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maxon motor control
EPOS2 Positioning Controller
Hardware Reference
Edition November 2017
Positioning Controller
Hardware Reference
Document ID: rel7748
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.com
Page 2
PLEASE READ THIS FIRST
These instructions are intended for qualified technical per sonnel. Prior commencing with any
activities …
• you must carefully read and understand this manual and
• you must follow the instructions given therein.
We have tried to provide you with all information necessary to install and commission the equipment in a
secure, safe and time-saving manner. Our main focus is …
• to familiarize you with all relevant technical aspects,
• to let you know the easiest way of doing,
• to alert you of any possibly dangerous situation you might encounter or that you might cause if
you do not follow the description,
•to write as little and to say as much as possible and
• not to bore you with 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 – the n go back and continue with
the task!
PREREQUISITES FOR PERMISSION TO COMMENCE INSTALLATION
The EPOS2 24/2 is considered as partly completed machinery according to EU directive 2006/42/EC,
Article 2, Clause (g) and therefore is intended to be incorporated into or assembled with other
machinery or other partly completed machinery or equipment.
You must not put the device into service, …
• unless you have made completely sure that the other machinery – the surrounding system the device
is intended to be incorporated to – fully complies with the requirements stated in EU directive 2006/
42/EC!
• unless the surrounding system fulfills all relevant health and safety aspects!
• unless all respective interfaces have been established and fulfill the stated requirements!
maxon motor control
A-2 Document ID: rel7748 EPOS2 Positioning Controller
Edition: November 2017 EPOS2 24/2 Hardware Reference
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TABLE OF CONTENTS
1 About this Document 5
2 Introduction 7
2.1 Documentation Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Technical Data 9
3.1 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Mechanical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4 Order Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 Connections 15
4.1 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1.1 EPOS2 24/2 for maxon DC motors (390438). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1.2 EPOS2 24/2 for maxon DC/EC motors (390003). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.1.3 EPOS2 24/2 for maxon DCX motors (530239) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1.4 EPOS2 24/2 for maxon EC motors (380264). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.1 Supply/Control Signals Connector (J1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2.2 Communication/Analog Inputs Connector (J2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2.3 Motor/Encoder Connector (J3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2.4 Encoder Connector (J4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2.5 Motor Connectors (J5 / J6 / J7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2.6 Motor/Hall Sensors Connector (J8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2.7 Encoder Connector (J9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.2.8 Motor/Hall Sensors Connector (J10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.2.9 Encoder Connector (J11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.2.10 RS232 Connector (J12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2.11 CAN Connector (J13). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.2.12 Supply/Control Signals Connector (J14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2.13 USB Connector (J15). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.3 CAN Node Identification (JP1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.3.1 CAN ID (Node Address). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.3.2 CAN Bus Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4 CAN Bit Rate Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.5 Status LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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© 2017 maxon motor. Subject to change without prior notice.
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1 About this Document
1.1 Intended Purpose
The purpose of the present document is to familiarize you with the described equipment and the tasks
on safe and adequate installation and/or commissioning.
Observing the described instructions in this document will help you …
• to avoid dangerous situations,
• to keep installation and/or commissioning time at a minimum and
• to increase reliability and service life of the described equipment.
Use for other and/or additional purposes is not permitted. maxon motor, the manufacturer of the equipment described, does not assume any liability for loss or damage that may arise from any other and/or
additional use than the intended purpose.
1.2 Target Audience
This document is meant for trained and skilled personnel working with the equipment described. It conveys 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.
About this Document
1.3 How to use
Take note of the following notations and codes which will be used throughout the document.
Notation Explanation
(n) referring to an item (such as order number, list item, etc.)
denotes “see”, “see also”, “take note of” or “go to”
Table 1-1 Notations used in this Document
1.4 Symbols and Signs
In the course of the present document, the following symbols and sings will be used.
Typ e Symbol Meaning
Safety Alert
(typical)
DANGER
WARNING
CAUTION
Indicates an imminent hazardous situation. If not
avoided, it will result in death or serious injury.
Indicates a potential hazardous situation. If not
avoided, it can result in death or serious injury.
Indicates a probable hazardous situation or calls
the attention to unsafe practices. If not avoided, it
may result in injury.
Prohibited
Action
(typical)
Mandatory
Action
(typical)
maxon motor control
EPOS2 Positioning Controller Document ID: rel7748
EPOS2 24/2 Hardware Reference Edition: November 2017
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Indicates a dangerous action. Hence, you must not!
Indicates a mandatory action. Hence, you must!
1-5
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About this Document
Typ e Symbol Meaning
Information
Table 1-2 Symbols & Signs
1.5 Trademarks and Brand Names
For easier legibility, registered brand names are listed below and will not be further tagged with their
respective trademark. It must be understood that the brands (the below list is not necessarily concluding) are protected by copyright and/or other intellectual property rights even if their legal trademarks are
omitted in the later course of this document.
The brand name(s) … … is/are a registered trademark(s) of …
Adobe® Reader® © Adobe Systems Incorporated, USA-San Jose, CA
Micro-Fit™
Mini-Fit Jr.™
Requirement /
Note / Remark
Best Practice
Material
Damage
© Molex, USA-Lisle, IL
Indicates an activity you must perform prior
continuing, or gives information on a particular item
you need to observe.
Indicates an advice or recommendation on the
easiest and best way to further proceed.
Indicates information particular to possible damage
of the equipment.
Table 1-3 Brand Names and Trademark Owners
1.6 Copyright
© 2017 maxon motor. All rights reserved.
The present document – including 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 41 666 15 00
Fax +41 41 666 16 50
www.maxonmotor.com
Pentium® © Intel Corporation, USA-Santa Clara, CA
Windows® © Microsoft Corporation, USA-Redmond, WA
maxon motor control
1-6 Document ID: rel7748 EPOS2 Positioning Controller
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2Introduction
The present document provides you with information on the EPOS2 24/2 Positioning Controller’s hardware. It contains…
• performance data and specifications,
• information on connections and pin assignment and
• wiring examples.
The EPOS2 24/2 Positioning Controller is available in different variants possessing an identical basic
setup, however, their individual configuration varies slightly. The present document covers the entire
scope on all variants, thus providing you with all relevant information regardless of the actual type of
controller you are using.
maxon motor control’s EPOS2 24/2 is a small-sized, full digital, smart motion controller. Due to its flexible and high efficient power stage, the EPOS2 24/2 drives brushed DC motors with digital encoder as
well as brushless EC motors with digital Hall 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 24/2 is especially designed being
commanded and controlled as a slave node in a CANopen network. In addition, the unit can be operated
via any USB or RS232 interface.
