maxon motor control ESCON Servo Controller Hardware Reference Edition November 2015 ESCON Module 24/2 Servo Controller P/N 466023 Hardware Reference Document ID: rel5730 maxon motor ag Brünigstrasse 220 P.O.Box 263 CH-6072 Sachseln Phone +41 41 666 15 00 Fax +41 41 666 16 50 www.maxonmotor.
TABLE OF CONTENTS 1 2 3 About 3 1.1 1.2 1.3 About this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 About the Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 About the Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Specifications 7 2.1 2.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About About this Document 1 About 1.1 About this Document 1.1.1 Intended Purpose The purpose of the present document is to familiarize you with the ESCON Module 24/2 Servo Controller. It will highlight the tasks for safe and adequate installation and/or commissioning. Follow the described instructions … • to avoid dangerous situations, • to keep installation and/or commissioning time at a minimum, • to increase reliability and service life of the described equipment.
About About this Document Type Symbol Mandatory Action Meaning Indicates a mandatory action. Hence, you must! (typical) Information Table 1-2 1.1.5 Requirement / Note / Remark Indicates an activity you must perform prior to continuing, or gives information on a particular item you need to observe. Best Practice Indicates advice or a recommendation on the easiest and best way to proceed. Material Damage Indicates instructions on how to prevent damage to the equipment.
About About the Device 1.2 About the Device The ESCON Module 24/2 is a small-sized, powerful 4-quadrant PWM servo controller for the highly efficient control of permanent magnet-activated brushed DC motors or brushless EC motors up to approximately 48 Watts. The featured operating modes – speed control (closed loop), speed control (open loop), and current control – meet the highest requirements.
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Specifications Technical Data 2 Specifications 2.1 Technical Data ESCON Module 24/2 (466023) Electrical Rating Inputs & Outputs Voltage Outputs Motor Connections Interface Status Indicators Physical Nominal operating voltage +VCC 10…24 VDC Absolute operating voltage +VCC min/+VCC max 8 VDC / 28 VDC Output voltage (max.) 0.98 x +VCC Output current Icont/Imax (<4 s) 2A/6A Pulse width modulation frequency 53.6 kHz Sampling rate of PI current controller 53.
Specifications Technical Data ESCON Module 24/2 (466023) Temperature Environmental Conditions Altitude *2) 2-8 −30…+60 °C Extended range *1) +60…+80 °C Derating Figure 2-1 Storage −40…+85 °C Operation 0…6’000 m MSL Extended range *1) 6’000…10’000 m MSL Derating Figure 2-1 *2) Humidity *1) Operation 5…90% (condensation not permitted) Operation within the extended range (temperature and altitude) is permitted.
Specifications Standards 2.2 Standards The described device has been successfully tested for compliance with the below listed standards. In practical terms, only the complete system (the fully operational equipment comprising all individual components, such as motor, servo controller, power supply unit, EMC filter, cabling etc.) can undergo an EMC test to ensure interference-free operation.
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Setup Generally applicable Rules 3 Setup IMPORTANT NOTICE: PREREQUISITES FOR PERMISSION TO COMMENCE INSTALLATION The ESCON Module 24/2 is considered as partly completed machinery according to EU Directive 2006/ 42/EC, Article 2, Clause (g) and is intended to be incorporated into or assembled with other machinery or other partly completed machinery or equipment.
Setup Configuration of Power Supply 3.2 Configuration of Power Supply Basically, any power supply may be used, provided it meets the minimal requirements stated below. Power Supply Requirements Output voltage +VCC 10…24 VDC Absolute output voltage min. 8 VDC; max. 28 VDC Output current Depending on load • continuous max. 2 A • short-time (acceleration, <4 s) max. 6 A 1) Use the formula below to calculate the required voltage under load.
Setup Connections 3.3 Connections The actual connection will depend on the overall configuration of your drive system and the type of motor you will be using. Follow the description in the given order and choose the wiring diagram that best suits the components you are using. For corresponding wiring diagrams Chapter “4 Wiring” on page 4-25. 3.3.
Setup Connections Figure 3-4 Pin Assignment Pin Description 14 DigIN/DigOUT4 Digital input/output 4 15 DigIN/DigOUT3 Digital input/output 3 16 DigIN2 Digital input 2 17 DigIN1 Digital input 1 18 GND Ground 19 AnOUT2 Analog output 2 20 AnOUT1 Analog output 1 21 AnIN2− Analog input 2, negative signal 22 AnIN2+ Analog input 2, positive signal 23 AnIN1− Analog input 1, negative signal 24 AnIN1+ Analog input 1, positive signal Table 3-7 3-14 Signal Pin Assignment (Pins 14
Setup Connections 3.3.2 Hall Sensor Hall sensor supply voltage +5 VDC Max. Hall sensor supply current 30 mA Input voltage 0…5.5 VDC Max. input voltage ±5.5 VDC Logic 0 typically <1.0 V Logic 1 typically >2.4 V Internal pull-up resistor 10 kΩ (referenced to +5.
