RoboteQ MDC1230 User manual

MDC1230/MDC1460 Motor Controller Datasheet 1
MDC1230/MDC1460
Roboteq’s MDC1230 and MDC1460 controllers are designed
to convert commands received from an RC radio, Analog
Joystick, wireless modem, PC (via RS232) or microcomputer
into high voltage and high current output for driving one
DC motor. Using CAN bus, up to 127 controllers can be
networked on a single twisted pair. Numerous safety features
are incorporated into the controller to ensure reliable and safe
operation.
The controller features a high-performance 32-bit microcom-
puter and quadrature encoder inputs to perform advanced
motion control algorithms in Open Loop or Close Loop (Speed
or Position) modes. The MDC1xxx features several Analog,
Pulse and Digital I/Os which can be remapped as command or
feedback inputs, limit switches, or many other functions.
Numerous safety features are incorporated into the controller
to ensure reliable and safe operation. The controller’s operation
can be extensively automated and customized using Basic
Language scripts. The controller can be reprogrammed in the
field with the latest features by downloading new operating
software from Roboteq.
Applications
• Industrial Automation
• Fan and Pump control
• Winch and Cranes
• Personal transportation
• Automatic Guided Vehicles
• Terrestrial and Underwater Robotic Vehicles
• Automated machines
• Telepresence Systems
• Animatronics
Features List
• RS232, 0-5V Analog, or Pulse (RC radio) command modes
• Auto switch between RS232, Analog, or Pulse based on
user-defined priority
• CAN bus interface at up to 1Mbit/s
• Built-in high-power power drivers for one DC motor at up
to 80A (MDC1230) and 120A (MDC1460)
• Support for 10 KOhm NTC temperature sensors through
analog inputs (requires an external 10 KOhm pull-up
resistor)
• Full forward and reverse control. Four quadrant operation.
Supports regeneration
• Operates from a single power source
• Built-in programming language for automation and
customization
• Programmable current limit up to 80A (MDC1230) or 120A
(MDC1460) for protecting controller, motors, wiring and
battery
• Up to six Analog Inputs for use as command and/or feed-
back
• Up to six Pulse Length, Duty Cycle or Frequency Inputs
for use as command and/or feedback
• Up to six Digital Inputs for use as Deadman Switch, Limit
Switch, Emergency stop or user inputs
• Quadrature Encoder input with 32-bit counter
• Two general purpose 24V, 1A output for brake release or
accessories
• Selectable min/max, center and deadband in Pulse and
Analog modes
• Selectable exponentiation factors for each command
inputs
• Trigger action if Analog, Pulse or Encoder capture are out-
side user selectable range (soft limit switches)
• Open loop or closed loop speed control operation
• Closed loop position control with analog or pulse/fre-
quency feedback
1x80A and
1x120A
Single Channel
Brushed DC Motor
Controller with
Encoder Input,
USB and CAN

2 MDC1230/MDC1460 Motor Controller Datasheet Version 1.5 October 7, 2023
Orderable Product References
TABLE 1.
Reference Number of Channels Amps/Channel Volts Ethernet Resolver
MDC1230 1 80 30 No No
MDC1460 1120 60 No No
• Precise speed and position control when Encoder feed-
back is used
• PID control loop
• Configurable Data Logging of operating parameters on
RS232 Output for telemetry or analysis
• Built-in Battery Voltage and Temperature sensors
• Power Control input for turning On or Off the controller
from external microcomputer or switch
• No consumption by output stage when motor is stopped
• Regulated 5V output for powering Encoders, RC radio, RF
Modem or microcomputer
• Programmable acceleration and deceleration
• Programmable maximum forward and reverse power
• Ultra-efficient 6 mOhm (MDC1230) or 3 mOhm
(MDC1460) ON resistance MOSFETs
• Stall detection and selectable triggered action if Amps is
outside user-selected range
• Overvoltage and Undervoltage protection
• Programmable Watchdog for automatic motor shutdown
in case of command loss
• Overtemperature protection
• Diagnostic LED indicators
• Efficient heat sinking using conduction bottom plate.
Operates without a fan in most applications
• Power wiring via FASTON terminals
• Open frame or enclosed design with heat conducting
bottom plate
• 5.50” (140mm) L, 4.45” W (113mm), 0.78” (20mm) H
• -40º to +85 ºC operating environment
• 380 g
• Easy configuration, tuning and monitor using provided PC
utility
• Field upgradeable software for installing latest features via
the Internet

