BLWS23MDC Series - Anaheim Automation
BLWS23MDC SeriesProgrammable Brushless DC Motor ControllerUser’s GuideA N A H E I MA U T O M A T I O N4985 E. Landon Drive Anaheim, CA 92807e-mail: info@anaheimautomation.comL0113881(714) 992-6990 fax: (714) 992-0471website: www.anaheimautomation.comNovemberJuly 20152018
Table of ContentsSection 1: Introduction. 3Description. 3Methods of Communication. 3Baud Rate. 3Electrical Specifications. 4Ordering Information. 4Dimensions. 5Wiring Diagrams. 5Torque Curves. 6Section 2: Functions. 7PI Control Tuning. 8Section 3: BMC100 Software. 9Installation. 9Getting Started. 9Section 4: Direct Talk Mode. 12Command Format. 12Unit Selection. 12Command Summary. 12Section 5: Troubleshooting. 19Error Codes. 19Appendix 1: ASCII Table for Direct Mode. 20Appendix 2: Firmware Revisions. 20L0113882NovemberJuly 20152018
Section 1: IntroductionThe BLWS23MDC Series is a compact microcontroller-based Programmable Brushless DC Motor Controller with Hall Effect Sensor Feedback for accurate speed measurement. With the motor andits respective controller/driver in a single package, the task of wiring up the motor has been eliminated.This motor controller provides flexible, independent control of a Brushless DC motor from computers, orany machine controller with serial communication. It is also capable of standalone operation, making itan embedded machine controller. The easy-to-use Windows software, BMC100, can be used to directlycontrol the BLWS23MDC for Real Time Motion through serial communication.The BLWS23MDC Series has an easy-to-remember set of commands for direct control. Thecontroller communicates via two-wire RS485 which is a preferred interface for communication in environments where a substantial amount of electromagnetic noise is present. In addition, the user caneasily connect the controller to a PC by using an RS485-to-USB adapter in order to take advantage ofthe included software.DescriptionThe BLWS23MDC Series provides accurate control of motor speed, direction, and brake settingfor a Brushless DC Motor. The BLWS23MDC Series controllers are embedded with a Proportional-Integrator (PI) controller program. Proportional and Integrator Constants, Kp and Ki, can be programmedusing the BMC100 Windows Software or in Direct Talk Mode thorugh a terminal program. The controller has two modes through which it can control the speed of the motor: Analog Mode and Digital Mode.In Digital Mode, the controller is very accurate in keeping the motor running at the desired speed. TheAnalog Mode provides standalone functionality to the controller with a dynamic DC voltage input to control the speed of the motor. An analog voltage can be used to set the desired speed between the upperand lower programmable limits. Such a functionality can be easily achieved by using a potentiometerand the 5V output of the controllerMethods of CommunicationThere are two methods for sending commands to the BLWS23MDC Series. One is to directlytalk to the BLWS23MDC Series using Direct Talk Mode via the controller’s RS485 serial interface. Notethat an RS485-to-USB adaptor can be used to easily connect the controller to a PC. Also, the RS485interface allows the BLWS23MDC to connect to PLCs (Programmable Logic Controller) or HMIs (Human Machine Interfaces), where the PLC or HMI gives the BLWS23MDC serial commands to control itsopeartion.The second way to give commands to the BLWS23MDC is to use the BMC100 software formanual control. Through the BMC100 software, the user can control motion as well as modifying motorand controller parameters even when the motor is running. Additionally, the software can be used tomonitor motor speed at any time.Baud RateBaud rate is a term frequently used in serial data communications;a “baud” is defined as the reciprocal of the shortest pulse duration in a data word signal, including start, stop, and parity bits. This isoften taken to mean the same as “bits per second,” a term that expresses only the number of “data” bitsper second. Very often, the parity bit is included as an information or data bit. The BLWS23MDC Seriesaccepts a baud rate of 38400 only.L0113883July 20152018November
