................................................................21 
FIGURE 7 – MOTOR POWER SUPPLY CABLE (HURST PART NUMBER: 120016) ........................21 
FIGURE 8 – MOTOR POWER SUPPLY MATING CONNECTOR (C1).................................................. 22 
FIGURE 9 – CONTROL CABLE (HURST PART NUMBER: 120106).................................................... 23 
FIGURE 10 – CONTROL MATING CONNECTOR (C2)............................................................................ 23 
LIST OF TABLES
TABLE 1 – MOTOR POWER SUPPLY CONNECTOR PIN FUNCTIONS (C1).....................................15 
TABLE 2 - CONTROL CONNECTOR PIN FUNCTIONS (C2)................................................................16 
TABLE 3 – MOTOR POWER SUPPLY CABLE REFERENCE .................................................................... 22 
TABLE 4 – CONTROL CABLE REFERENCE................................................................................................. 24 

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SAFETY INFORMATION
Safety Symbols
In this operator’s manual and on the product, safety symbols and signal words are used to
communicate important safety information. This section is provided to improve understanding
of these signal words and symbols.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
NOTICE indicates information that relates to the protection of property.
This symbol means read the operator’s manual carefully before using the equipment. The
operator’s manual contains important information on the safe and proper operation of the
equipment.
This is the electrical shock symbol.

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General Safety Rules
Failure to follow safe installation guidelines can cause death or serious injury. The voltages used
in motion control systems can cause severe electric shock and/or burns, and could be lethal.
Extreme care is necessary at all times when working with or adjacent to this equipment. The
installation must comply with all relevant safety regulations and standards in the country of use.
Safety Precautions
This product is intended for professional incorporation into a complete system by qualified
persons. If you install the product incorrectly, it may present a safety hazard. The product and
system may use high voltages and currents, carry a high level of stored electrical energy, or are
used to control mechanical equipment that can cause injury. You must give close attention to the
electrical installation and system design to avoid hazards either in normal operation or in the
event of equipment malfunction. System design, installation, commissioning, and maintenance
must be carried out by personnel who have the necessary training and experience. Read and
follow this safety information and this instruction manual carefully.
Qualified Person
For the purpose of this manual and product, a “qualified person” is one who is familiar with the
installation, construction, operation, and potential hazards associated with the equipment into
which this motor and drive will be installed. In addition, this individual has the following
qualifications:
Is trained and authorized to energize, de-energize, clear and ground and tag circuits and
equipment in accordance with established safety practices.
Is trained in the proper care and use of protective equipment in accordance with
established safety practices.
Is trained in rendering first aid.
Setup, Commissioning and Maintenance
It is essential that you give careful consideration to changes to control settings. Depending on
the application, a change could have an impact on safety. You must take appropriate precautions
against inadvertent changes or tampering. Restoring default parameters in certain applications
may cause unpredictable or hazardous operation.

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Safety of Machinery
All machinery in which this product is used must comply with all federal, state, and local safety
standards. The level of integrity offered by the product’s control function – for example
stop/start, forward/reverse and maximum speed is not sufficient for use in safety-critical
applications without additional independent channels of protection. All applications where
malfunction could cause injury or loss of life must be subject to a risk assessment, and further
protection provided where needed.
Fuses
Fuses or over-current protection must be provided in accordance with the National Electrical
Code and any additional local codes.
Specific Safety Information
Users must determine the suitability of the control for their application, including the level of
reliability required, and are solely responsible for the function of the end-use product. These
controls contain exposed electrical components and are not intended to withstand exposure to
water or other environmental contaminants which can compromise insulating components. Such
exposure may result in insulation breakdown and accompanying localized electrical heating.
A control may remain permanently closed or open as a result of exposure to excessive mechanical,
electrical, thermal or environmental conditions or at normal end-of-life. If failure of the control
to operate could result in personal injury or property damage, the user should incorporate
supplemental system control features to achieve the desired level of reliability and safety. For
example, backup controls have been incorporated in a number of applications for this reason.

