maxon motor EPOS2 24/5, Hardware Reference Manual

Page 1: ... Box 263 CH 6072 Sachseln Phone 41 41 666 15 00 Fax 41 41 666 16 50 www maxonmotor com Edition October 2014 EPOS2 Positioning Controller Hardware Reference maxon motor control Positioning Controller Hardware Reference Document ID rel5190 ...

Page 2: ...things you already know Likewise we tried to skip repetitive information Thus you will find things mentioned just once If for example an earlier mentioned action fits other occasions you then will be directed to that text passage with a respective reference Follow any stated reference observe respective information then go back and continue with the task PREREQUISITES FOR PERMISSION TO COMMENCE IN...

Page 3: ... Use of separate Logic Supply 19 4 2 Motor Connector J2 20 4 2 1 maxon EC motor brushless 20 4 2 2 maxon DC motor with separated Motor Encoder Cable 20 4 2 3 maxon DC motor with integrated Motor Encoder Ribbon Cable 21 4 3 Hall Sensor Connector J3 22 4 4 Encoder Connector J4 23 4 5 Signal Connector J5 25 4 5 1 Digital Inputs 1 2 and 3 26 4 5 2 Digital Inputs 4 5 and 6 27 4 5 3 Analog Inputs 1 and ...

Page 4: ...ntrol A 4 Document ID rel5190 EPOS2 Positioning Controller Edition October 2014 EPOS2 24 5 Hardware Reference 2014 maxon motor Subject to change without prior notice p a g e i n t e n ti o n a l l y l e f t b l a n k ...

Page 5: ...l working with the equipment described It con veys information on how to understand and fulfill the respective work and duties This document is a reference book It does require particular knowledge and expertise specific to the equipment described 1 3 How to use Take note of the following notations and codes which will be used throughout the document Table 1 1 Notations used in this Document 1 4 S...

Page 6: ...irement Note Remark Indicates an action you must perform prior continuing or refers to information on a particular item Best Practice Gives advice on the easiest and best way to proceed Material Damage Points out information particular to potential damage of equipment Reference Refers to particular information provided by other parties DANGER High Voltage and or Electrical Shock Touching live wire...

Page 7: ... and Trademark Owners 1 6 Copyright 2014 maxon motor All rights reserved The present document including all parts thereof is protected by copyright Any use including repro duction translation microfilming and other means of electronic data processing beyond the narrow restrictions of the copyright law without the prior approval of maxon motor ag is not permitted and sub ject to persecution under t...

Page 8: ...ntrol 1 8 Document ID rel5190 EPOS2 Positioning Controller Edition October 2014 EPOS2 24 5 Hardware Reference 2014 maxon motor Subject to change without prior notice p a g e i n t e n ti o n a l l y l e f t b l a n k ...

Page 9: ...sensors and encoder The sinusoidal current commutation by space vector control offers the possibility to drive brushless EC motors with minimal torque ripple and low noise The integrated position velocity and current control functionality allows sophisticated positioning applications The EPOS2 24 5 is especially designed being commanded and controlled as a slave node in a CANopen network In additi...

Page 10: ...monitoring and safety equipment If the machine apparatus should break down if it is operated incorrectly if the control unit breaks down or if the cables break or get disconnected etc the complete drive system must return and be kept in a safe operating mode Be aware that you are not entitled to perform any repair on components supplied by maxon motor Best Practice For initial operation make sure ...

Page 11: ... commutation motors with 1 pole pair 100 000 rpm Built in motor choke per phase 15 μH 5 A Inputs Hall sensor signals Hall sensor 1 Hall sensor 2 and Hall sensor 3 for Hall effect sensor ICs Schmitt trigger with open collector output Encoder signals A A B B I I max 5 MHz internal line receiver EIA RS422 Standard Digital Input 1 General Purpose 3 24 VDC Ri 8 kΩ Digital Input 2 General Purpose 3 24 V...