Power Wires Identifications and Connection
MDC1230/MDC1460 Motor Controller Datasheet 3
Warning
Dangerous, uncontrolled motor runaway condition can occur for a number of reasons, including, but
not limited to: command or feedback wiring failure, configuration error, faulty firmware, errors in user
script or user program, or controller hardware failure.
The user must assume that such failures can occur and must make their system safe in all conditions.
Roboteq will not be liable in case of damage or injury as a result of product misuse or failure.
Important Note
All products are not serviceable. If damage is suspected, the item must be replaced rather than
repaired.
Attempting to service or repair the product voids any existing warranty and may pose safety risks.
Consult customer support for more information on replacements
Power Wires Identifications and Connection
Power connections are made through FASTON™ tabs. For more power handling the Supply and Motor tabs are
doubled and should be connected in parallel.
FIGURE 1. MDC1xxx Front View
FIGURE 2. MDC1xxx Rear View
I/O Connector USB
Connector
LEDs
I/O Connector USB
Connector
LEDs
Power Supply and Motor Connections
FIGURE 1.

4 MDC1230/MDC1460 Motor Controller Datasheet Version 1.5 October 7, 2023
Figure 3, below shows how to wire the controller and how to turn power On and Off.
FIGURE 3. Powering the Controller. Thick lines identify MANDATORY connections
Caution
Carefully follow the wiring instructions provided in the Power Connection section of the User Manual.
The information on this datasheet is only a summary.
Mandatory Connections
It is imperative that the controller is connected as shown in Figure 3, above, in order to ensure a safe and trou-
ble-free operation. All connections shown as thick black lines line are mandatory. The controller must be pow-
ered On/Off using switch SW1on the Power Control Header.
Emergency Switch or Contactor
The battery must be connected in permanence to the controller’s VMot power via an input emergency switch
or contactor SW2 as additional safety measure. The user must be able to deactivate the switch or contactor at
any time, independently of the controller state.
Electrostatic Discharge Protection
In accordance with IEC 61000-6-4, Roboteq Motor Controllers are designed to withstand ESD up to 4kV touch
and 8kV air gap. This protection is implemented without any additional external connections required.
Some specifications, such as EN12895, require a higher level of protection. To maximize ESD protection, up to
8kV touch and 15kV air gap, you may connect the metallic heatsink of the controller to your battery negative
terminal. See App Note 062918 for example connections.
Precautions and Optional Connections
Note 1: Optional backup battery to ensure motor operation with weak or discharged battery.
Note 2: Use precharge 1K Resistor to prevent switch arcing.
Note 3: Insert a high-current diode to ensure a return path to the battery during regeneration in case the fuse
is blown.
Motor
VMot
PwrCtrl
SW1 Main
On/Off Switch 1A
F2
1A
Diode
>20A
Resistor
1K, 0.5W
+-
SW2
Emergency
Contactor or
Cut-off Switch
F1
M+
M+
M-
M-
I/O Connector
VMot
Ground
Ground
Ground
Main
Battery
Backup
Battery
Note 5
Do not Connect!
Note 1
Note 4
Note 3 Note 2

Use of Safety Contactor for Critical Applications
MDC1230/MDC1460 Motor Controller Datasheet 5
Note 4: Optionally ground the VMot wires when the controller is Off if there is any concern that the motors
could be made to spin and generate voltage in excess of 30V (MDC1230) or 60V (MDC1460).
Note 5: Be sure not to create a path from the ground pins on the I/O connector and the battery’s minus terminal.
Use of Safety Contactor for Critical Applications
An external safety contactor must be used in any application where damage to property or injury to person can oc-
cur because of uncontrolled motor operation resulting from failure in the controller’s power output stage.
FIGURE 4. Contactor Wiring Diagram
The contactor coil must be connected to a digital output configured to activate when “No MOSFET Failure”.
The controller will automatically deactivate the coil if the output is expected to be off and battery current of
2.5A or more is measured for more than 0.5s. This circuit will not protect against other sources of failure such
as those described in the “Warning” on Page3.
Controller Mounting
During motor operation, the controller will generate heat that must be dissipated. The published amps rating
can only be fully achieved if adequate cooling is provided. Good conduction cooling can be achieved by mount-
ing the controller to a metallic surface, such as the chassis, cabinet, etc.
Sensor and Commands Connection
Connection to RC Radio, Microcomputer, Joystick and other low current sensors and actuators is done via the
15 connector located in front of the board. The functions of many pins vary depending on user configuration.
Pin assignment is found in the table below.
FIGURE 5. Connector Pin Locations
PwrCtrl
SW1 Main
On/Off Switch 1A
F2
1A
Diode
>20A
Resistor
1K, 0.5W
+-
F1
I/O Connector
VMot
to +40V Max Digital Out
Ground
Ground
Main
Battery
FIGURE 1.Contactor wiring diagram

