MDC200-048051 Brushless DC Controller (User`s Guide)
Contents
1. AC INPUT 85 132VAC September 2012 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 indemnifies 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 specification2. 200 048051 110VAC Input Brushless Controller User s Guide HALL POWER UTOMATION HALL A HALL B HALL C HALL GND MOTION CONTROL MADE EASY PHASE C PHASE B PHASE A PG OUT C PG OUT E DIRECTION DIRECTION FREEWHEEL FREEWHEEL EGND RUN STOP AC IN RUN STOP 85 132VAC aC IN FAULT OUT C FAULT OUT E 2 7 3 2 Cy z 7 MDC200 048051 ZAY ANAHEIM AUTOMATION UTOMA TION 910 East Orangefair Lane Anaheim CA 92801 714 992 6990 fax 714 992 0471 e mail info anaheimautomation com website www anaheimautomation com L010404 1 September 2012 048051 Driver Features Maximum Current Limit Setting from 1 5Amps peak up to 100W Power Output Internal or External Potentiometer Speed Control e 48VDC Motor Voltage Bus 2 Quadrant Operation Hall Sensor Feedback Constant Velocity Mode Short Circuit Protection Requires 85 135 VAC Power Input Speed Out Fault Out Brake Disable and Direction Inputs Selectable Ramp Up Down Optically Isolated Inputs and Outputs e Compact Size 6 25 x 4 35 x 1 93 Dual Mounting Option Detachable Screw type Terminal Blocks General Description The MDC200 048051 driver is a velocity control driver designed to drive DC Brushless Motors from a supply of 120VAC With a motor bus voltage of 48V maximum phase current of 5A peak and power output of 100W
3. 8 2886 1 1 52 E Pin Description 3 EARTH GND must be connected TB3 AC Voltage In Terminals TB Pin Description Ce 6 Pot Wiper P1 10K External Pot September 2012 Dip Switch Settings cont Function Constant Speed Mode Closed Loop Voltage Controlled Speed Mode Open Loop Closed Loop Compensation 1 Closed Loop Compensation 2 Closed Loop Compensation 3 Standard Product Ready to Ship SW1 Open Loop and Closed Loop If Closed Loop selected Closed Loop compensation switches must be set according to the motor speed desired Motor Freewheel The motor freewheel feature allows the de energizing of the motor phases Zero current into this input causes the motor to run at the given speed while 1mA into 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 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 Zero current into this input causes the motor to turn in the CW direction while 1mA into this input causes the motor to turn in the CCW direction Speed Adjust Setting
4. There are two ways to set the speed on this drive One is to use the onboard or external potentiometer To use the onboard potentiometer set INT EXT SPD Switch to the off position default To use the external 10K potentiometer set INT EXT SPD switch to the on position If an external potentiometer is used to control the speed of the motor connect the pot wiper to P1 pin W the positive end of the potentiometer to P1 pin H and the negative end to P1 L Fault Protection and Fault Output 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 internal or external current limit potentiometer is produced an over current latch is activated shutting off the output This driver is equipped with a FAULT LED 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 Under voltage Lockout activation at 9 1VDC for the input voltage and 4 5VDC for Hall Sen sor voltage The fault output on the MDC200 048051 is an opto deocoupled open collector output When a latched fault condition occurs no current conducts into the emitter 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 101
5. 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 SW1 pos1 must be in the on position To operate Closed Loop the O C LOOP switch must be in the off position and the CLADJ poten tiometer R3 and CLADJ dip switches SW1 pos2 4 must be set to optimize the driver for each 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 respect to the required motor speed The following tables show Closed Loop potentiometer and dip switch settings for each motor These adjustments will set the maximum setting of the internal external speed potentiometer to the motors maximum running speed If operation at slower speeds is needed for the application CL POT can be adjusted toward 100 until desired motor speed is achieved The motor speed can be monitored by measuring the pulse rate of PG OUT 2 1 amp 2 1010404 3 September 2012 4 Pole Motors CL MAX SPD POT RPM Motor CL1 CL3 Pon e BLWS231D 36V 4000 BLWS231S 36V 4000 ee BLWS232D 36V 4000 BLWS232S 36V 4000 BLWS233S 36V 4000 65 4010 BLWS234D 36V 4000 4010 BLWS235 36V 4000 6