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INTRODUCTION
Thank you for selecting the Dynamo Motor powered by the integrated GreenDrive
TM
control.
This manual contains all basic and necessary information concerning the brushless DC motor and
GreenDrive
TM
control.
If you require any additional information, please contact Nidec Motor Company/Hurst Division
at 812-385-2564 or [email protected].
Features
NEMA 17 Motor
Ball Bearing System
Stainless Steel Shaft
12 to 36 Vdc Input Voltage
Closed Loop Speed Operating Mode
Pulse Width Modulated (PWM) Control Method
Enable and Direction Inputs
Efficiency up to 85%
Tachometer Output
4-Quadrant Operation
Current Limit Protection
Under Voltage Protection
Industry Standard Connectors
Product Description
The Nidec brushless DC motion control system is an integrated, variable-speed brushless DC
motor and control package. This system includes a low voltage customer interface that can be
connected to a system controller or connected to an external potentiometer, forward/reverse
switch, run/stop switch, or other user I/O. The motor is equipped with a triple-fixed preloaded
ball bearing system and multiple mounting arrangements. The system also includes internal
current limiting, and under voltage protection for system safeguarding.
Two channel encoder signals are available to close system loop internally or externally. The
encoder also permits the user to determine speed and direction of the motor. A Tachometer
signal is also accessible for a low cost alternative to the encoder.
The integrated motor control includes a power amplifier designed to operate directly from a DC
voltage input of 12 to 36 volts. The power amplifier contains an inverter and an optional low

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voltage power supply. The inverter converts input DC power into three phase voltages. The
optional low voltage power supply can be used to supply an auxiliary 5 Vdc to power additional
customer circuitry.
The GreenDrive
TM
also includes a variety of control methods and operating modes. The
integrated motor operating modes are:
●Closed loop speed - Together with the internal two-channel quadrature encoder or
tachometer signal, allows the user to close a speed loop internally to the control for
applications requiring minimum speed variation with varying loading.
The system control methods are:
PWM & Direction - Varies speed and direction based on PWM duty cycle.
GETTING STARTED
Minimum Requirements:
Hurst BLDC Motor
Power Supplies
●Motor Power Supply 12 to 36 Vdc (dependent on motor rating)
●Control Power Supply 0 to 5 Vdc optional internal power supply available
Customer Data Sheet
Cables available upon request
Refer to the label on the motor to retrieve information about rated speed, torque,
voltage, and current.

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MOUNTING RECOMMENDATIONS
Dynamo Motor Size 17
Axial & Radial Loading Recommendations
Radial - 10lbs max [45N max]
Axial - 2lbs max [9N max]
The threaded mounting holes on the motor housing have a depth as shown in the figure below.
Using screws longer than specified will result in the screw bottoming-out in the motor
housing and not securing the motor properly.
The figure below illustrates the screw thread sizes, thread engagement length and torque
requirements for mounting the Dynamo Size 17 motor.
FIGURE 1 – DYNAMO SIZE 17 MOTOR
At 25°C ambient the max motor winding operating temperature rise is 65°C with motor mounted to a 4" x 4" x 0.25"
aluminum plate. See Technical Specifications, Mechanical Outline, Dynamo Size 17 Motor for additional information.
Maximum length of screw
threads into motor
housing .300” (7.62mm)
English version: (4X) #6-32 Screw
Metric version: (4X) M4x0.7 Screw
Maximum Tightening Torque:
15.4 lb-in (17.7 kg-cm) for M4x0.7 screw
9.2 lb-in (10.6 kg-cm) for #6-32 screw
Mounting Flange
or Adapter Plate

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CHOOSING A POWER SUPPLY
There are two important parameters to consider when choosing a power supply in your
application, voltage and current.
Motor Power Supply
Voltage Input Range: 12 to 36 Vdc
Refer to your motor label for rated voltage. The integrated motor control is intended to be
operated from a low voltage DC power supply rated between 12 to 36 Vdc . The maximum voltage
of the GreenDrive
TM
is 42 Vdc, therefore do not exceed this voltage. The maximum continuous
operating current handled by the GreenDrive
TM
is 10 amps. Where the maximum motor current
is less than 10A, the power supply rating should be based on the rated motor current as shown
on the nameplate. Filter capacitors are supplied internal to the GreenDrive
TM
control for
increased reliability under typical power conditions. It is recommended that the power supply
meet the latest editions of UL60950 and CSA 60950 specifications.
Current Input Range: 3x Rated Motor Current (Typical)
The maximum or rated power supply current needed should typically be at least three times the
rated motor current to ensure adequate current headroom for intermittent motor overloading.