Find the latest edition of the present document, as well as additional documentation and software to the
EPOS2 24/2 Positioning Controller also on the Internet: www.maxonmotor.com
Introduction
Documentation Structure
2.1 Documentation Structure
The present document is part of a documentation set. Please find below an overview on the documentation hierarchy and the interrelationship of its individual parts:
Figure 2-1 Documentation Structure
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Introduction
Safety Precautions
2.2 Safety Precautions
Prior continuing …
• make sure you have read and understood chapter “ PLEASE READ THIS FIRST” on page A-2,
• do not engage with any work unless you possess the stated skills (chapter “1.2 Target Audience” on page 1-5),
• refer to chapter “1.4 Symbols and Signs” on page 1-5 to understand the subsequently used
indicators,
• you must observe any regulation applicable in the country and/or at the site of implementation
with regard to health and safety/accident prevention and/or environmental protection,
• take note of the subsequently used indicators and follow them at all times.
DANGER
High Voltage and/or Electrical Shock
Touching live wires causes death or serious injuries!
• Consider any power cable as connected to live power, unless having proven the opposite!
• Make sure that neither end of cable is connected to live power!
• Make sure that power source cannot be engaged while work is in process!
• Obey lock-out/tag-out procedures!
• Make sure to securely lock any power engaging equipment against unintentional engagement and
tag with your name!
Requirements
• Make sure that all associated devices and components are installed according to local regulations.
• Be aware that, by principle, an electronic apparatus can not be considered fail-safe. Therefore, you
must make sure that any machine/apparatus has been fitted with independent monitoring and safety
equipment. If the machin e/appa ratus shou ld brea k 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 that the motor is free running. If not the case, mechanically disconnect the motor from the load.
Maximal permitted Supply Voltage
• Make sure that supply power is between 9…24 VDC.
• Supply voltages above 30 VDC will destroy the unit.
• Wrong polarity will destroy the unit.
Electrostatic Sensitive Device (ESD)
• Make sure to wear working cloth in compliance with ESD.
• Handle device with extra care.
Hot plugging the USB interface may cause hardware damage
If the USB interface is being hot-plugged (connecting while the power supply is on), the possibly high
potential differences of the two power supplies of controller and PC/Notebook can lead to damaged
hardware.
• Avoid potential differences between the power supply of controller and PC/Notebook or, if possible,
balance them.
• Insert the USB connector first, then switch on the power supply of the controller.
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3 Technical Data
3.1 Electrical Data
Rating
Nominal power supply voltage VCC
Absolute min. supply voltage VCC
Absolute max. supply voltage VCC
Max. output voltage
Max. output current I
Continuous output current I
Switching frequency 100 kHz
Max. efficiency 90%
Sample rate PI – current controller 10 kHz
Sample rate PI – speed controller 1 kHz
Sample rate PID – positioning controller 1 kHz
Max. speed @ sinusoidal commutation
(motors with 1 pole pair)
Max. speed @ block commutation
(motors with 1 pole pair)
Built-in motor choke per phase 47 μH / 2 A
(<1 sec)
max
cont
9…24 VDC
8 VDC
28 VDC
0.9 • V
CC
4 A
2 A
25 000 rpm
100 000 rpm
Technical Data
Electrical Data
Table 3-4 Electrical Data – Rating
Inputs
Hall sensor 1, Hall sensor 2 and Hall sensor 3
Hall sensor signals (380264 and 390003 only)
Encoder signals
Digital Input 1 (“General Purpose”) +2.4…+24 VDC (Ri = 11 kΩ)
Digital Input 2 (“General Purpose”) +2.4…+24 VDC (Ri = 11 kΩ)
Digital Input 3 (“General Purpose”) +2.4…+24 VDC (Ri = 11 kΩ)
Digital Input 4 (“Home Switch”) +2.4…+24 VDC (Ri = 11 kΩ)
Digital Input 5 (“Positive Limit Switch”) +2.4…+24 VDC (Ri = 11 kΩ)
Digital Input 6 (“Negative Limit Switch”) +2.4…+24 VDC (Ri = 11 kΩ)
Analog Input 1 resolution 12-bit 0…+5 V (Ri = 47 kΩ)
Analog Input 2 resolution 12-bit 0…+5 V (Ri = 47 kΩ)
CAN ID (CAN identification) ID 1…15 configurable via DIP switch 1…4
for Hall effect sensor ICs (Schmitt trigger with open
collector output)
A, A\, B, B\, I, I\ (max. 5 MHz)
internal line receiver EIA RS422 Standard
Table 3-5 Electrical Data – Inputs
Outputs
Digital Output 3 (“General Purpose”), open drain
Digital Output 4 (“General Purpose”), open drain
max. 24 VDC (IL <50 mA)
max. 24 VDC (IL <50 mA)
Table 3-6 Electrical Data – Outputs
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Technical Data
Electrical Data
Voltage Outputs
Encoder supply voltage
Hall sensors supply voltage (380264 and 390003 only)
Auxiliary output voltage
+5 VDC (IL <100 mA)
+5 VDC (IL <30 mA)
+5 VDC (IL <10 mA)
Table 3-7 Electrical Data – Voltage Outputs
Motor Connections
maxon EC motor (380264 and 390003 only) maxon DC motor
Motor winding 1 + Motor
Motor winding 2 − Motor
Motor winding 3
Table 3-8 Electrical Data – Motor Connections
Connections
Purpose Connector Type
DC
(390438)
DC/EC
(390003)
DC(X)
(530239)EC(380264)
J1 – J1 J1
J2 – J2 J2
J3 – – –
– – J4 – Encoder Half pitch box header, 2 x 5 poles, pitch 1.27/1.27 mm
– – J5 – Motor PCB screw clamps, 2 poles, pitch 2.54 mm
– – J6 – Motor
– – J7 – Motor
– – – J8
– J11 J3 J9 Encoder
– J10 – –
– J12 – – RS232
– J13 – – CAN
– J14 – –
J15 J15 J15 J15 USB
Supply /
Control Signals
Communication /
Analog Inputs
*1)
Motor
/
Encoder
Motor /
Hall Sensors
DC Motor /
EC Motor with
Hall Sensors
Supply /
Control Signals
PCB screw clamps, 13 poles, pitch 2.54 mm
PCB screw clamps, 8 poles, pitch 2.54 mm
DIN41651; 10 poles for ribbon cable, pitch 1.27 mm, AWG 28
Suitable clip: Tyco C42334-A421-C42 (right); C42334-A421-C52 (left)
Hirose DF3-3P-2DSA
Suitable plug/terminal: Hirose DF3-3S-2C / Hirose DF3-22SC
JST B2B-PH-K-S
Suitable plug/terminal: JST PHR-2 / JST SPH-002T
Lumberg 2.5 MSF/O 08, 8 poles, pitch 2.5 mm
DIN41651; 10 poles for ribbon cable, pitch 1.27 mm, AWG 28
Suitable clip: Tyco C42334-A421-C42 (right); C42334-A421-C52 (left)
Dual row male header (8 poles) Molex Micro-Fit 3.0
Suitable plug/terminal: Molex Micro-Fit 3.0 430-25-0800 / female crimp
terminal 43030-xxxx (AWG 20-30)
Dual row male header (6 poles) Molex Micro-Fit 3.0
Suitable plug/terminal: Molex Micro-Fit 3.0 430-25-0600 / female crimp
terminal 43030-xxxx (AWG 20-30)
Dual row male header (4 poles) Molex Micro-Fit 3.0
Suitable plug/terminal: Molex Micro-Fit 3.0 430-25-0400 / female crimp
terminal 43030-xxxx (AWG 20-30)
Dual row male header (16 poles) Molex Micro-Fit 3.0
Suitable plug/terminal: Molex Micro-Fit 3.0 430-25-1600 / female crimp
terminal 43030-xxxx (AWG 20-30)
USB connector type mini-B jack (5 poles)
Suitable plug: Standard USB cable with type mini-B plug connector (5
poles)
*1) with interface according to MR Encoder Type S with Line Driver and MR Encoder Type M with Line Driver.