Page 12: ...terfaces Table 3 9 Electrical Data LEDs Voltage Outputs Encoder supply voltage 5 VDC IL 100 mA Hall sensors supply voltage 5 VDC IL 30 mA Auxiliary output voltage Vcc IL 1300 mA Motor Connections maxon EC motor maxon DC motor Motor winding 1 Motor Motor winding 2 Motor Motor winding 3 Interfaces RS232 RxD TxD max 115 200 bit s USB 2 0 USB 3 0 Data Data full speed CAN 1 CAN_H high CAN_L low max 1 M...

Page 13: ...rminal dual row male header 16 poles Molex Micro Fit 3 0 dual row female receptacle 12 poles Molex Micro Fit 3 0 430 25 1600 female crimp terminal Molex Micro Fit 3 0 43030 xxxx AWG 20 30 RS232 On board Suitable plug Suitable terminal dual row male header 6 poles Molex Micro Fit 3 0 dual row female receptacle 6 poles Molex Micro Fit 3 0 430 25 0600 female crimp terminal Molex Micro Fit 3 0 43030 x...

Page 14: ... extended temperature range is permitted However a respective derating declination of max output current as to the stated value will apply Table 3 12 Environmental Conditions 3 4 Order Details Table 3 13 Order Details Mechanical Data Weight approx 170 g Dimensions L x W x H 105 x 83 x 24 mm Mounting plate for M3 screws Environmental Condition Temperature Operation 10 45 C Extended Range 1 45 83 C ...

Page 15: ...61000 6 2 Immunity for industrial environments IEC EN 61000 6 3 Emission standard for residential commercial and light industrial environments Applied Standards IEC EN 61000 6 3 IEC EN 55022 CISPR22 Radio disturbance characteristics radio interference IEC EN 61000 4 2 Electrostatic discharge immunity test 8 kV 6 kV IEC EN 61000 4 3 Radiated radio frequency electromagnetic field immunity test 10 V ...

Page 16: ...trol 3 16 Document ID rel5190 EPOS2 Positioning Controller Edition October 2014 EPOS2 24 5 Hardware Reference 2014 maxon motor Subject to change without prior notice p a g e i n t e n ti o n a l l y l e f t b l a n k ...

Page 17: ...ning Controller Document ID rel5190 4 17 EPOS2 24 5 Hardware Reference Edition October 2014 2014 maxon motor Subject to change without prior notice 4 Connections Figure 4 3 Interfaces Designations and Location Figure 4 4 Wiring Diagram ...

Page 18: ...m 1 SOUGHT VALUE Supply voltage VCC Volt SOLUTION 2 Choose power supply capable as to above calculation Thereby consider a During braking of the load the power supply must be capable of buffering the fed back energy e g in a capacitor b When using an electronically stabilized power supply observe that the overcurrent protec tion must not be activated in any operating state Figure 4 5 Power Connect...

Page 19: ... any power supply may be used provided it meets below stated minimal requirements Using a separate logic supply you will need to change the jumper JP4 STOP Check on safety precautions before continuing page 2 10 1 Open housing and find jumper JP4 2 Open jumper JP4 Figure 4 7 right 3 Connect to respective supply voltage chapter 4 5 Signal Connector J5 on page 4 25 Figure 4 6 Jumper JP4 Location and...

Page 20: ...rs JP2 and JP3 Figure 4 8 Motor Connector J2 4 2 1 maxon EC motor brushless 4 2 2 maxon DC motor with separated Motor Encoder Cable Accessories Cable Motor Cable 275851 Notes Suitable connector Suitable crimp terminals Suitable hand crimper Molex Mini Fit Jr 4 poles 39 01 2040 Molex Mini Fit Jr female crimp terminals 44476 xxxx Molex hand crimper 63819 0900 Pin Signal Description 1 Motor winding 1...