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Connecting inputs and outputs
Motor Power Supply Connections
Never connect or disconnect the power supply to a motor or control while the power is
turned on. Minor or moderate injury could result if not avoided.
All wire gauge sizes must be in accordance with all federal, state, and local
codes.
FIGURE 2 – POWER SUPPLY CONNECTIONS (C1)
Connect the power supply to the GreenDrive
TM
using a 2-pin connector (Molex P/N 39-01-2020
or equivalent) and terminals (Molex P/N 39-00-0039 or equivalent).
1. Connect the positive lead from the external power supply to pin 1 on the motor’s power
supply connector labeled as C1 .
2. Connect the negative lead from the external power supply to pin 2 on the motor’s power
supply connector labeled as C1 .
Power Supply Connector (C1)
Pin 1

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TABLE 1 – MOTOR POWER SUPPLY CONNECTOR PIN FUNCTIONS (C1)
Pin
No. Description Input/ Output Notes
1 +DC Input 12-36 Vdc, Maximum continuous current is 10A
2 GND Input
Control Connections
Never connect or disconnect the power supply to a motor or control while the power is
turned on. Minor or moderate injury could result if not avoided.
All wire gauge sizes must be in accordance with all federal, state, and local
codes.
FIGURE 3 – CONTROL CONNECTIONS (C2)
Connect the control inputs and outputs to the GreenDrive
TM
using a 10-pin connector (Molex P/N
50-57-9410 or equivalent) and terminals (Molex P/N 16-02-0103 or equivalent).
Pin 1
Control Connector (C2)

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TABLE 2 - CONTROL CONNECTOR PIN FUNCTIONS (C2)
Pin
No. Description Input/
Output
Notes
1 Tachometer Output
Speed Output – 15 Pulses/Revolution (PPR) for Dynamo at TTL
Level (0 to 5 Vdc) and 50% Duty Cycle
2 NA -- --
3 PWM Input
Input - PWM Control Method
●0% duty cycle minimum command
●100% duty cycle maximum command
●Used with Direction Input pin (Pin 7)
4 NA -- --
5 NA -- --
6 Direction Output
Direction Output – 0 Vdc output = clockwise lead end
5 Vdc output = counter-clockwise lead end
Can be used in conjunction with Tachometer output
(Pin 1) to determine speed and direction
7 PWM & Direction Input
PWM & Direction -
●0% duty cycle maximum command in the
counterclockwise direction lead end
●50% duty cycle minimum command
●100% duty cycle maximum command in the clockwise
direction lead end
8 Enable Input
Low level signal (0 Vdc) enables drive
9 GND -- Return path for + 5 Vdc (Pin 10)
10 +5 Vdc Input Input - User supplied 5 Vdc

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Inputs/Outputs
Tachometer (Pin 1)
Tachometer outputs are generated from an internal controller by the three hall effect sensors.
On the standard Dynamo motor, the output is 15 pulses per revolution. The tachometer output
provides speed information. At each commutation point, the tachometer output changes state
independent of motor direction. The GreenDrive
TM
can be used in conjunction with the Direction
output (Pin 6). See Table 2 for additional information.
Externally Supplied Voltage Command Input
The user must supply a 0-4 Vdc input into Pin 2 on the control connector. If a 5 Vdc supply is to
be used, a 22 Kresistor must be placed in series with a 100 K. potentiometer. If a 4 Vdc
supply is used, a resistor is not needed. The potentiometer consists of three pins, a supply
voltage input, a GND input and a variable command output. The user can adjust the command
output by adjusting the potentiometer with the wiper connected to the command input and the
other two potentiometer connections attached to the control connector Pin 10 and control
connector Pin 9 pins.
In torque mode, care must be taken by the user not to exceed the 0-4 volt range of the variable
command input (Pin 2). Voltages outside this range could cause permanent damage to the control.
PWM (Pin 3)
The PWM input can be used in Open Loop Speed and Closed Loop Speed Operating Modes. The
PWM input operates in PWM Control method, where the PWM command is from 0 to 100%; 0%
being no current applied to the windings and 100% full current applied to the windings. The
frequency of the PWM signal in the PWM control method operates between 15 kHz and 25 kHz.