Table 3-9 Electrical Data – Connections
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3-10 Document ID: rel7748 EPOS2 Positioning Controller
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Interfaces
RS232 RxD; TxD max. 115 200 bit/s
USB 2.0 /
USB 3.0
CAN 1 CAN_H (high); CAN_L (low) max.1 Mbit/s
CAN 2 CAN_H (high); CAN_L (low) max.1 Mbit/s
Table 3-10 Electrical Data – Interfaces
Status Indicators
Operation green LED
Error red LED
Table 3-11 Electrical Data – LEDs
3.2 Mechanical Data
Technical Data
Mechanical Data
Data+; Data− full speed
Mechanical Data
Weight approx. 27 g approx. 28 g approx. 27 g approx. 30 g
Dimensions (L x W x H) 55 x 40 x 15.6 mm 55 x 40 x 18.2 mm 55 x 40 x 18.2 mm 55 x 40 x 19.6 mm
Mounting plate for M2.5 screws
*1) Max. tightening torque 0.16 Nm.
DC
(390438)
DC/EC
(390003)
*1)
for M2.5 screws
DCX
(530239)
*1)
for M2.5 screws
EC
(380264)
*1)
for M2.5 screws
Table 3-12 Mechanical Data
Figure 3-2 Dimensional Drawing [mm] – DC (390438)
*1)
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Technical Data
Mechanical Data
Figure 3-3 Dimensional Drawing [mm] – DC/EC (390003)
Figure 3-4 Dimensional Drawing [mm] – DCX (530239)
Figure 3-5 Dimensional Drawing [mm] – EC (380264)
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3.3 Environmental Conditions
Environmental Condition
Temperature
*2)
Altitude
Humidity 5…90% (condensation not permitted)
*1) Operation within the extended range (temperature and altitude) is permitted. However, a respective derating
*2) Operating altitude in meters above Mean Sea Level, MSL.
Table 3-13 Environmental Conditions
Operation 0…10’000 m MSL
(declination of output current I
Operation −10…+55 °C
Extended Range
Storage −40…+85 °C
) as to the stated values will apply.
cont
*1)
+55…+74 °C / Derating Figure 3-6
Technical Data
Environmental Conditions
Figure 3-6 Derating Output Current
3.4 Order Details
Table 3-14 Order Details
Order # Order Details
380264 EPOS2 24/2 for maxon EC motors
390003 EPOS2 24/2
390438 EPOS2 24/2 for maxon DC motors
530239 EPOS2 24/2
for maxon DC motors
for maxon EC motors
for maxon DC motors
for maxon DCX motors
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Technical Data
Standards
3.5 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.
Important Notice
The device’s compliance with the mentioned standards does not imply its compliance within the final,
ready to operate setup. In order to achieve compliance of your operational system, you must perform
EMC testing of the involved equipment as a whole.
Generic Standards
Electromagnetic Compatibility
IEC/EN 61000-6-2 Immunity for industrial environments
IEC/EN 61000-6-3
Emission standard for residential, commercial and lightindustrial environments
IEC/EN 61000-6-3
IEC/EN 55022
Radio disturbance characteristics / radio interference
(CISPR22)
IEC/EN 61000-4-3
Applied Standards
Radiated, radio-frequency, electromagnetic field immunity
test >10 V/m
IEC/EN 61000-4-4 Electrical fast transient/burst immunity test ±2 kV
IEC/EN 61000-4-6
Immunity to conducted disturbances, induced by radiofrequency fields 10 Vrms
IEC/EN 61000-4-8 Power frequency magnetic field 30 A/m
Others
Environmental
IEC/EN 60068-2-6
Environmental testing – Test Fc: Vibration (sinusoidal,
2
10…500 Hz, 20 m/s
)
Standards
MIL-STD-810F
Random transport (10…500 Hz up to 2.53 g
rms
)
Safety Standards UL File Numbers E76332, E174311; unassembled printed circuit board
Reliability prediction of electronic equipment
Environment: Ground, benign
Ambient temperature: 298 K (25 °C)
Component stress: In accordance with circuit diagram and
Reliability MIL-HDBK-217F
nominal power
Mean Time Between Failures (MTBF)
• DC (390438): 912'810 hours
• DC/EC (390003): 751'966 hours
• DCX (530239): 912'810 hours
• EC (380264): 750'015 hours
Table 3-15 Standards
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4 Connections
4.1 Wiring Diagrams
4.1.1 EPOS2 24/2 for maxon DC motors (390438)
Figure 4-7 Interfaces – Designations and Location «DC» (390438)
Connections
Wiring Diagrams
Figure 4-8 Wiring Diagram «DC» (390438)
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Connections
Wiring Diagrams
4.1.2 EPOS2 24/2 for maxon DC/EC motors (390003)
Figure 4-9 Interfaces – Designations and Location «DC/EC» (390003)
Figure 4-10 Wiring Diagram «DC/EC» (390003)
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4.1.3 EPOS2 24/2 for maxon DCX motors (530239)
Figure 4-11 Interfaces – Designations and Location «DCX» (530239)
Connections
Wiring Diagrams
Figure 4-12 Wiring Diagram «DCX» (530239)
maxon motor control
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Connections
Wiring Diagrams
4.1.4 EPOS2 24/2 for maxon EC motors (380264)
Figure 4-13 Interfaces – Designations and Location «EC» (380264)
Figure 4-14 Wiring Diagram «EC» (380264)
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4.2 Connectors
Use below table to determine the connectors installed on the type of controller you are using. Follow the
respective hyperlink to receive detailed information and data on the respective connector.