Setup Connections 3.3.3 Encoder Best practice • Differential signals offer good resistance against electrical interference. Therefore we recommend using a differential scheme. Nevertheless, the controller supports both schemes – differential and single-ended (unsymmetrical). • The controller does not require an index impulse (Ch I, Ch I\). • For best performance, we strongly recommend using encoders with a line driver. Otherwise, speed limitations may apply due to slow switching edges. Differential Min.
Setup Connections Single-ended Input voltage 0…5 VDC Max. input voltage +12 VDC/−12 VDC Logic 0 <1.0 V Logic 1 >2.4 V Input high current IIH = typically +420 μA @ 5 V Input low current IIL = typically −170 μA @ 0 V Max. input frequency 100 kHz Figure 3-7 maxon motor control ESCON Servo Controller ESCON Module 24/2 Hardware Reference Encoder Input Circuit Ch A “Single-ended” (analogously valid also for Ch B) Document ID: rel5730 Edition: November 2015 © 2015 maxon motor.
Setup Connections 3.3.4 Digital I/Os 3.3.4.1 Input voltage 0…28 VDC Max. input voltage +36 VDC/−36 VDC Logic 0 typically <1.0 V Logic 1 typically >2.4 V Input resistance typically 47 kΩ (<3.3 V) typically 38.5 kΩ (@ 5 V) typically 25.5 kΩ (@ 24 V) Input current at logic 1 typically 130 µA @ +5 VDC Switching delay <8 ms PWM frequency range 10 Hz…5 kHz PWM duty cycle range (resolution) 10...
Setup Connections 3.3.4.2 Digital Input 2 Input voltage 0…28 VDC Max. input voltage +36 VDC/−36 VDC Logic 0 typically <1.0 V Logic 1 typically >2.4 V Input resistance typically 47 kΩ (<3.3 V) typically 38.5 kΩ (@ 5 V) typically 25.5 kΩ (@ 24 V) Input current at logic 1 typically 130 µA @ +5 VDC Switching delay <8 ms Figure 3-9 3.3.4.3 DigIN2 Circuit Digital Inputs/Outputs 3 and 4 DigIN Input voltage 0…28 VDC Max. input voltage +36 VDC Logic 0 typically <1.0 V Logic 1 typically >2.
Setup Connections DigOUT 3-20 Max. input voltage +36 VDC Max. load current 50 mA Max. voltage drop 0.5 V @ 50 mA Max. load inductance Only possible with external protective circuitry (free-wheeling diode) Figure 3-11 DigOUT3 Circuit (analogously valid also for DigOUT4) Figure 3-12 DigOUT3 Wiring Examples (analogously valid also for DigOUT4) Document ID: rel5730 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Setup Connections 3.3.5 Analog I/Os 3.3.5.1 Analog Inputs 1 and 2 Input voltage −10…+10 VDC (differential) Max. input voltage +24 VDC/−24 VDC Common mode voltage −5…+10 VDC (referenced to GND) Input resistance 80 kΩ (differential) 65 kΩ (referenced to GND) A/D converter 12-bit Resolution 5.64 mV Bandwidth 10 kHz Figure 3-13 3.3.5.2 AnIN1 Circuit (analogously valid also for AnIN2) Analog Outputs 1 and 2 Output voltage −4…+4 VDC D/A converter 12-bit Resolution 2.
Setup Connections 3.3.6 USB (J7) Figure 3-15 USB Socket J7 Note Column “Head B” (Table 3-8) refers to USB terminals of your PC. J7 & Head A Head B Pin Pin 1 1 VBUS USB BUS supply voltage input +5 VDC 2 2 D− USB Data− (twisted pair with Data+) 3 3 D+ USB Data+ (twisted pair with Data−) 4 – ID not connected 5 4 GND USB ground Signal Table 3-8 Description USB Socket J7 – Pin Assignment & Cabling USB Type A - micro B Cable (403968) Cable cross-section According to USB 2.
Setup Status Indicators 3.4 Status Indicators Light-emitting diodes (LEDs) indicate the actual operating status (green) and possible errors (red).