Page 21: ... motor with integrated Motor Encoder Ribbon Cable STOP Check on safety precautions before continuing page 2 10 1 Open housing and find jumpers JP2 and JP3 2 Set jumpers JP2 and JP3 to closed position Figure 4 10 right 3 For encoder connections chapter 4 4 Encoder Connector J4 on page 4 23 Figure 4 9 Jumpers JP2 JP3 Location and Factory Setting Figure 4 10 Jumpers JP2 JP3 open left closed right ...

Page 22: ...r supply voltage 5 VDC Max Hall sensor supply current 30 mA Input voltage 0 24 VDC Logic 0 typically 0 8 VDC Logic 1 typically 2 4 VDC Internal pull up resistor 2 7 kΩ against 5 VDC Pin Signal Description 1 Hall sensor 1 Hall sensor 1 Input 2 Hall sensor 2 Hall sensor 2 Input 3 Hall sensor 3 Hall sensor 3 Input 4 GND Ground of Hall sensor supply 5 VHall Hall sensor supply voltage 5 VDC 30 mA 6 Hal...

Page 23: ...e driver is mandatory Even though 2 channel will do we strongly recommend to use only 3 channel versions By default the controller is set for a 500 count per turn encoder For other encoders you will need to adjust respective settings via software Figure 4 13 Encoder Input Channel Encoder supply voltage 5 VDC Max encoder supply current 100 mA Min differential Input voltage 200 mV Line receiver inte...

Page 24: ...der Ribbon Cable on page 4 21 Pin Signal Description 1 EC motor none DC motor Motor EC motor not connected DC motor Motor 1 2 5 VDC 100 mA Encoder supply voltage 3 GND Ground 4 EC motor none DC motor Motor EC motor not connected DC motor Motor 1 5 Channel A Channel A complement 6 Channel A Channel A 7 Channel B Channel B complement 8 Channel B Channel B 9 Channel I Index complement 10 Channel I In...

Page 25: ...al ground 2 D_Gnd Digital signal ground 3 DigIN6 Digital Input 6 Negative Limit Switch 4 DigIN5 Digital Input 5 Positive Limit Switch 5 DigIN4 Digital Input 4 Home Switch 6 DigIN3 Digital Input 3 General Purpose 7 DigIN2 Digital Input 2 General Purpose 8 DigIN1 Digital Input 1 General Purpose 9 VOUT 1 VC 2 Auxiliary supply voltage output 11 24 VDC Logic supply voltage input 11 24 VDC 10 DigOUT4 Di...

Page 26: ...al Purpose and may be configured via software Figure 4 16 DigIN1 Circuit analogously valid also for DigIN2 3 DigIN1 General Purpose DigIN2 General Purpose DigIN3 General Purpose D_Gnd Connector J5 Pin 8 Connector J5 Pin 7 Connector J5 Pin 6 Connector J5 Pin 1 2 Input voltage 0 24 VDC Max input voltage 30 VDC Logic 0 typically 1 5 V Logic 1 typically 3 0 V Input resistance typically 8 kΩ Input curr...

Page 27: ...ital Input 5 Positive Limit Switch Digital Input 6 Negative Limit Switch Figure 4 17 DigIN4 Circuit analogously valid also for DigIN5 6 For wiring examples page 4 28 DigIN4 Home Switch DigIN5 Positive Limit Switch DigIN6 Negative Limit Switch D_Gnd Connector J5 Pin 5 Connector J5 Pin 4 Connector J5 Pin 3 Connector J5 Pin 1 2 Input voltage 0 24 VDC Max input voltage 30 VDC Logic 0 typically 5 0 V L...

Page 28: ...hout prior notice WIRING EXAMPLE PROXIMITY SWITCH TYPE PNP Figure 4 18 DigIN4 Type PNP Proximity Switch analogously valid also for DigIN5 6 WIRING EXAMPLE PROXIMITY SWITCH TYPE NPN Figure 4 19 DigIN4 Type NPN Proximity Switch analogously valid also for DigIN5 6 3 Wire Model RIN 4 kΩ 2 Wire Model 3 Wire Model Rext 12 V 510 Ω 300 mW Rext 24 V 4 3 kΩ 150 mW RIN 4 kΩ ...