Connections
Connectors
DC
(390438)
EPOS2 24/2
DC/EC
(390003)
DCX
(530239)EC(380264)
Purpose
Find detailed
information
here:
J1 – J1 J1 Supply/Control Signals page 4-20
J2 – J2 J2 Communication/Analog Inputs page 4-27
J3 – – – Motor/Encoder page 4-29
––
–––
J3 – Encoder page 4-29
J9 Encoder page 4-32
– J11 – – Encoder page 4-34
––
––
J4 – Encoder page 4-30
J5 – Motor page 4-30
––J6 – Motor page 4-30
––
–––
J7 – Motor page 4-30
J8 Motor/Hall Sensors page 4-31
– J10 – – Motor/Hall Sensors page 4-33
–
–
J12 ––RS232 page 4-35
J13 ––CAN page 4-36
– J14 – – Supply/Control Signals page 4-37
J15 J15 J15 J15 USB page 4-38
Table 4-16 Controller Types and their Connectors
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Connections
Connectors
4.2.1 Supply/Control Signals Connector (J1)
Contains multi-purpose digital I/Os configurable as…
• “Home Switch”
• “Positive Limit Switch”
• “Negative Limit Switch”
Additionally available are “General Purpose” digital I/Os and supply voltage.
Figure 4-15 Supply/Control Signals Connector (J1)
Pin Signal Description
1 DigIN1 Digital Input 1 “General Purpose”
2 DigIN2 Digital Input 2 “General Purpose”
3 DigIN3 Digital Input 3 “General Purpose”
4 DigIN4 Digital Input 4 “Home Switch”
5 DigIN5 Digital Input 5 “Positive Limit Switch”
6 DigIN6 Digital Input 6 “Negative Limit Switch”
7 D_Gnd Digital signal ground
8
9 DigOUT3 Digital Output 3 “General Purpose”
10 DigOUT4 Digital Output 4 “General Purpose”
11 D_Gnd Digital signal ground
12 Power_Gnd Power ground
13
+V
+V
OUT
CC
Auxiliary supply voltage Output (+5 VDC / 10 mA)
Power supply voltage (+9…24 VDC)
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Connections
Connectors
4.2.1.1 Digital Input 1
By default, the digital input is defined as “General Purpose” and may be configured via software.
DigIN1 “General Purpose”
D_Gnd
Input voltage 0…24 VDC
Max. input voltage ±30 VDC
Logic 0
Logic 1
Input resistance
Input current at logic 1 typically 2 mA @ 24 VDC
Switching delay <300 µs @ 5 VDC
Connector [J1] Pin [1]
Connector [J1] Pin [7]
Uin <0.7 VDC
Uin >2.4 VDC
typically 22 kΩ (<3.3 VDC)
typically 11 kΩ (>3.3 VDC)
Figure 4-16 DigIN1
4.2.1.2 Digital Inputs 2 and 3
By default, the digital inputs are defined as “General Purpose” and may be configured via software.
DigIN2 “General Purpose”
DigIN3 “General Purpose”
D_Gnd
Input voltage 0…24 VDC
Max. input voltage ±30 VDC
Logic 0
Logic 1
Input resistance
Input current at logic 1 typically 2 mA @ 24 VDC
Switching delay <1 µs @ 5 VDC
Connector [J1] Pin [2]
Connector [J1] Pin [3]
Connector [J1] Pin [7]
Uin <0.7 VDC
Uin >2.4 VDC
typically 22 kΩ (<3.3 VDC)
typically 11 kΩ (>3.3 VDC)
Figure 4-17 DigIN2 (analogously valid also for DigIN3)
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Connections
Connectors
4.2.1.3 Digital Inputs 4, 5 and 6
By default, the digital inputs are defined as follows and may be configured via software.
• Digital Input 4 “Home Switch”
• Digital Input 5 “Positive Limit Switch”
• Digital Input 6 “Negative Limit Switch”
DigIN4 “Home Switch”
DigIN5 “Positive Limit Switch”
DigIN6 “Negative Limit Switch”
D_Gnd
Input voltage 0…24 VDC
Max. input voltage ±30 VDC
Logic 0
Logic 1
Input resistance
Input current at logic 1 typically 2 mA @ 24 VDC
Switching delay <300 µs @ 5 VDC
Connector [J1] Pin [4]
Connector [J1] Pin [5]
Connector [J1] Pin [6]
Connector [J1] Pin [7]
Uin <0.7 VDC
Uin >2.4 VDC
typically 22 kΩ (<3.3 VDC)
typically 11 kΩ (>3.3 VDC)
Figure 4-18 DigIN4 (analogously valid also for DigIN5/6)
IRING EXAMPLE: “PROXIMITY SWITCH TYPE PNP”
W
3-Wire Model
RIN = 11 kΩ
Figure 4-19 DigIN4 – Type PNP Proximity Switch (analogously valid also for DigIN5/6)
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WIRING EXAMPLE: “PHOTOELECTRIC SENSOR”
3-Wire Model
R
= (12 V) = 20 kΩ (300 mW)
ext
= (24 V) = 51 kΩ (150 mW)
R
ext
R
= 11 kΩ
IN
Figure 4-20 DigIN4 – Photoelectric Sensor (analogously valid also for DigIN5/6)
Connections
Connectors
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EPOS2 Positioning Controller Document ID: rel7748
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Connections
Connectors
4.2.1.4 Auxiliary Output Voltage
Can be used as supply voltage for external loads connected to the digital inputs.