Electrical SpecificationsPower Requirement with No Connections:24VDC @ 50mACommunication Interface:Two-wire RS485Operating Temperature:0 to 60 degrees CData Format:Half-Duplex1 start bit8 data bitsNo parity1 Stop bit5VDC Max Output Current:25mARun/Stop Max Input Voltage:7VDCBaud Rate:38400 baud, FixedAnalog Input Range:0 - 5VDCOrdering InformationThe table below lists a variety of products available from Anaheim Automation, Inc. These products includethose covered by this manual, along with supporting cables and devices. We are continually adding newproducts to our line, so please consult Anaheim Automation, Inc. or its representatives for information onthe latest releases.Part NumberDescriptionBLWS23MDCFeatured Programmable Brushless DC Motor Controller485SD9TBL011388USB-to-RS485 data converterPSAM 24V 2.7ADC Power Supply 24V at 2.7 Amps (60 Watts)PSAM 24V 5.2ADC Power Supply 24V at 5.2 Amps (125 Watts)PSAM 24V 8.3ADC Power Supply 24V at 8.3 Amps (200 Watts)4NovemberJuly 20152018
85674231DimensionsDD.81 .022.26.062.236.2004 PLCSCC2.45 .0000.2500 - .0005.1752.741.20BABLWS23MDC12.977.79ANAHEIM AUTOMATION23.060.96 LANEINC, 910 E. WS23MDC55.77Power (W)7BL (in.)BLWS23MDC3Torque (oz-in)2.630 .002ModelCurrent (A)ANAHEIMAUTOMATIONANAHEIM, CA 92801 (714) 992-6990UNLESS OTHERWISE SPECIFIED:46.12DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONALANGULAR: MACHBENDTWO PLACE DECIMAL.01THREE PLACE DECIMAL.00531.1592.21THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFANAHEIM AUTOMATION INC. ANYREPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFANAHEIM AUTOMATION INC. ISPROHIBITED.5USED ONNEXT KEDAENG APPR.3.84SPEC DRAWING, DIMENSIONSBLWS23MDC SERIESMFG APPR.SIZE DWG. NO.5.59FINISHDO NOT SCALE A.INTERPRET GEOMETRICTOLERANCING PER:PROPRIETARY AND CONFIDENTIAL8 .0001.500 - .001L7.683AA6472BSHEET 1 OF 1SCALE: 1:1 WEIGHT:21Wiring DiagramTerminal DescriptionBLWS23MDC SERIESPositionTB1DACSW124VDCDescription1Power 24VDC IN2Power Ground3RS485 Isolated Ground4RS485 A(-)5RS485 B( )ANALOG IN6Analog Speed InputRUN/STOP7RUN/STOP Input124V IN85VDC Output2PGND8 5V OUT3IGND4A(-)5B( )675L011388THIS DRAWING OR DOCUMENT AND THE INFORMATION SET FORTH HEREIN ARE THE PROPERTYOF ANAHEIM AUTOMATION AND SHALL NOT BEUSED OR DISCLOSED EXCEPT IN ACCORDANCEWITH ITS WRITTEN PERMISSION.REFERENCE DRAWINGSANAHEIM AUTOMATION910 EAST ORANGEFAIR LANEANAHEIM, CA. 92801-1195TITLESPEC DRAWING, HOOK UPBLWS23MDA, BLWR23MDA SERIESREVNovemberJuly 20152018
Torque CurvesBLWS23MDC2S-24V-4000, 24VDCBLWS23MDC1S-24V-4000, 468101214161820220002468 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44Torque (oz-in)Torque (oz-in)BLWS23MDC3S-24V-4000, 24VDCBLWS23MDC4S-24V-4000, 004100021000200001020304050RPMCurrent (Amp)105000RPM0Torque (oz-in)0102030401050Current (Amp)RPM3300063000Current (Amp)44000Current (Amp)Torque-Speed5000845000Torque (oz-in)BLWS23MDC5S-24V-4000, 0004100020010203040506070Current (Amp)RPM50000Torque (oz-in)L0113886NovemberJuly 20152018
Section 2: FunctionsRun at the Set Speed: This command starts the motion of the motor in the set direction and at the setspeed. The set speed, which can be set either digitally or with an analog input to the controller, is inunits of RPM. The motor will run and get up to speed accroding to the configurable controller parameters. When the set speed is too high for the motor to reach of if the load is more than what the motorcan hadle, the motor will run at the maximum speed that is possible under such cirmustances. The usercan give this command to the BLSW23MDC by interfacing the controller with a pc and using the provided software or by grounding the RUN/STOP input.Note: If the motor is started digitally, it must be stopped digitally; similarly, if it is started with the RUN/STOP input, it must be stop through that input.Hard Brake: This command causes the motor to come to an inmediate stop. If the motor is moving atfast speed, it will experience jerk. The motor will perform a hard brake when that brake setting has beenselected. See also Freewheel/Coast.Freewheel/Coast: This command causes the motor to naturally decelerate and come to stop. Note thatthe deceleration time will depend on the load attached to the shaft as this will change the shaft’s rotational inertia. The motor will perform this function when the respective brake setting has been selected.See also Hard Brake.Direction: The motor can be set to run clockwise or counterclockwise. This setting can be changedthrough the used of the provided software.Analog Speed Input: This function allows for the speed of the motor to be set with an analog voltagevalue fed to the the Analog Input terminal pin. This voltage value must be between 0 and 5VDC. Using this analog value, the controller will calculate the set speed based on the user-configurable AnalogLower and Upper Limits. For example, if the Analog Lower Limit is set to 1000 RPM and the AnalogUpper Limit is set to 4000 RPM, feeding an analog voltage value of 2.5V will yield a Set Speed of 2500RPM. Note that the Analog Speed functionality can be easily achieved by using a potentiometer with itsend terminals connected to GND and 5VDC Out, and the wiper terminal connected to the Analog Input.Analog Speed Calculations:Speed(RPM) Lower Limit (Upper Limit - Lower Limit) * (Analog Voltage / 5 )Analog Voltage(V) (Speed - Lower Limit) * 5 / (Upper Limit - Lower Limit)Example 1:Analog Lower Limit 100,Analog Upper Limit 2000Analog Input Voltage 3.2VSpeed 100 (2000 - 100) * (3.2 / 5) 1316 RPMExample 2:Analog Lower Limit 500,Analog Upper Limit 4000Desired Speed 3300 RPMAnalog Voltage (3300 - 500) * 5 / (4000-500) 4.0V L0113887NovemberJuly 20152018
RUN/STOP Input: Grounding this input will cause the motor to start its motion with the set parameters.Driving this input High(5VDC) or making it High Impedance(i.e. no electrical connection), will stop themotor with a Hard Brake or Coast it to a stop depending on the current brake setting. See Hard Brakeand Freewheel for more details on the brake setting.Set Address: This command allows the user to set the address of the device to any value between 0and 99. This is useful when communicating with different devices connected to the same RS485 bus.The default address of the device is 0.Read Address: This command retrieves the current address of the device. See command summary formore details.Read Error: Thic command returns the errors, if any, that the controller has encountered. Reading theerror also clears it. See the Error Code Section for more details.PI Control TuningThe BLWS23MDC implements a custom Proportional and Integral speed control algorithm with userconfigurable parameters. The user can customize the control parameters via the provided software orby using Direct Talk Mode.The following chart describes the effects of an increase in each of the parameters. It follows that a decrease in the specified parameter would have the opposite effect.Parameter IncreaseRise TimeOvershootSettling TimeSteady State ErrorKi [0-10] Kp [0-100] No effectIV [0-100] No effectIntegrator Constant [Ki]: The integrating component of the control algorithm accumulates the errorbetween the set speed and the actual speed of the motor and adjusts the speed control accordingly.This component of the control system is important because it helps reduce the long term error of themotor speed.Proportional Constant [Kp]: The proportional component of the control algorithm adjusts the speedcontrol based on the immediate difference between the set speed and the actual speed. This component is important because its increase reduces the time it takes for the motor to reach the set speed.Note that increasing this constant will cause the overshoot in speed to increase.Initial Value [IV]: This is the initial power applied to the motor in order to get its load in motion. If theload requires a higher torque to begin its motion, a higher Initial Value can be set. Note that if the loadis very small and the Initial Value is high, the motor may experience jerk.L0113888NovemberJuly 20152018