Page 29: ...usly valid also for AnIN2 4 5 4 Auxiliary Supply Voltage Output Can be used as supply voltage for external loads connected to EPOS2 24 5 s digital outputs Figure 4 21 Auxiliary Output Voltage Circuit AnIN1 AnIN2 A_Gnd Connector J5 Pin 16 Connector J5 Pin 15 Connector J5 Pin 14 Input voltage 0 5 VDC Max input voltage 30 VDC Input resistance typically 47 kΩ referenced to A_Gnd A D converter 12 bit R...

Page 30: ...ously valid also for DigOUT2 3 WIRING EXAMPLES Figure 4 23 DigOUT1 Sinks Circuit analogously valid also for DigOUT2 3 Figure 4 24 DigOUT1 Source Circuit analogously valid also for DigOUT2 3 DigOUT1 DigOUT2 DigOUT3 D_Gnd Connector J5 Pin 13 Connector J5 Pin 12 Connector J5 Pin 11 Connector J5 Pins 1 2 Circuit Open drain internal pull up resistor 2k2 and diode to 5 VDC DigOUT Sinks Max input voltage...

Page 31: ...t DC voltage applied to serve as magnet brake Figure 4 25 DigOUT4 Circuit WIRING EXAMPLES Figure 4 26 DigOUT4 Sinks Circuit Figure 4 27 DigOUT4 Source Circuit DigOUT4 D_Gnd Connector J5 Pin 10 Connector J5 Pins 1 2 Circuit Open drain internal pull up resistor 2k2 and diode to 5 VDC DigOUT Sinks Max input voltage 30 VDC Max load current 1 A Max voltage drop 0 3 V 1 A DigOUT Source Output voltage Uo...

Page 32: ...V 3 kΩ to Ground Max bit rate 115 200 bit s Internal RS232 driver receiver EIA RS232 Standard EPOS2 24 5 PC Interface RS232 DIN41652 Connector J6 Pins 4 5 GND Pin 5 GND Connector J6 Pin 1 EPOS RxD Pin 3 PC TxD Connector J6 Pin 2 EPOS TxD Pin 2 PC RxD Pin Signal Description 1 EPOS RxD EPOS RS232 receive 2 EPOS TxD EPOS RS232 transmit 3 not connected 4 GND RS232_Ground 5 GND RS232_Ground 6 Shield Ca...

Page 33: ...2003 Max bit rate 1 Mbit s Max number of CAN nodes 127 Protocol CANopen DS 301 Identifier setting DIP switch or software EPOS2 24 5 CAN 9 pin D Sub DIN41652 Connector J7 or J8 Pin 1 CAN high Pin 7 CAN_H high bus line Connector J7 or J8 Pin 2 CAN low Pin 2 CAN_L low bus line Connector J7 or J8 Pin 3 CAN GND Pin 3 CAN_GND Ground Connector J7 or J8 Pin 4 CAN shield Pin 5 CAN_Shield cable shield Pin S...

Page 34: ...anging object Node ID range 1 127 The CAN ID results in the summed values of DIP switch addresses 1 ON DIP switch 8 does not have any impact on the CAN ID Table 4 15 CAN ID Binary Code Values EXAMPLES Use following table as a non concluding guide Table 4 16 CAN ID DIP Switch Settings Example Switch Binary Code Valence DIP Switch 1 20 1 Figure 4 30 JP1 Numbering Scheme 2 21 2 3 22 4 4 23 8 5 24 16 ...

Page 35: ...ller individual CAN bus termination settings must be performed Using DIP switch 8 the controller internal bus termination resistor can be activated deactivated By default bus termination is OFF nevertheless the bus is not terminated Figure 4 31 DIP Switch JP1 8 CAN Bus Termination left OFF right ON EXAMPLE 1 MULTIPLE AXIS SYSTEM WITH EPOS2 24 5 WITHIN CANOPEN BUS Figure 4 32 EPOS2 24 5 without CAN...