6 MDC1230/MDC1460 Motor Controller Datasheet Version 1.5 October 7, 2023
TABLE 2.
Connector Pin Power Dout Com RC Ana Dinput Enc Default Config
1DOUT1 Brake
9 DOUT2 Contactor
2 TxOut RS232Tx
10 RC5 ANA5 (1) DIN5 ENCA (2) Encoder (2)
3 RxIn RS232Rx
11 RC4 ANA4 DIN4 AnaCmd (3)
4RC1 ANA1 (1) DIN1 RCRadio1
12 RC3 ANA3 DIN3 Unused
5 GND
13 GND
6 CANL CAN Low
14 5VOut
7 CANH CAN High
15 RC6 (1) ANA6 DIN6 ENCB (2) Encoder (2)
8RC2 ANA2 DIN2 Unused
Note 1: Pin assignment for this signal may differ from other Roboteq controller models.
Note 2: Encoder input requires RC inputs 3, 4, 5 and 6 to be disabled. Encoders are enabled in factory default.
Note 3: Analog command is disabled in factory default configuration.
Default I/O Configuration
The controller can be configured so that practically any Digital, Analog and RC pin can be used for any purpose.
The controller’s factory default configuration provides an assignment that is suitable for most applications. The
figure below shows how to wire the controller to one analog potentiometer, an RC radio, and the RS232 port.
It also shows how to connect the output to a motor brake solenoid. You may omit any connection that is not
required in your application. The controller automatically arbitrates the command priorities depending on the
presence of a valid command signal in the following order: 1-RS232, 2-RC Pulse, 3-None. If needed, use the
Roborun+ PC Utility to change the pin assignments and the command priority order.
FIGURE 6. Factory Default Pins Assignment
18
915
1
RS232
Ground
TxOut
RxIn
Motor Brake
Safety Contactor
Pot 1
RC in

Enabling Analog Commands
MDC1230/MDC1460 Motor Controller Datasheet 7
CAN Bus Operation
The controller can interface to a standard CAN Bus network, using four possible protocols: A simple and pow-
erful meshed network (RoboCAN), Standard CANOpen, and two simplified proprietary schemes (MiniCAN and
RawCAN). Please refer to the User Manual for details. It is impossible to operate USB and CAN at the same
time. The controller starts up with CAN available, but CAN will be disabled as soon as the controller is plugged
into USB. To re-enable CAN, disconnect USB and restart the controller.
USB Communication
Use USB only for configuration, monitoring and troubleshooting the controller. USB is not a reliable communi-
cation method when used in electrically noisy environments. Further, communication will not always recover
after it is lost without unplugging and replugging the connector, or restarting the controller. RS232 communica-
tion is always preferred when interfacing to a computer. Connecting to a computer via the USB will not disable
the CAN interface.
Enabling Analog Commands
For safety reasons, the Analog command mode is disabled by default. To enable the Analog mode, use the PC
utility and set Analog in Command Priority 2 or 3 (leave Serial as priority 1). Note that by default the additional
securities are enabled and will prevent the motor from starting unless the potentiometer is centered, or if the
voltage is below 0.25V or above 4.75V. Figure 6, above, shows suggested assignment of Pot 1 to ANA1. Use
the PC utility to enable and assign analog inputs.
Connecting Thermistors
10 KOhm NTC temperature sensors can be connected to the controller’s analog inputs. This enables reading of
motor temperature through the controller’s runtime variables and allows for active temperature protection. This
connection can be achieved by using a 10 KOhm pull-up resistor between the analog input and the controller’s
5V output. For more information about motor temperature readings and controller parameterization, please re-
fer to the Roboteq Controller’s User Manual.
Status LED Flashing Patterns
After the controller is powered on, the Power LED will turn on, indicating that the controller is On. The Status LED
will be flashing at a two second interval. The flashing pattern provides operating or exception status information.
Additional status information may be obtained by monitoring the controller with the PC utility.
Measured and Calculated Amps
Including Amps sensors on the wires allows for fast and efficient collection of information. Battery amps are
measured in real-time and which allows precise calculation of motor amps.
On the A-version, both motor and battery amps are measured.