Section 3: BMC100 SoftwareThe BCM100 software is a useful utility that supports Anaheim Automation’s BLWS23MDC Series andMDC100-050101USB controllers. The BMC100 software communicates via a serial port on the PC andit uses the Anaheim Automation ASCII protocol. For more details regarding the Anaheim AutomationASCII protocol, see the Direct Talk Mode section. The BMC100 software allows you to perform the following tasks: Exercise the motor Monitor the speed of the motor Configure motor and control parametersInstallationSoftware Download The BMC100 software is available for download on our website ware/software.php The software is compatible with all versions of Windows including Windows XP, WindowsVista, Windows 7, and Windows 8.Windows XP/Vista/7/8 Installation1. Extract the previously downloaded .zip file containing the software2. Navigate into the resulting extracted folder3. Double click on the file named setup.exe4. Follow the prompts to complete the installationGetting Started1. In order to interface the BLWS23MDC to a PC, an RS485-to-USB converter is required. See our Ordering Information section.2. Connect the BLWS23MDC to the PC using the previously mentioned RS485-toUSB converter.3. Apply power to the BLWS23MDC. The power LED should turn on if the controller has powered correctly.4. Double click on the BMC100 software icon.5. Select the controller; in this case, select BLWS23MDC.L0113889NovemberJuly 20152018
6. The BMC100 software will attempt to establish communications with the controller; if a connection isestablished, the BMC100 graphical interface will appear as shown below.7. If the software did not automatically establish a connection with the controller, make sure that thecontroller is properly connected to the PC using an RS485-to-USB adapter and that the controlleris powered on. Then, manually connect the controller by clicking on Setup Connect. The Connectwindow will appear as shown below. Select the appropriate COM port from the dropdown menu andclick on Connect Controller.8. Once the connection is succesfully made, all the buttons on the graphical interface will be enabledand the default(if the controller is new) or previously programmed parameters will fill the respectivefields.L01138810NovemberJuly 20152018
Motion ControlModeSets the controller to run in Analog or Digital ModeDirectionSets the direction of rotation of the motor to Clockwise or Counter-ClockwiseFreewheelIf this is set, the motor will coast to a stop when the stop command is receivedBrakeIf this is set, the motor will immediately stop when the stop command is receivedStart MotorRuns the motor at the set speedStopImmediately stops the motor or lets it coast to a stop depending on the brake settingMotor ParametersSet PolesThis parameter is not configurable in the BLWS23MDCSet Digital SpeedSets the speed to run the motor at in Digital ModeSet Analog Lower LimitSets the Lower Speed Limit for Analog ModeSet Analog Upper LimitSets the Upper Speed Limit for Analog ModeRead AllRefreshes all the parameters fields of the graphical interfaceFactory ResetSets all the parameter of factory default valuesSee the Functions Section for more details.Controller ParametersSet KpSets the Proportional ConstantSet KiSets the Integrator ConstantSet GainSets the Gain ConstantSet Initial PowerSets the Initial Power to be applied to the motorRead ErrorReads the error registers of the controllerFor more details on fine tuning the controller for your application, see the PI Tuning Section.L01138811NovemberJuly 20152018
Section 4: Direct Talk ModeDirect Talk Mode is used to directly control the BLWS23MDC through serial commands sent out of aPC’s COM port. The BLWS23MDC has easy-to-remember commands for direct motion control.COM Port SettingsBaud Rate38400Data Bits8ParityNoneStop Bits1Flow ControlXon/XoffCommand FormatStartAddressCommandParameters(1)End‘@’ character1 - 2 characters1 - 2 characters0 - 8 charactersCarriage ReturnThe command does not need to be sent as a continuous string; this allows user to use a simple terminalprogram to communicate and control the device via a serial connection. The command must not containany spaces.(1) Not all commands require parameters. See Command Summary for details.Unit SelectionIn an RS485 network, multiple devices may share the same commmunication lines; therefore, it is importantto be able to address the messages or commands sent through these lines to the device that we want.In order
ANAHEIM AUTOMATION July 2018. L011388 2 November 2015 Table of Contents . manual control. Through the BMC100 software, the user can control motion as well as modifying motor and controller parameters even when the motor is running. Additionally, the software can be used to . (Amp) Torque (oz -in) BLWS23MDC1S-24V -4000, 24VDC Torque- Speed .
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