Project Files of RS-775 DC Motor Library for Proteus V1.0 (12V, 775 Motor, BTS7960)

RS-775 DC MOTOR LIBRARY FOR PROTEUS - V1.0 (the 42 mm 12 V RS-775 motor, its fan behind the vents, a pop-up panel)
Designed by The Engineering Projects
www.TheEngineeringProjects.com

IMPORTANT LINKS
Article (read it first - pictures, step by step, every feature explained):
  https://www.theengineeringprojects.com/2026/10/rs-775-dc-motor-library-for-proteus-v1-0.html
Report a bug or suggest a feature (our forum):
  https://www.theengineeringprojects.com/forum/category/motor-driver-proteus-library
The demo runs on our Arduino UNO V4.0 (included) - working LEDs, RESET and a
built-in serial monitor - its own article:
  https://www.theengineeringprojects.com/2026/10/arduino-uno-library-for-proteus-v40.html
The demo's driver is our BTS7960 Motor Driver - a SEPARATE library, not in this
package: download and install it first - its own article:
  https://www.theengineeringprojects.com/2026/10/bts7960-motor-driver-library-for-proteus-v1-0.html
Support us (the libraries are free):
  https://www.theengineeringprojects.com/donate

FILE STRUCTURE
RS-775-DC-Motor-TEP-v1.0/
|-- Proteus Library Files/
|   |-- ArduinoV4TEP.LIB                              201.9 KB   TEP Arduino boards V4.0 (UNO) -> LIBRARY
|   |-- TEPRS775.LIB                                   19.2 KB   the library -> LIBRARY folder
|-- Proteus Model Files/
|   |-- TEPARDUINO.DLL                                883.5 KB   the Arduino board model -> MODELS folder
|   |-- TEPRS775.DLL                                  278.5 KB   the model -> MODELS folder
|-- Proteus Simulation/
|   |-- RS775_Demo.hex                                 16.7 KB   the demo firmware
|   |-- RS-775-DC-Motor-BTS7960-ArduinoUnoV4.pdsprj    25.0 KB   the demo project
|   |-- TEPARDUINO.DLL                                883.5 KB   copy of the board model
|   |-- TEPRS775.DLL                                  278.5 KB   copy of the model
|-- Arduino Code/
|   |-- RS775_Demo/RS775_Demo.ino                       5.6 KB   the demo sketch (source of the .hex)
|-- README.txt                                        ~17.3 KB   this file
Total: 2.55 MB (unzipped). The C++ source code of the models is not included.

WHAT IS IT?
A simulation model of the RS-775 - the big 42 mm brushed DC motor of drills,
grinders, mini table saws, water pumps, blowers and heavy robot drives: a
42 mm steel can, 66.7 mm long, a 5 mm D-shaft, two M4 holes 28.8 mm apart on
the front, ball bearings and a cooling fan inside. This one is the common 12 V
version, no gearbox. Our own model, not Proteus's DC motor:
  * The motor between + and - is analog: the winding (0.40 ohm), the
    back-EMF, the brushes' and bearings' friction, the cooling fan's air, the
    inertia of the rotor and a load torque - about 10,000 RPM / 0.71 A with
    no load at 12 V, 4,900 RPM at 6 V, a stall at about 30 A and 3.4 kg.cm.
    A 12 V start takes about 30 A for a moment. Any driver works: a BTS7960,
    a MOSFET, a relay, an L298N for light loads, PWM or DC, either way.
  * The front face on the sheet turns with the simulation: the white fan
    blades move behind the four vent slots and the shaft's D-flat turns; at
    speed they blur, as the eye sees a spinning motor. The CW and CCW LEDs
    show the direction.
  * The load: property LOAD (kg.cm), the pop-up's load buttons, or a click on
    the motor's face: a brake pad pressed on the shaft (1 kg.cm) - the speed
    drops, the current rises; enough load and it stalls.
  * What it tells: the speed and direction, the average voltage, the current,
    PWM (frequency and duty) when the driver really switches, the power, and
    the warnings - STALLED, OVER-VOLTAGE (more than 15 V), a reversal at
    speed.
The symbol shows the motor from its shaft end at 1.1 x its size: the silver
front face with the crimped edge of the can, the two M4 holes, four vent slots
with the fan behind them, the bearing boss and the 5 mm D-shaft, and the red /
black wires from the + / - pins (on a real motor they come from the two
terminals at the back). The plate, the LEDs and the strip under the plate
(RPM, VOLTS, AMPS, OPEN PANEL) are TEP additions; the real motor has none of
them.