8 MDC1230/MDC1460 Motor Controller Datasheet Version 1.5 October 7, 2023
Secure Connection to Faston™ Tabs
Power Motor and Battery connections are made via standard 250mils (6.35mm) AMP FASTON™ Tabs. FASTON
connectors provide a high current and very secure connection, proven over decades of use in the automotive
industry. For maximum current handling, use connectors for AWG10 wires recognizable by their yellow plastic
insulator.
FASTON connectors have an extremely tight fit and will not come off on their own. It is recommended, never-
theless, that the wiring is made so that the cables are never pulling the connector outward.
Frequent disconnects and reconnects will eventually loosen the connector’s grip on the tab. If frequent discon-
nection is required, consider using Positive Lock connectors from TE Connectivity or their equivalent. These
connectors have a spring loaded tab latch pin that will lock into the hole of the male tab.
Electrical Specifications
Absolute Maximum Values
The values in the table below should never be exceeded. Permanent damage to the controller may result.
TABLE 3.
Parameter Measure point Model Min Typical Max Units
Battery Leads Voltage Ground to VMot MDC1230 10 35 Volts
MDC1460 10 62 Volts
Reverse Voltage on Battery Leads Ground to VMot All -1 Volts
Motor Leads Voltage Ground to M+, M- MDC1230 30 Volts
MDC1460 62 Volts
Digital Output Voltage Ground to Output pins All 40 Volts
Analog and Digital Inputs Voltage Ground to any signal pin on
15-pin connectors
All 30 Volts
RS232 I/O pins Voltage External voltage applied to Rx
Pins
All 30 Volts
Board Temperature Board All -40 85 ºC
Humidity Board All 100 (3) %
Note 1: Maximum regeneration voltage in normal operation. Never inject a DC voltage from a battery or other fixed source
Note 2: No voltage must be applied on Tx pin
Note 3: Non condensing

Electrical Specifications
MDC1230/MDC1460 Motor Controller Datasheet 9
Power Stage Electrical Specifications (at 25ºC ambient)
TABLE 4.
Parameter Measure point Model Min Typical Max Units
Battery Leads Voltage Ground to VMot MDC1230 10 (1) 30 Volts
MDC1460 10 (1) 62 Volts
Motor Leads Voltage Ground to M+, M- MDC1230 0 (1) 30 (2) Volts
MDC1460 0 (1) 62 (2) Volts
Over Voltage protection range Ground to VMot MDC1230 5 30 (4) 35 (2) Volts
MDC1460 5 50 (4) 62 (2) Volts
Under Voltage protection range Ground to VMot MDC1230 0 5 (4) 30 Volts
MDC1460 0 5 (4) 62 Volts
Idle Current Consumption VMot or Pwr Ctrl wires All 50 75 (5) 100 mA
ON Resistance (Excluding wire
resistance)
VMot to M+, plus M- to
Ground at 100% power
MDC1230 6 mOhm
MDC1460 3 mOhm
Max Current for 30s Motor current MDC1230 80 (6) Amps
MDC1460 120 (6) Amps
Continuous Max Current Motor current MDC1230 50 (7) Amps
MDC1460 70 (7) Amps
Current Limit range Motor current MDC1230 1 60 (8) 80 Amps
MDC1460 1 80 (8) 120 Amps
Stall Detection Amps range Motor current MDC1230 1 60 (8) 80 Amps
MDC1460 1 80 (8) 120 Amps
Stall Detection timeout range Motor current All 1 500 (9) 65000 milliseconds
Motor Acceleration/Decelera-
tion range
Motor current All 100 500 (10) 65000 milliseconds
Note 1: Negative voltage will cause a large surge current. Protection fuse needed if battery polarity inversion is possible
Note 2: Maximum regeneration voltage in normal operation. Never inject a DC voltage from a battery or other fixed source
Note 3: Minimum voltage must be present on VMot or Power Control wire
Note 4: Factory default value. Adjustable in 0.2V increments
Note 5: Current consumption is lower when higher voltage is applied to the controller’s VMot or PwrCtrl wires
Note 6: Max value is determined by current limit setting. Duration is estimated and is dependent on ambient temperature
cooling condition
Note 7: Estimate. Limited by heatsink temperature. Current may be higher with better cooling
Note 8: Factory default value. Adjustable in 0.1A increments
Note 9: Factory default value. Time in ms that Stall current must be exceeded for detection
Note 10: Factory default value. Time in ms for power to go from 0 to 100%