+V
OUT
Output voltage +5 VDC (referenced to D_Gnd)
Output current max. 10 mA
Connector [J1] Pin [8]
4.2.1.5 Digital Outputs 3 and 4
By default, the digital outputs are defined as “General Purpose” and may be configured via software.
DigOUT3
DigOUT4
D_Gnd
Circuit
Connector [J1] Pin [9]
Connector [J1] Pin [10]
Connector [J1] Pin [11]
Open drain (internal pull-up resistor 2k2 and
diode to +5 VDC
Figure 4-21 DigOUT3 Circuit (analogously valid also for DigOUT4)
W
IRING EXAMPLES:
DigOUT “Sinks”
Max. input voltage +30 VDC
Max. load current 50 mA
Max. voltage drop <1.0 V @ 50 mA
Figure 4-22 DigOUT3 “Sinks” Circuit (analogously valid also for DigOUT4)
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DigOUT “Source”
Output voltage
Max. load current
≈5V − 0.75 V − (I
out
I
≤2 mA
load
× 2200 Ω)
load
U
Figure 4-23 DigOUT3 “Source” Circuit (analogously valid also for DigOUT4)
Connections
Connectors
maxon motor control
EPOS2 Positioning Controller Document ID: rel7748
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Connections
V
CC
U
N
n
O
-------
n
B
Δn
ΔM
---------
M
B
⋅+
1
0.9
-------
⋅⋅ 1 V[]+=
Connectors
4.2.1.6 Supply Voltage
Best Practice
Keep the motor mechanically disconnected during setup and adjustment phase.
D
ETERMINATION OF POWER SUPPLY
Basically, any power supply may be used, provided it meets below stated minimal requirements.
Power Supply Requirements
Output voltage
Absolute output voltage min. 8 VDC; max. 28 VDC
Output current Depending on load (continuous max. 2 A / acceleration, short-time max. 4 A)
1) Calculate required voltage under load using following scheme (the formula takes a max. PWM
cycle of 90% and a max. voltage drop of −1 V at EPOS2 24/2 into account):
NOWN VAL UES:
K
• Operating torque M
• Operating speed n
• Nominal motor voltage U
• Motor no-load speed at U
• Speed/torque gradient of the motor Δn/ΔM [min
VCC min. 9 VDC; VCC max. 24 VDC
[mNm]
B
[min−1]
B
[Volt]
N
, n0 [min−1]
N
−1
mNm−1]
OUGHT VAL UE:
S
• Supply voltage VCC [Volt]
OLUTION:
S
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.
+VCC
Power_Gnd
Connector [J1] Pin [13]
Connector [J1] Pin [12]
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4.2.2 Communication/Analog Inputs Connector (J2)
Contains CAN bus and RS232 communication signals.
Additionally available are multi-purpose analog inputs.
Figure 4-24 Communication/Analog Inputs Connector (J2)
Pin Signal Description
1 CAN high CAN high bus line
2 CAN low CAN low bus line
3 RS232 RxD RS232 receive
4 RS232 TxD RS232 transmit
5 GND Ground
6 AnIN1 Analog Input 1
7 AnIN2 Analog Input 2
8 A_Gnd Analog signal ground
Connections
Connectors
4.2.2.1 CAN Communication
Standard ISO 11898-2:2003
Max. bit rate 1 Mbit/s
Max. number of CAN nodes 127
Protocol CANopen DS-301 V4.02
Identifier setting DIP switch or software
C
ONNECTION OF POSITIONING CONTROLLER TO CAN BUS LINE CIA DS-102
EPOS2 24/2 CAN 9 pin D-Sub (DIN41652)
Connector [J2] Pin [1] “CAN high” Pin 7 “CAN_H” high bus line
Connector [J2] Pin [2] “CAN low” Pin 2 “CAN_L” low bus line”
Connector [J2] Pin [5] “GND” Pin 3 “CAN_GND” Ground
Note
• Consider CAN Master’s maximal baud rate.
• The standard baud rate setting (factory setting) is “Auto Bit Rate”.
• Use termination resistor at both ends of the CAN bus (
chapter “4.3.2 CAN Bus Termination” on
page 4-40).
• For detailed CAN information separate document «EPOS2 Communication Guide».
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Connections
Connectors
4.2.2.2 RS232 Communication
Max. input voltage ±30 V
Output voltage typically ±9 V @ 3 kΩ to Ground
Max. bit rate 115 200 bit/s
Internal RS232 driver/receiver EIA RS232 Standard
C
ONNECTION OF POSITIONING CONTROLLER TO PC
EPOS2 24/2 PC Interface (RS232), DIN41652
Connector [J2] Pin [3] “EPOS RxD” Pin 3 “PC TxD”
Connector [J2] Pin [4] “EPOS TxD” Pin 2 “PC RxD”
Connector [J2] Pin [5] “GND” Pin 5 “CAN_GND” Ground
Note
• Consider your PC's serial port maximal baud rate.
• The standard baud rate setting (factory setting) is 115'200 bauds.
4.2.2.3 Analog Inputs 1 and 2
By default, the analog inputs are defined as “General Purpose” and may be configured via software.
AnIN1
AnIN2
A_Gnd
Input voltage 0…5 VDC
Max. input voltage ±30 VDC
Input resistance typically 47 kΩ (referenced to A_Gnd)
A/D converter 12-bit
Resolution 0.0012 V
Bandwidth 5 kHz
Connector [J2] Pin [6]
Connector [J2] Pin [7]
Connector [J2] Pin [8]
Figure 4-25 AnIN1 Circuit (analogously valid also for AnIN2)
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4.2.3 Motor/Encoder Connector (J3)
Figure 4-26 Motor/Encoder Connector (J3)
Pin Signal Description
1 Motor+ Motor terminal “+” DC version (390438) only
2 +5 VDC / 100 mA Encoder supply voltage
3 GND Ground
4 Motor− Motor terminal “−” DC version (390438) only
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 Index
Connections
Connectors
Accessories Cable Encoder Cable (275934)
Notes Suitable connector DIN 41651 Plug, pitch 2.54 mm, 10 poles, strain relief
Best Practice
The use of encoder with built-in line 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.