ONE DEVICE (search "RS775" or "775" in Pick Devices):
  RS775MOTORTEP   "RS-775 DC Motor V1.0"   (category Electromechanical > DC
                  Motors), model TEPRS775.DLL
  The pop-up panel "TEP RS-775 DC Motor" opens at Run (and with OPEN PANEL on
  the strip) - the look of the TEP Serial Monitor. Tabs Motor, Graphs, Event
  log and Check; gear and ? icons for Settings and Help:
    Motor      the state in big letters (RUNNING CW / CCW, STOPPED, STALLED,
               OVER-VOLTAGE); the speed gauge (-15,000 .. +15,000 RPM, CW to
               the right, the no-load band about 10,000 RPM marked); the live
               values (speed, direction, the average voltage, the current,
               the drive: PWM Hz and duty, or STEADY; the power, the load,
               turns a second); the drive across + / - over the last 5 ms.
               The toolbar: the load on the shaft (None, 0.5, 1, 2, 3 kg.cm)
               and the brake pad.
    Graphs     the speed, the current and the average voltage over the last
               1, 3 or 6 s. Live / Freeze.
    Event log  the drive, every steady speed ("steady 3793 RPM CW at 11.71 V
               average, 18.150 A"), every direction change, stops, the load,
               the warnings; filters All / Drive + speed / Warnings, Pause,
               Clear
    Check      Good for: a motor that does not turn, turns slowly or the wrong
               way, stalls, or resets the Arduino - the drive, the PWM, the
               current against the common drivers, the speed, the load, the
               peaks
    Settings   theme, text size, open at Run, window size
    Help       report a bug, suggest a feature, article, updates, donate,
               forum; Copy diagnostics for a bug report

TEST STATUS
V1.0: verified in Proteus 8.5 on 29 Oct 2026 (the demo project as shipped: an
A3 sheet, an Arduino UNO V4.0 with its built-in monitor, our BTS7960 driver -
its pop-up version - with B+ on +12V, the RS-775 on M+ / M-, RV1 on A0; all
pop-ups open). What the runs showed:
  * The project loads and starts cleanly. RV1 at 75 %: "Pot 768 -> forward
    49 % (PWM 127/255) (soft ramp)", then "reached forward 49 %": 4,884 RPM at
    5.99 V, 0.65 A.
  * "r 60": the soft ramp takes the motor through zero gently (no reversal
    warning) - 5,919 RPM CCW at -7.21 V, 0.67 A.
  * "f 100": 9,979 RPM at 11.99 V, 0.71 A.
  * 2 kg.cm on the shaft at full drive: 3,793 RPM at 11.71 V, 18.15 A;
    3 kg.cm: 702 RPM at 11.57 V, 26.86 A.
  * 3 kg.cm + the brake pad (4 kg.cm): "STALLED - 28.84 A at 2.2 RPM" (the
    BTS7960 drops 0.46 V at 28.8 A: 11.54 V across the motor).
  * "soft off", "f 100" from a standstill: the current's 50 ms average peaks
    at about 16 A (the instant peak near 30 A); "soft on", "f 100": about
    6 A, full speed in about 0.6 s.
  * "knob": back to 4,885 RPM on the pot.
  * The BTS7960's own pop-up: B+ 12.00 V, PWM 50 % at 977 Hz on RPWM, the
    run's peak current 28.8 A (the stall).
  * The simulation runs at about 0.27 x real time on a desktop PC (the whole
    demo run: 38 s of simulation in under 3 minutes).
  Plus automatic checks on a PC, 0 failed: 22 on the motor (12 V: 9,989 RPM,
  0.71 A, a 29.7 A start peak, 90 % of the speed in 0.22 s; 6 V: 4,893 RPM;
  PWM 980 Hz found with its duty, the speed following 25 / 50 / 75 % (2,335 /
  4,879 / 7,431 RPM); an averaging driver gives no false PWM; a reversal at
  12 V: 58.7 A peak and its warning; braked to a stop; 4 kg.cm stalls at
  30.0 A, 2 kg.cm turns at 4,039 RPM / 18.2 A, 3.2 kg.cm at 470 RPM / 28.6 A;
  16 V: over-voltage); 3 on the pop-up pages rendered; the demo project read
  back from disk (90 checks: devices, pins, wires, labels, no wire through a
  part, no crossing).