6. this driver eliminates the need for an external power supply Using hall sen sor feedback a constant velocity mode can be selected The driver is protected against over current cycle by cycle or latched hall sensor error and under voltage When an error occurs a fault light is 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 optional external potentiometer 10K can be used to control the speed as well The direction of the motor freewheel input When using the run stop input there are three ramp up down profiles from standstill to select from The run stop input overrides all other inputs into the driver Pin Descriptions The inputs on the MDC200 048051 are optically isolated with an 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 the input a minimum of 1 0 mA needs to be sourced or sinked through the opto diode This is done simply by placing a voltage of 5 to 7 VDC across two inputs of the opto diode If sourcing current into the inputs then all three cathodes shou
7. 0404 7 September 2012 Speed Output The PG OUT terminal TB2 pin 1 and 2 is used to determine the speed of the motor shaft An opto decoupled open collector output 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 Care must be taken not to pass more than 50mA through this transistor Poles RPM 8 15 PGOUT in Hz 6 20 PGOUT in Hz 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 Dimensions 1 0 156 SLOT 8 PLCS 0 58 sss FEH 1 93 0 75 HWL Ais UTOMATION HALL MOTION CONTROL MADE EASY HALL HALL GND PHASE C PHASE B PG OUT PG OUT DIRECTION DIRECTION FREEWHEEL FREEWHEEL RUN STOP EGND RUNISTOP 85 132VAC AC IN FAULT OUT C ACIN FAULT OUT E 4 35 MDC200 048051 All units are in inches L010404 8 September 2012 Typical Wiring Diagram 1010404 MDC200 048051 CURRENT SPEED SW2 SW1 SETTING OPTIONAL 5 0 12345 1234 HALL POWER 2 SENSOR Q SENSOR C Q FREEWHEEL HALL GND Q RUN STOP RUN STOP FLT OUT C PHASE Q
8. 5 4010 8 Pole Motors BLWR235D 36V 4000 BLWR232S 24V 1350 wres on CL MAX SPD Motor CL1 CL3 POT RPM on on On on on or BLY173D 24V 4000 ras 80 BLY174D 24V 4000 5 2 BLY174S 24V 4000 if BLY341D 48V 3200 n 258 BLY341S 48V 3200 1 BLY342D 24V 3000 40 BLY342D 30V 3000 BLY342D 30V 3000 BLY342D 48V 3200 309 BLY342S 48V 3200 a BLY343S 48 3200 1010404 4 September 2012 Commutation Sequence Phase A 1 1 1 1 1 21 1 121 1 Phase Z Z Haia 1 110 01 0 1 120 Hall Spacing Sequence Reverse mrasa z f lz Phases Z e z Phasec Z Z Hara 1 1 1 0 0 Hag o i t 4 o 0 o ft 1 t o 60 Hall Spacing Sequence Forward 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 first 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 o
9. ld be tied together and grounded sinking current then all three anodes should be tied together to the voltage The PG Out and Fault output on the MDC200 048051 are an opto decoupled open collector output 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 1010404 2 2012 Optically Isolated Inputs and Output The following inputs and output to the MDC200 048051 are Optically Isolated Pin 9 amp 10 To enable an input apply a DC voltage source of 5VDC to 7VDC across the inputs The Anodes are pins 3 5 and 7 and the Cathodes are pins 4 6 and 8 Absolute Maximum Ratings Output Current Rating Adjustable 1 0 5 0 amperes per phase maximum operating peak current 0 5 2 5 amperes per phase maximum operating continuous current Power Requirements TB4 Pins 1 and 2 85VAC min 135VAC max Operating Temperature Heat Sink 0 70 C Hall Sensor Power Output 6 25V 30mA maximum Typical current draw from hall sensors is 20 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
10. n 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 1010404 5 September 2012 Terminal and Dip Switch Descriptions Pin Description Hall Sensor Power TB1 Motor Hall Terminals Pin Description TB4 Motor Phase Terminals SW Description SW1 Dip Switch Dip Switch Settings Function Pin Description PG OUT collector 6 Ce 90 Fault Out collector Fault Out emitter TB2 Opto isolated Control Inputs and Outputs SW Description INT EXT SPEED FLT LATCH SW2 Dip Switch Speed Connora External Speed 9 SW1 Speed Adjustment Over Current and Ramp settings L010404 SW1 Or
11. s 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 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 ANAHEIM AUTOMATION 1010404 10 2012
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