Encoder supply voltage +5 VDC
Max. encoder supply current 100 mA
Min. differential Input voltage ± 200 mV
Line receiver (internal) EIA RS422 Standard
Max. encoder input frequency 5 MHz
Figure 4-27 Encoder Input Circuit Channel A (analogously valid also for Channel B/Index)
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Connections
Connectors
4.2.4 Encoder Connector (J4)
Figure 4-28 Encoder Connector (J4)
Pin Signal Description
1 not connected
2 +5 VDC / 100 mA Encoder supply voltage
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 Channel I\ Index complement
10 Channel I Index
Accessories Suitable cable Flat ribbon cable AWG 30
Samtec: FFSD series
Notes Suitable plugs
W+P Products: 376 series
Elcotron: IDC32 series
For further details page 4-29.
4.2.5 Motor Connectors (J5 / J6 / J7)
Figure 4-29 Motor Connectors (J5, left) / (J6, center) / (J7, right)
Pin Signal Description
1 Motor+ Motor terminal “+”
2 Motor− Motor terminal “−”
3 not connected –
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4.2.6 Motor/Hall Sensors Connector (J8)
Figure 4-30 Motor/Hall Sensors Connector (J8)
Pin Signal Description
1 Motor winding 1 Winding 1
2 Motor winding 2 Winding 2
3 Motor winding 3 Winding 3
+V
4
5 GND Ground of Hall sensor supply
6 Hall Sensor 1 Hall sensor 1 Input
7 Hall Sensor 2 Hall sensor 2 Input
8 Hall Sensor 3 Hall sensor 3 Input
Hall
Hall sensor supply voltage +5 VDC / 30 mA
Connections
Connectors
Notes Suitable connector MKF 13268-6-0-808 STOCKO Elektronik GmbH
Hall sensor 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)
Figure 4-31 Hall Sensor Input Circuit
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Connections
Connectors
4.2.7 Encoder Connector (J9)
Figure 4-32 Encoder Connector (J9)
Pin Signal Description
1 not connected –
2 +5 VDC / 100 mA Encoder supply voltage
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 Channel I\ Index complement
10 Channel I Index
Accessories Cable Encoder Cable (275934)
Notes Suitable connector DIN 41651 Plug, pitch 2.54 mm, 10 poles, plug strain relief
For further details page 4-29.
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4.2.8 Motor/Hall Sensors Connector (J10)
Figure 4-33 Motor/Hall Sensors Connector (J10)
4.2.8.1 DC Motor
Pin Signal Description
1 not connected –
2 not connected –
3 not connected –
4 Motor+ Motor terminal “+”
5 not connected –
6 not connected –
7 not connected –
8 Motor− Motor terminal “−”
Connections
Connectors
Accessories Cable DC Motor Cable (303490)
Notes
Suitable connector
Suitable crimp terminals
Suitable hand crimper
Molex Micro-Fit 8 poles (430-25-0800)
Molex Micro-Fit female crimp terminals (43030-xxxx)
Molex hand crimper (63819-0000)
4.2.8.2 EC Motor
Pin Signal Description
1 Hall Sensor 3 Hall sensor 3 Input
2 Hall Sensor 2 Hall sensor 2 Input
3 Motor winding 3 Winding 3
4 Motor winding 1 Winding 1
+V
5
6 Hall Sensor 1 Hall sensor 1 Input
7 GND Ground
8 Motor winding 2 Winding 2
Accessories Cable Motor/Hall Sensor Cable (302948)
Notes
Hall
Suitable connector
Suitable crimp terminals
Suitable hand crimper
Hall sensor supply voltage +5 VDC / 30 mA
Molex Micro-Fit 8 poles (430-25-0800)
Molex Micro-Fit female crimp terminals (43030-xxxx)
Molex hand crimper (63819-0000)
For further details page 4-31.
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Connections
Connectors
4.2.9 Encoder Connector (J11)
Figure 4-34 Encoder Connector (J11)
The use of the connector depends on the type of DC motor (respectively its connecting cable) you are
using. Possible configurations are:
A maxon DC motor with separated motor/encoder cable
For further details “Motor/Encoder Connector (J3)” on page 4-29.
B maxon DC motor with integrated motor/encoder ribbon cable
Proceed as follows:
Figure 4-35 Controller PCB – Solder Pads (JP701 & JP702
1) Find solder pads (Figure 4-35, arrows) on controller PCB.
2) Bridge both solder pad pairs.
3) Connect motor/encoder ribbon cable to connector J11.
Note
With maxon DC motor with integrated motor/encoder ribbon cable, connector J10 will not be used!
Accessories Cable Encoder Cable (275934)
For further details page 4-29.
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4.2.10 RS232 Connector (J12)
Figure 4-36 RS232 Connector (J12)
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 Cable shield
Accessories Cable RS232-COM Cable (275900)
Notes
Suitable connector
Suitable crimp terminals
Suitable hand crimper
Molex Micro-Fit 3.0 6 poles (430-25-0600)
Molex Micro-Fit 3.0 female crimp terminals (43030-xxxx)
Molex hand crimper (63819-0000)
Connections
Connectors
Max. input voltage ±30 V
Output voltage typically ±9 V @ 3 kΩ to Ground
Max. bit rate 115 200 bit/s
Internal RS232 driver/receiver EIA RS232 Standard
CONNECTION OF POSITIONING CONTROLLER TO PC
EPOS2 24/2 PC Interface (RS232), DIN41652
Connector [J12] Pin [1] “EPOS RxD” Pin 3 “PC TxD”
Connector [J12] Pin [2] “EPOS TxD” Pin 2 “PC RxD”
Connector [J12] Pins [4] + [5] “GND” Pin 5 “GND”
Note
• Consider your PC's serial port maximal baud rate.
• The standard baud rate setting (factory setting) is 115'200 bauds.
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Connections
Connectors
4.2.11 CAN Connector (J13)
Figure 4-37 CAN Connector (J13)
Pin Signal Description
1 CAN high CAN high bus line
2 CAN low CAN low bus line
3 CAN GND CAN Ground
4 CAN Shield Cable shield
CAN-COM Cable (275908)
Accessories Cable
Suitable connector
Notes
Suitable crimp terminals
Suitable hand crimper
CAN-CAN Cable (275926)
CAN-Y Cable (319471)
Molex Micro-Fit 3.0 4 poles (430-25-0400)
Molex Micro-Fit 3.0 female crimp terminals (43030-xxxx)
Molex hand crimper (63819-0000)
4.2.11.1 CAN Communication
Standard ISO 11898-2:2003
Max. bit rate 1 Mbit/s
Max. number of CAN nodes 127
Protocol CANopen DS-301 V4.02
Identifier setting DIP switch or software
ONNECTION OF POSITIONING CONTROLLER TO CAN BUS LINE CIA DS-102
C
EPOS2 24/2 CAN 9 pin D-Sub (DIN41652)
Connector [J13] Pin [1] “CAN high” Pin 7 “CAN_H” high bus line
Connector [J13] Pin [2] “CAN low” Pin 2 “CAN_L” low bus line”
Connector [J13] Pin [3] “GND” Pin 3 “CAN_GND” Ground
Connector [J13] Pin [4] “CAN Shield” Pin 5 “CAN_Shield” Cable shield
Note
• Consider CAN Master’s maximal baud rate.