INSTALLATION (about 2 minutes)
1. Close Proteus. Extract the WHOLE ZIP to a normal folder (e.g. Desktop).
2. Copy everything in "Proteus Library Files" (TEPRS775.LIB and our Arduino
   library V4.0, ArduinoV4TEP.LIB) to the LIBRARY folder of Proteus, for
   example:
     C:\Program Files (x86)\Labcenter Electronics\Proteus 8 Professional\LIBRARY
   (on some PCs: C:\ProgramData\Labcenter Electronics\Proteus 8 Professional\
   LIBRARY - use the folder that already holds Proteus's own .LIB files).
3. Copy TEPRS775.DLL and TEPARDUINO.DLL from "Proteus Model Files" to the MODELS
   folder (...\Proteus 8 Professional\MODELS). The demo's driver is NOT in this
   package: install our BTS7960 Motor Driver library the same way (its own ZIP
   - see IMPORTANT LINKS): TEPBTS7960.LIB and TEPBTS7960.DLL.
4. Delete TEPRS775.IDX from the LIBRARY folder if it is there.
5. Start Proteus. In Pick Devices (P) search "RS775".

RUN THE DEMO
"Proteus Simulation\RS-775-DC-Motor-BTS7960-ArduinoUnoV4.pdsprj" - keep the
.hex file and the DLLs beside the project.
  ARD1: Arduino UNO V4.0 running RS775_Demo.hex, its serial monitor built in
        (window "TEP Arduino UNO - ARD1").
  DRV1: the BTS7960 (IBT-2) driver, pop-up version: RPWM on D5, LPWM on D6,
        R_EN on D7, L_EN on D8, VCC on 5V, GND - by net labels; B+ on a +12V
        power terminal (Proteus's 12 V rail), B- on ground; R_IS / L_IS open.
  M1:   the RS-775 on M+ / M- (M+ to +, M- to -).
  RV1:  a 10k potentiometer on A0: the speed and the direction.
  1. Press Run. The monitor and the two pop-ups open (move them aside). The
     motor ramps up to about half speed forward (RV1 at 75 %).
  2. Click RV1's arrows: the middle stops it, right = forward, left = reverse.
  3. Type in the monitor and press Enter (or Send): f 50, r 30, stop, coast,
     soft on, soft off, ramp, knob.
  4. Click the motor's face: a brake pad on the shaft. Add a load on the
     pop-up (3 kg.cm + the pad at full drive: it stalls).
  5. Try "soft off" then "f 100" from a stop, and watch the start current on
     the pop-up's Graphs page; then "soft on" and the same again.

WIRING (the same in Proteus and on a real board)
  BTS7960 (IBT-2)  Arduino UNO / supply
   RPWM            D5 (PWM, forward)
   LPWM            D6 (PWM, reverse)
   R_EN, L_EN      D7, D8 (HIGH = on; both LOW = the outputs open: coast)
   VCC, GND        5V, GND
   R_IS, L_IS      not used here (the current sense: see the BTS7960 library)
   B+, B-          the 12 V motor supply (GND common with the Arduino)
  RS-775           M+ to the motor's + (red), M- to - (black)
In the sketch (no library needed):
  forward:  analogWrite(LPWM, 0);  analogWrite(RPWM, speed);   // 0 - 255
  reverse:  analogWrite(RPWM, 0);  analogWrite(LPWM, speed);
  brake:    both 0;   coast: R_EN and L_EN LOW
  the soft start: move the PWM at most 5 steps every 10 ms (0 to 255 in
  about 0.5 s)
REAL HARDWARE:
 * The current: a 12 V RS-775 takes about 30 A for a moment at every hard
   start and at a stall, and a reversal at full speed can pull near 60 A.
   Use a driver made for it - a BTS7960 / IBT-2 (43 A peak; about 15 - 20 A
   continuous without extra cooling) or a MOSFET stage - ramp the PWM, and
   never reverse at full speed. An L298N (2 A) or an L9110S (0.8 A) is far too
   small.
 * The supply: a 12 V supply or a 3S pack that can give the start current,
   thick wires (14 - 16 AWG), a fuse, GND common with the Arduino.
 * Brush noise: a 100 nF capacitor across the motor's terminals (and from each
   terminal to the can) keeps the Arduino from resetting.
 * Heat: a stalled RS-775 turns about 350 W into heat - it burns in seconds.
 * Know your motor: 775 motors come in many windings (12 V from about 3,000 to
   12,000 RPM, 18 V and 24 V versions); this one is the 12 V 10,000 RPM type.