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Wiring 4 Wiring Figure 4-17 Interfaces – Designations and Location Note The subsequent diagrams feature this symbol: • Ground safety earth connection (optional) maxon motor control ESCON Servo Controller ESCON Module 24/2 Hardware Reference Document ID: rel5730 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Wiring DC Motors 4.1 DC Motors MAXON DC MOTOR Figure 4-18 4-26 maxon DC motor Document ID: rel5730 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Wiring DC Motors MAXON DC MOTOR WITH DC TACHO Figure 4-19 maxon motor control ESCON Servo Controller ESCON Module 24/2 Hardware Reference maxon DC motor with DC Tacho Document ID: rel5730 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Wiring DC Motors MAXON DC MOTOR WITH ENCODER Figure 4-20 4-28 maxon DC motor with Encoder Document ID: rel5730 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Wiring EC Motors 4.2 EC Motors MAXON EC MOTOR WITH HALL SENSORS Figure 4-21 maxon motor control ESCON Servo Controller ESCON Module 24/2 Hardware Reference maxon EC motor with Hall Sensors Document ID: rel5730 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Wiring EC Motors MAXON EC MOTOR WITH HALL SENSORS & ENCODER Figure 4-22 4-30 maxon EC motor with Hall Sensors & Encoder Document ID: rel5730 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Motherboard Design Guide Requirements for Components of Third-party Suppliers 5 Motherboard Design Guide The following provides helpful information on integrating the ESCON Module 24/2 on a printed circuit board. The «Motherboard Design Guide» contains recommendations for the layout of the motherboard and specifies external components that may be required, pin assignments, and connection examples.
Motherboard Design Guide Requirements for Components of Third-party Suppliers CAPACITOR (C1) The function of the ESCON Module 24/2 does not necessarily require the use of an external capacitor (C1). To further reduce voltage ripple and feedback currents, an electrolytic capacitor can be connected to the voltage supply cable. 5.1.3 Encoder Inputs To protect the encoder inputs of the ESCON Module 24/2 against overcurrent, we recommend using an external TVS diode network. Figure 5-24 5.1.
Motherboard Design Guide Requirements for Components of Third-party Suppliers 5.1.5 Motor Cables/Motor Chokes The ESCON Module 24/2 is not equipped with internal motor chokes. The majority of motors and applications do not require additional chokes. However, in the case of high supply voltage with very low terminal inductance, the ripple of the motor current can reach an unacceptably high value. This causes the motor to heat up unnecessarily and causes instable control behavior.
Motherboard Design Guide Requirements for Components of Third-party Suppliers 5.1.6 Recommended Components and Manufacturers Recommended components Straight socket header, pluggable with 0.64 x 0.64 mm pin headers, 2.54 mm pitch, 3 A, contact material: gold Socket Header Preci-Dip (801-87-013-10-005101) Würth (613 013 118 21) E-tec (BL1-013-S842-55) 11 poles, 1 row Preci-Dip (801-87-011-10-005101) Würth (613 011 118 21) E-tec (BL1-011-S842-55) FU1 Fuse Littelfuse 157 series, fuse holder incl.
Motherboard Design Guide Design Guidelines 5.2 Design Guidelines The following instructions are intended to serve as an aid for designing an application-specific motherboard and ensuring the correct and reliable integration of the ESCON Module 24/2. 5.2.1 Ground All ground connections (GND) should be internally connected to the ESCON Module 24/2 (equal potential). It is customary to equip the motherboard with a ground plane.
Motherboard Design Guide Pin Assignment 5.4 Pin Assignment For detailed specifications chapter “3.3 Connections” on page 3-13. 5.5 Technical Data For detailed specifications chapter “2 Specifications” on page 2-7. 5.6 Dimensional Drawing For the dimensional drawing Figure 2-2 on page 2-8. 5-36 Document ID: rel5730 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Motherboard Design Guide ESCON Module 24/2 Motherboard (486400) 5.7 ESCON Module 24/2 Motherboard (486400) The ESCON Module 24/2 Motherboard (subsequently named ESCON Module MoBo) is available as an alternative to developing an own motherboard. All required connections are already in place and designed as screw-type terminals.
Motherboard Design Guide ESCON Module 24/2 Motherboard (486400) 5.7.1 Assembly The ESCON Module MoBo is designed to easily be screw-mounted or integrated into standard rail systems. For ordering information for the components required Figure 5-30 (only for illustrative purposes) and Table 5-13. Figure 5-30 ESCON Module MoBo – Mounting on DIN Rail Specification / Accessories Adapter for DIN rail Table 5-13 5-38 PHOENIX CONTACT 2 x panel mounting base element 11.25 mm UMK-SE11.
Motherboard Design Guide ESCON Module 24/2 Motherboard (486400) 5.7.2 Connections Note The USB interface is located directly at the ESCON Module 24/2. 5.7.2.1 Power Supply (J1) Figure 5-31 ESCON Module MoBo – Power Plug J1 J1 Signal Description Pin 1 Power_GND Ground of operating voltage 2 +VCC Nominal operating voltage (+10…+24 VDC) Table 5-14 ESCON Module MoBo – Power Plug J1 – Pin Assignment Specification / Accessories Type Pluggable screw-type terminal block, 2 poles, 3.