• The standard baud rate setting (factory setting) is “Auto Bit Rate”.
• Use termination resistor at both ends of the CAN bus (
chapter “4.3.2 CAN Bus Termination” on
page 4-40).
• For detailed CAN inform at ion separate document «EPOS2 Communication Guide».
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4.2.12 Supply/Control Signals Connector (J14)
Contains multi-purpose digital I/Os configurable as…
• “Home Switch”
• “Positive Limit Switch”
• “Negative Limit Switch”
Additionally available are “General Purpose” digital I/Os and supply voltage.
Figure 4-38 Supply/Control Signals Connector (J14)
Pin Signal Description
1 D_Gnd Digital signal 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
10 DigOUT4 Digital Output 4 “General Purpose”
11 DigOUT3 Digital Output 3 “General Purpose”
12
13 Power_Gnd Power ground
14 A_Gnd Analog signal ground
15 AnIN2 Analog Input 2
16 AnIN1 Analog Input 1
+V
+V
OUT
CC
Auxiliary supply voltage Output (+5 VDC / 10 mA)
Power supply voltage (+9…24 VDC)
Connections
Connectors
Accessories Cable Signal Cable 16core (275932)
Suitable connector
Notes
Suitable crimp terminals
Suitable hand crimper
Find detailed information, electrical data and circuits in below listed sections:
• “Digital Input 1” on page 4-21
• “Digital Inputs 2 and 3” on page 4-21
• “Digital Inputs 4, 5 and 6” on page 4-22
• “Analog Inputs 1 and 2” on page 4-28
• “Auxiliary Output Voltage” on page 4-24
• “Digital Outputs 3 and 4” on page 4-24
• “Supply Voltage” on page 4-26
maxon motor control
EPOS2 Positioning Controller Document ID: rel7748
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Molex Micro-Fit 3.0 16 poles (430-25-1600)
Molex Micro-Fit 3.0 female crimp terminals (43030-xxxx)
Molex hand crimper (63819-0000)
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Connections
Connectors
4.2.13 USB Connector (J15)
Hot plugging the USB interface may cause hardware damage
If the USB interface is being hot-plugged (connecting while the power supply is on), the possibly high
potential differences of the two power supplies of controller and PC/Notebook can lead to damaged
hardware.
• Avoid potential differences between the power supply of controller and PC/Notebook or, if possible,
balance them.
• Insert the USB connector first, then switch on the power supply of the controller.
Figure 4-39 USB Connector (J15)
Pin Signal Description
1
2 USB D− USB Data−
3 USB D+ USB Data+
4 not connected –
5 GND USB Ground
V
BUS
Shield Cable Shield
USB bus supply input voltage +5 VDC
Accessories Cable USB Type A - mini B Cable (370513)
Notes Suitable connector Standard USB cable with type mini B plug (5 poles)
USB Standard USB 2.0 / USB 3.0 (full speed)
Max. bus supply voltage +5.25 VDC
Typical input current 15 mA
Max. DC data input voltage −0.5…+3.8 VDC
ONNECTION OF POSITIONING CONTROLLER TO PC
C
EPOS2 24/2 PC Interface (USB 2.0 / USB 3.0)
Connector [J15] Pin [1] “V
Connector [J15] Pin [2] “USB D−” Pin 2 “USB D−”
Connector [J15] Pin [3] “USB D+” Pin 3 “USB D+”
Connector [J15] Pin [5] “GND” Pin 4 “GND”
Connector [J15] Housing “Shield” Housing “Shield”
” Pin 1 “V
BUS
BUS
”
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4.3 CAN Node Identification (JP1)
4.3.1 CAN ID (Node Address)
The CAN ID is set with DIP switches 1…4. Addresses (1…15) may be coded using binary code.
Note
• By setting the DIP switch (1…4) address 0 (“OFF”), the CAN ID may be configured by software
(changing object “Node ID”, range 1…15).
• The CAN ID results in the summed values of DIP switch addresses 1 (“ON”).
• DIP switches 5 and 6 do not have any impact on the CAN ID.
Switch Binary Code Valence DIP Switch
1
2
Connections
CAN Node Identification (JP1)
0
1
2
3
4
1
2
2
2
3
2
2
4
8
Table 4-17 CAN ID – Binary Code Values
XAMPLES:
E
Use following table as a (non-concluding) guide:
CAN ID/Switch 1234
Val ence 1248
CAN ID DIP Setting Calculation
110001
201002
800018
11 1101 1 + 2 + 8
15 1 1 1 1 1 + 2 + 4 + 8
Table 4-18 CAN ID – DIP Switch Settings (Example)
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Connections
CAN Bit Rate Detection
4.3.2 CAN Bus Termination
The CAN bus must be terminated at both ends by a termination resistor of 120 Ω, typically. Depending
on utilization of the controller, individual CAN bus termination settings must be performed.
Using DIP switch 6, the controller-internal bus termination resistor can be activated/deactivated. By
default, bus termination is “OFF”, nevertheless, the bus is not terminated.
Figure 4-40 DIP Switch (JP1 [6]) – CAN Bus Termination (left “OFF” / right “ON”)
4.4 CAN Bit Rate Detection
Automatic bit rate detection may be forced by DIP switch 5.
Figure 4-41 DIP Switch (JP1 [5]) – Auto Bit Rate (left “OFF” / right “ON”)
4.5 Status LEDs
The LEDs display the current status of the EPOS2 24/2 as well as possible errors:
• Green LED shows the operating status
• Red LED indicates errors
For detailed information separate document «EPOS2 Firmware Specification».
LED
Red Green
OFF Slow
OFF ON
ON OFF
ON ON
ON Flash No valid firmware or firmware download in progress.