THE DEMO SKETCH ON THE SERIAL MONITOR (RS775_Demo V1.0, 9600 baud)
  f 50      forward at 50 %           r 30      reverse at 30 %
  stop      both PWM LOW (the motor brakes)
  coast     R_EN = L_EN = LOW (the outputs open: the motor rolls out)
  soft on   the soft start (default)  soft off  every change at once
  ramp      0 -> 100 % forward and back, then reverse the same (2 s each way)
  knob      follow the pot again      help      the list
EXPECTED MONITOR OUTPUT
  RS-775 DC Motor demo - The Engineering Projects
  BTS7960: RPWM D5, LPWM D6, R_EN D7, L_EN D8. Turn the pot on A0: the middle stops, right = forward, left = reverse.
  Commands: f 50 | r 30 | stop | coast | soft on | soft off | ramp | knob | help
  Pot 768 -> forward 49 % (PWM 127/255) (soft ramp)
    reached forward 49 % (PWM 127/255)

PROPERTIES (double-click the part > Edit Properties)
  LOAD     a constant load on the shaft in kg.cm (default 0; it stalls at
           about 3.4 kg.cm at 12 V - about 3.2 kg.cm through a BTS7960)
Every run starts again from the properties.

TROUBLESHOOTING
* The shaft never turns and the pop-up says NO DRIVE: the driver's R_EN / L_EN
  (LOW = coast), its B+ supply, or the motor wires on the wrong outputs.
* Slow, about half speed: the driver's B+ is on 5 V or 6 V, not 12 V.
* It turns the wrong way: swap the motor's wires (or RPWM / LPWM).
* STALLED: less load, or more drive.
* The Arduino resets when the motor starts (on a real board): the start
  current pulls the supply down - the soft start, a stronger supply, the
  capacitors.
* The part is not simulated / the face never turns: TEPRS775.DLL is missing
  from MODELS and from the project folder. No driver: install our BTS7960
  library (TEPBTS7960.LIB / .DLL). No UNO / no monitor window: TEPARDUINO.DLL,
  or click the UNO's USB port.
* The pop-up does not appear: click OPEN PANEL on the strip, or turn "Open the
  panel at Run" on its Settings page back on.

BUG REPORTS AND FEATURE REQUESTS
Please post them in our forum with a screenshot, the Serial Monitor text, the
simulation log and the pop-up's Copy diagnostics text:
  https://www.theengineeringprojects.com/forum/category/motor-driver-proteus-library

SUPPORT US
This library is free. If it saves you time, please support our work:
  https://www.theengineeringprojects.com/donate

LICENCES AND THIRD-PARTY NOTES
* The motor model (TEPRS775.DLL), the symbol and artwork and the Arduino Library
  V4.0 (ArduinoV4TEP.LIB / TEPARDUINO.DLL) are made by The Engineering Projects.
  The model is an independent implementation written from the typical data of
  the 12 V RS-775 DC motor. The models use only standard Windows libraries; no
  Visual C++ redistributable is needed.
  The C++ source code is not included.
  The demo's driver, our BTS7960 Motor Driver library (TEPBTS7960.LIB /
  TEPBTS7960.DLL), is a separate download.
* The potentiometer is Proteus's own POT-HG.
* The demo's .hex is built from the demo sketch and the Arduino AVR core 1.8.6,
  which includes LGPL-licensed code; its source code is available at
  https://github.com/arduino/ArduinoCore-avr/tree/1.8.6
* Proteus is a product of Labcenter Electronics and is not included. Arduino is
  a trademark of Arduino SA.
  This library is not made or endorsed by Arduino or Labcenter.

REBUILDING THE FIRMWARE (OPTIONAL)
The HEX file is supplied; Arduino IDE is not needed to run the demo. To edit the
sketch, open Arduino Code\RS775_Demo\RS775_Demo.ino, select Arduino Uno and use
Sketch > Export Compiled Binary. The sketch needs 6,078 bytes of flash (18 % of
the UNO) and 288 bytes of RAM.

MODEL SCOPE AND LIMITS
Modelled: the winding resistance, the back-EMF, the friction (Coulomb and
viscous: the brushes, the bearings and the cooling fan), the inertia, a load
torque, the current both ways (driving and braking), any voltage either way.
How it runs: the speed is an internal analog node solved together with the
driver (backward Euler, analog steps of 2 ms or less); the angle is the speed
integrated, for the face on the sheet.
Not modelled: the winding inductance (a real 775's current ripples under PWM),
the brushes' sparks and noise, heating, magnetic saturation at very high
current, the differences between real motors.

VERSION
TEP RS-775 DC Motor library V1.0 (Oct 2026). Device RS775MOTORTEP (TEPRS775.LIB
/ TEPRS775.DLL). Demo sketch RS775_Demo V1.0. Demo driver: BTS7960ADVTEP (TEP
BTS7960 Motor Driver library V1.0). Demo board: ARDUINO UNO V4.0 (TEP Arduino
Library V4.0) with its built-in serial monitor.