Page 36: ...nput current 15 mA Max DC data input voltage 0 5 3 8 VDC EPOS2 24 5 PC Interface USB 2 0 USB 3 0 Connector J9 Pin 1 VBUS Pin 1 VBUS Connector J9 Pin 2 USB D Pin 2 USB D Connector J9 Pin 3 USB D Pin 3 USB D Connector J9 Pin 5 GND Pin 4 GND Connector J9 housing Shield Housing Shield Pin Signal Description 1 VBUS USB bus supply input voltage 5 VDC 2 USB D USB Data 3 USB D USB Data 4 not connected 5 G...

Page 37: ...ormation separate document EPOS2 Firmware Specification Table 4 17 LEDs Interpretation of Condition LED Status Error Red Green OFF Slow Power stage is disabled Device is in status Switch ON Disabled Ready to Switch ON Switched ON OFF ON Power stage is enabled Device is in status Operation Enable Quick Stop Active ON OFF FAULT state Device is in status Fault ON ON Power stage is enabled Device is i...

Page 38: ...trol 4 38 Document ID rel5190 EPOS2 Positioning Controller Edition October 2014 EPOS2 24 5 Hardware Reference 2014 maxon motor Subject to change without prior notice p a g e i n t e n ti o n a l l y l e f t b l a n k ...

Page 39: ...analogously valid also for DigIN2 3 26 Figure 4 17 DigIN4 Circuit analogously valid also for DigIN5 6 27 Figure 4 18 DigIN4 Type PNP Proximity Switch analogously valid also for DigIN5 6 28 Figure 4 19 DigIN4 Type NPN Proximity Switch analogously valid also for DigIN5 6 28 Figure 4 20 AnIN1 Circuit analogously valid also for AnIN2 29 Figure 4 21 Auxiliary Output Voltage Circuit 29 Figure 4 22 DigOU...

Page 40: ...ata Inputs 11 Table 3 5 Electrical Data Outputs 11 Table 3 6 Electrical Data Voltage Outputs 12 Table 3 7 Electrical Data Motor Connections 12 Table 3 8 Electrical Data Interfaces 12 Table 3 9 Electrical Data LEDs 12 Table 3 10 Electrical Data Connections 13 Table 3 11 Mechanical Data 14 Table 3 12 Environmental Conditions 14 Table 3 13 Order Details 14 Table 3 14 Standards 15 Table 4 15 CAN ID Bi...

Page 41: ...23 J5 25 J6 32 J7 33 J8 33 J9 36 country specific regulations 10 D digital inputs 26 27 digital outputs 30 31 DIP switch JP1 34 JP1 bus termination 35 JP1 numbering scheme 34 E electrical data 11 environmental conditions permitted 14 error display 37 ESD 10 example setting CAN IDs 34 terminating CANopen bus 35 wiring proximity switches 28 H how to calculate required supply voltage 18 configure CAN...

Page 42: ...ce data 11 power backup 19 precautions 10 prohibitive signs 6 purpose of the device 9 of this document 5 R regulations additionally applicable 10 RS232 interface 32 S safety alerts 5 safety first 10 signs informative 6 mandatory 6 prohibitive 6 signs used 5 standards fulfilled 15 status display 37 status LEDs 37 supply voltage required 18 symbols used 5 T technical data 11 U USB interface 36 ...

Page 43: ... motor control EPOS2 Positioning Controller Document ID rel5190 Z 43 EPOS2 24 5 Hardware Reference Edition October 2014 2014 maxon motor Subject to change without prior notice p age intentionally left blank ...

Page 44: ...g all parts thereof is protected by copyright Any use including reproduction translation microfilming and other means of electronic data processing beyond the narrow restrictions of the copyright law without the prior approval of maxon motor ag is not permitted and subject to persecution under the applicable law maxon motor ag Brünigstrasse 220 P O Box 263 CH 6072 Sachseln Switzerland Phone 41 41 ...