10 MDC1230/MDC1460 Motor Controller Datasheet Version 1.5 October 7, 2023
Warning
Beware that regenerative braking can create high voltage at the controller’s power inputs. Use the con-
troller only with batteries. See user manual for special precautions when using a power supply.
Command, I/O and Sensor Signals Specifications
TABLE 5.
Parameter Measure point Min Typical Max Units
Main 5V Output Voltage Ground to 5V pin on DSub15 4.7 4.9 5.1 Volts
5V Output Current 5V pin on DSub15 100 mA
Digital Output Voltage Ground to Output pins 40 Volts
Digital Output Current Output pins, sink current 1 Amps
Output On resistance Output pin to ground 0.75 1. 5 Ohm
Output Short circuit threshold Output pin 1.05 1. 4 1.75 Amps
Input Impedances AIN/DIN Input to Ground 53 kOhm
Digital Input 0 Level Ground to Input pins -1 1 Volts
Digital Input 1 Level Ground to Input pins 3 30 Volts
Analog Input Range Ground to Input pins 0 5.1 Volts
Analog Input Precision Ground to Input pins 0.5 %
Analog Input Resolution Ground to Input pins 1 mV
Pulse durations Pulse inputs 20000 10 us
Pulse repeat rate Pulse inputs 50 250 Hz
Pulse Capture Resolution Pulse inputs 1 us
Frequency Capture Pulse inputs 100 1000 Hz
Encoder count Internal -2.147 2.147 10^9 Counts
Encoder frequency Encoder input pins 200 KHz
Note1: Encoder input requires RC inputs 3, 4, 5 and 6 to be disabled. Encoders are enabled in factory default.
Operating & Timing Specifications
TABLE 6.
Parameter Measure Point Min Typical Max Units
Command Latency Command to output change 0 0.5 1 ms
PWM Frequency Motor outputs 10 18 (1) 20 kHz
Closed Loop update rate Internal 1000 Hz
RS232 baud rate Rx & Tx pins 115200 (2) Bits/s
RS232 Watchdog timeout Rx pin 1 (3) 1000 65000 ms
Note 1: May be adjusted with configuration program
Note 2: 115200, 8-bit, no parity, 1 stop bit, no flow control
Note 3: May be disabled with value 0

Electrical Specifications
MDC1230/MDC1460 Motor Controller Datasheet 11
Scripting
TABLE 7.
Parameter Measure Point Min Typical Max Units
Scripting Flash Memory Internal 8196 Bytes
Max Basic Language programs Internal 1000 Lines
Integer Variables Internal 1024 Words (1)
Boolean Variables Internal 8192 Symbols
Execution Speed Internal 50000 Lines/s
Note 1: 32-bit words
Thermal Specifications
TABLE 8.
Parameter Measure Point Min Typical Max Units
Board Temperature PCB -40 85 (1) ºC
Thermal Protection range PCB 70 80 (2) ºC
Thermal resistance Power MOSFETs to heats sink 2 ºC/W
Note 1: Thermal protection will protect the controller power
Note 2: Max allowed power out starts lowering at minimum of range, down to 0 at max of range
The MDC1xxx uses a conduction plate at the bottom of the board for heat extraction. For best results, attach
firmly with thermal compound paste against a metallic chassis so that heat transfers to the conduction plate to
the chassis. If no metallic surface is available, mount the controller on spacers so that forced or natural air flow
can go over the plate surface to remove heat.
Mechanical Specifications
TABLE 9.
Parameter Measure Point Min Typical Max Units
Weight Board 370 (0.81) g (lbs.)
Power Wire Gauge FASTON™Tabs 10 AWG
Torque D-sub standard connector 0.4 (3.54) Nm (in-lbs)
Torque Terminal block 0.8 (7.10) Nm (in-lbs)
Torque Mounting screws (4/M2.5) 0.36 (3.2) Nm (in-lbs)
4.45" (133.4mm)
0.7" (17
.8mm)
1.09"
(3.8mm)
2.0" (5.08mm)
0.120" (3.0mm)
0.16" (4.0mm)
0.325" (8.3 mm)
0.25"
(6.3 mm)
0.3"
(7.6 mm)
0.57"
(14.5mm)
0.120" (3.0mm)
5.50" (139 .7mm)
4.20" (106.7mm)
0.20" (5.0mm)
5.10" (129.7mm)
0.19" (5.0mm)
VMOT
Pwr
Ctrl
VMOT
M+
M+
M-
M-
GND
GND
0.98"
(25mm)
FIGURE 7. MDC1xxx Side View and Dimensions

12 MDC1230/MDC1460 Motor Controller Datasheet Version 1.5 October 7, 2023
FIGURE 8. MDC1xxx Top View and Dimensions
4.450" (113.03mm)
1.09"
(3.8mm)
2.0" (5.08mm)
0.120" (3.0mm)
0.120" (3.0mm)
5.500" (139 .70mm)
4.056" (103.03mm)
0.20" (5.0mm)
5.106" (129.70mm)
0.197" (5.00mm)
VMOT
Pwr
Ctrl
VMOT
M+
M+
M-
M-
GND
GND