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Direction (Pin 6)
Direction outputs are generated from an internal controller by the three hall effect sensors.
When the motor is rotating clockwise from the lead end, the direction output will be considered
a low level (GND). When rotation is counter-clockwise from the lead end, the direction output
will give a high level (5 Vdc). The GreenDrive
TM
can be used in conjunction with the Tachometer
output (Pin 1). The figure below displays additional information about the direction and
tachometer output.
FIGURE 4 – TACHOMETER AND DIRECTION INDICATION OUTPUTS
PWM & Direction (Pin 7)
The PWM & Direction input can be used in Open Loop Speed and Closed Loop Speed Operating
Modes. The PWM & Direction input operates in PWM & Direction Control Method where 0%
duty cycle maximum command in the counterclockwise direction (viewed from the lead end), 50%
duty cycle minimum command (0 input), 100% duty cycle maximum command in the clockwise
direction (viewed from the lead end). The frequency of the PWM signal in the PWM & Direction
control method operates at 2.5kHz.
Enable (Pin 8)
The Enable input is used in all control methods and operating modes. A low level (0 Vdc) on the
Enable pin enables the control to start the selected Control Type. A high level (+5 Vdc) on the
Enable input causes the GreenDrive
TM
to stop controlling the motor, thus allowing the motor to
coast. This line has an internal 2.15kpull up resistor. The 2.15kpull up resistor requires the
pin to be driven by a circuit capable of sourcing at least 2.33 mA.
Commutation
Points
Direction
Tachometer
Forward Motor Rotation
Reverse Motor Rotation
+5 Vdc
0 Vdc

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GND (Pin 9)
The GND pin (Pin 9) is the return path for + 5 Vdc (Pin 10) input/output pin. It is also common
connection for External, Analog or PWM Control Methods. Pin 9 (Gnd), is common to the (Gnd)
terminal of the power supply connector. Use isolated input signals as required to avoid ground
loop issues.
+5 Vdc (Pin 10) (Input)
In this section, pin 10 is described as an externally supplied input. If you selected the
internally generated output, see the section below.
Voltage Input Range: 4.75 to 5.25 Vdc
Current Input: power supply must provide a minimum of 56 mA
The +5 Vdc input is externally supplied by the end user depending on the GreenDrive
TM
option
selected.
The +5 Vdc input provides power for internal electronics. The user supplied +5 Vdc input is
critical to the performance of the motor control. Care and attention must be taken not to deviate
away from voltage specifications to prevent potential harm to the motor control system.

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PWM & DIRECTION
PWM & Direction - Pin 7
Enable – Pin 8
The PWM & Direction mode accepts a PWM signal on the Direction input pin (Pin 7) on the control
connector to control speed and direction. PWM & Direction permits the user to vary input
command and direction with change in duty cycle input. The PWM signal should be an active high
PWM signal at 25 kHz to the PWM input pin. A 0% duty cycle input indicates maximum command
in the counterclockwise direction when viewing the motor from the lead end. A 50% duty cycle
input indicates minimum command. A 100% duty cycle input indicates maximum command in the
clockwise direction when viewing the motor from the lead end. A high level on the Enable pin
enables the drive.
FIGURE 5 – PWM & DIRECTION CONTROL METHOD W/O INTERNAL 5 VDC SUPPLY
(TYPICAL CONNECTIONS)