Flash = Flashing (≈0.9 s OFF/≈0.1 s ON)
Slow = Slow blinking (≈1 Hz)
Table 4-19 LEDs – Interpretation of Condition
Status / Error
Power stage is disabled. Device is in status…
• “Switch ON Disabled”
• “Ready to Switch ON”
• “Switched ON”
Power stage is enabled. Device is in status…
• “Operation Enable”
• “Quick Stop Active”
FAULT state. Device is in status…
• “Fault”
Power stage is enabled. Device is in temporary status…
• “Fault Reaction Active”
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Connections
Status LEDs
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Connections
Status LEDs
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Page 43
LIST OF FIGURES
Figure 2-1 Documentation Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Figure 3-2 Dimensional Drawing [mm] – DC (390438) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Figure 3-3 Dimensional Drawing [mm] – DC/EC (390003) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Figure 3-4 Dimensional Drawing [mm] – DCX (530239) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Figure 3-5 Dimensional Drawing [mm] – EC (380264) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Figure 3-6 Derating Output Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Figure 4-7 Interfaces – Designations and Location «DC» (390438) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Figure 4-8 Wiring Diagram «DC» (390438) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Figure 4-9 Interfaces – Designations and Location «DC/EC» (390003) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Figure 4-10 Wiring Diagram «DC/EC» (390003) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Figure 4-11 Interfaces – Designations and Location «DCX» (530239) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Figure 4-12 Wiring Diagram «DCX» (530239) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Figure 4-13 Interfaces – Designations and Location «EC» (380264) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Figure 4-14 Wiring Diagram «EC» (380264) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Figure 4-15 Supply/Control Signals Connector (J1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Figure 4-16 DigIN1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Figure 4-17 DigIN2 (analogously valid also for DigIN3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Figure 4-18 DigIN4 (analogously valid also for DigIN5/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Figure 4-19 DigIN4 – Type PNP Proximity Switch (analogously valid also for DigIN5/6) . . . . . . . . . . . . . . . . . . . . . . . . .22
Figure 4-20 DigIN4 – Photoelectric Sensor (analogously valid also for DigIN5/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Figure 4-21 DigOUT3 Circuit (analogously valid also for DigOUT4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Figure 4-22 DigOUT3 “Sinks” Circuit (analogously valid also for DigOUT4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Figure 4-23 DigOUT3 “Source” Circuit (analogously valid also for DigOUT4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Figure 4-24 Communication/Analog Inputs Connector (J2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Figure 4-25 AnIN1 Circuit (analogously valid also for AnIN2) . .
Figure 4-26 Motor/Encoder Connector (J3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Figure 4-27 Encoder Input Circuit Channel A (analogously valid also for Channel B/Index) . . . . . . . . . . . . . . . . . . . . . . .29
Figure 4-28 Encoder Connector (J4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Figure 4-29 Motor Connectors (J5, left) / (J6, center) / (J7, right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Figure 4-30 Motor/Hall Sensors Connector (J8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Figure 4-31 Hall Sensor Input Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Figure 4-32 Encoder Connector (J9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Figure 4-33 Motor/Hall Sensors Connector (J10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Figure 4-34 Encoder Connector (J11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Figure 4-35 Controller PCB – Solder Pads (JP701 & JP702 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Figure 4-36 RS232 Connector (J12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Figure 4-37 CAN Connector (J13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Figure 4-38 Supply/Control Signals Connector (J14). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Figure 4-39 USB Connector (J15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Figure 4-40 DIP Switch (JP1 [6]) – CAN Bus Termination (left “OFF” / right “ON”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Figure 4-41 DIP Switch (JP1 [5]) – Auto Bit Rate (left “OFF” / right “ON”). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
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LIST OF TABLES
Table 1-1 Notations used in this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 1-2 Symbols & Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Table 1-3 Brand Names and Trademark Owners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 3-4 Electrical Data – Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Table 3-5 Electrical Data – Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Table 3-6 Electrical Data – Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Table 3-7 Electrical Data – Voltage Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Table 3-8 Electrical Data – Motor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Table 3-9 Electrical Data – Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Table 3-10 Electrical Data – Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Table 3-11 Electrical Data – LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Table 3-12 Mechanical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Table 3-13 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Table 3-14 Order Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Table 3-15 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Table 4-16 Controller Types and their Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Table 4-17 CAN ID – Binary Code Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Table 4-18 CAN ID – DIP Switch Settings (Example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Table 4-19 LEDs – Interpretation of Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
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© 2017 maxon motor. Subject to change without prior notice.
Page 45
INDEX
A
additionally applicable regulations 8
alerts
5
analog inputs
28
B
bus termination 40
C
cables
275900 35
36
275908
275926 36
275932 37
29, 32, 34
275934
302948 33
303490 33
36
319471
calculation of required supply voltage
CAN
bus termination
interface 27, 36
CAN ID settings
connectors
J1 20
J10 33
J11 34
35
J12
J13 36
J14 37
38
J15
J2
27
29
J3
30
J4
J5
30
30
J6
30
J7
J8
31
J9 32
country-specific regulations
40
39
8
D
digital inputs 21, 22
digital outputs
DIP switches
JP1 39
JP1, bus termination 40
24
26
E
electrical data 9
environmental conditions, permitted
error display
ESD
8
examples
setting CAN IDs
wiring photoelectric sensor 23
wiring proximity switches
40
39
22
13
H
how to
calculate required supply voltage 26
configure CAN ID
interpret icons (and signs) used in the document 5
39
I
informatory signs 6
intended purpose
interfaces
CAN
27, 36
RS232
USB 38
interfaces, location and designation
7
28, 35
15, 16, 17, 18
L
LEDs 40
M
mandatory action signs 5
mechanical data
11
N
Node Address, configuration 39
O
operating status, display 40
P
performance data 9
precautions
prohibitive signs
purpose
of the device
of this document
8
5
7
5
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R
regulations, additionally applicable 8
RS232
interface
28, 35
S
safety alerts 5
safety first!
signs used
solder pads
JP701
JP702
standards, fulfilled
status display
status LEDs
supply voltage, required
symbols used
8
5
34
34
14
40
40
26
5
T
technical data 9
U
USB
interface 38
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Z-46 Document ID: rel7748 EPOS2 Positioning Controller
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© 2017 maxon motor. All rights reserved.
The present document – including 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 41 666 15 00
Fax +41 41 666 16 50
www.maxonmotor.com
maxon motor control
Z-48 Document ID: rel7748 EPOS2 Positioning Controller
Edition: November 2017 EPOS2 24/2 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
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