Motherboard Design Guide ESCON Module 24/2 Motherboard (486400) 5.7.2.2 Motor (J2) The servo controller is set to drive either maxon DC motors (brushed) or maxon EC motors (brushless).
Motherboard Design Guide ESCON Module 24/2 Motherboard (486400) 5.7.2.3 Hall sensor (J3) Suitable Hall effect sensors IC use «Schmitt trigger» with open collector output.
Motherboard Design Guide ESCON Module 24/2 Motherboard (486400) 5.7.2.4 Encoder (J4) Figure 5-34 ESCON Module MoBo – Encoder Socket J4 J4 Signal Description Pin 1 not connected – 2 +5 VDC Encoder supply voltage (+5 VDC; ≤70 mA) 3 GND Ground 4 not connected – 5 Channel A\ Channel A complement 6 Channel A Channel A 7 Channel B\ Channel B complement 8 Channel B Channel B 9 not connected – 10 not connected – Table 5-21 ESCON Module MoBo – Encoder Socket J4 – Pin Assignment
Motherboard Design Guide ESCON Module 24/2 Motherboard (486400) Encoder Cable (275934) Cable cross-section 10 x AWG28, round-jacket, twisted pair flat cable, 1.27 mm pitch Length 3.20 m Head A DIN 41651 female, 2.54 mm pitch, 10 pins, with strain relief Head B DIN 41651 connector, 2.54 mm pitch, 10 poles, with strain relief Table 5-23 ESCON Module MoBo – Encoder Cable Best practice • Because of its resistance against electrical interferences, we recommend using differential scheme.
Motherboard Design Guide ESCON Module 24/2 Motherboard (486400) 5.7.2.
Motherboard Design Guide ESCON Module 24/2 Motherboard (486400) 5.7.2.
Motherboard Design Guide ESCON Module 24/2 Motherboard (486400) 5.7.3 Wiring Note The USB interface is located directly at the ESCON Module 24/2. Note The subsequent diagrams feature this symbol: • Ground safety earth connection (optional) 5.7.3.1 MAXON DC Motors DC MOTOR Figure 5-37 5-46 ESCON Module MoBo – maxon DC motor (J2) Document ID: rel5730 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Motherboard Design Guide ESCON Module 24/2 Motherboard (486400) MAXON DC MOTOR WITH DC TACHO Figure 5-38 maxon motor control ESCON Servo Controller ESCON Module 24/2 Hardware Reference ESCON Module MoBo – maxon DC motor with DC Tacho (J2) Document ID: rel5730 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Motherboard Design Guide ESCON Module 24/2 Motherboard (486400) MAXON DC MOTOR WITH ENCODER Figure 5-39 5-48 ESCON Module MoBo – maxon DC motor with Encoder (J2 / J4) Document ID: rel5730 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Motherboard Design Guide ESCON Module 24/2 Motherboard (486400) 5.7.3.2 MAXON EC motors EC MOTOR WITH HALL SENSORS Figure 5-40 maxon motor control ESCON Servo Controller ESCON Module 24/2 Hardware Reference ESCON Module MoBo – maxon EC motor with Hall Sensors (J2 / J3) Document ID: rel5730 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Motherboard Design Guide Spare Parts MAXON EC MOTOR WITH HALL SENSORS & ENCODER Figure 5-41 5.8 Spare Parts Order number Description 444144 2-pole pluggable screw-type terminal block, 3.5 mm pitch, labeled 1…2 444145 4-pole pluggable screw-type terminal block, 3.5 mm pitch, labeled 1…4 444146 5-pole pluggable screw-type terminal block, 3.5 mm pitch, labeled 1…5 444147 6-pole pluggable screw-type terminal block, 3.5 mm pitch, labeled 1…6 444148 7-pole pluggable screw-type terminal block, 3.
LIST OF FIGURES Figure 2-1 Derating Output Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Figure 2-2 Dimensional Drawing [mm]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Figure 3-3 Pin Assignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Figure 3-4 Pin Assignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF TABLES Z-52 Table 1-1 Notation used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Table 1-2 Symbols & Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Table 1-3 Brand Names and Trademark Owners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Table 2-4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX order numbers 275934 43 403968 22 438725 7 444144 50 444145 50 444146 50 444147 50 444148 50 486400 37 A additionally applicable regulations 5 analog inputs 21 applicable EU directive 11 assignment of the connections 13 C cables (prefab) Encoder Cable 43 USB Type A - micro B Cable 22 country-specific regulations 5 P performance data 7 pin assignment 13 precautions 5 prerequisites prior installation 11 prohibitive signs 3 purpose of the device 5 D digital inputs 18, 19 E error display 23 ESD 5 EU
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