maxon motor control
EPOS2 Positioning Controller
Hardware Reference
Edition May 2017
Positioning Controller
Hardware Reference
Document ID: rel7050
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
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 Module 36/2 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: rel7050 EPOS2 Positioning Controller
Edition: May 2017 EPOS2 Module 36/2 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
TABLE OF CONTENTS
1 About this Document 5
2 Introduction 9
2.1 Documentation Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Technical Data 11
3.1 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Mechanical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5 Order Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 Connections 17
4.1 Pin Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 Minimum external Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3 Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.3.1 Determination of Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.3.2 Use of separate Logic Supply (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.3.3 Low Supply Voltage Operation (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.4 Motor Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4.1 maxon EC motor (brushless) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4.2 maxon DC motor (brushed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.5 Hall Sensor Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.6 Encoder Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.7 Digital Input Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.7.1 Digital Inputs 1, 2, 3 and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.7.2 Digital Inputs 7 and 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.8 Analog Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.8.1 Analog Inputs 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.9 Digital Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.9.1 Digital Outputs 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.9.2 Digital Output 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.10 RS232 Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.11 SCI Interface Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.12 CAN Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.13 CAN Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.13.1 CAN ID (Node Address). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.13.2 CAN automatic Bit Rate Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.14 Status LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
maxon motor control
EPOS2 Positioning Controller Document ID: rel7050
EPOS2 Module 36/2 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
A-3
5 Motherboard Design Guide 37
5.1 Requirements for external Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1.1 Card Edge Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1.2 Power Supply Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1.3 Logic Supply Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.1.4 Motor Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1.5 Supplier Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1.6 USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.2 Design Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2.1 Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2.2 Communication Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2.3 I/Os . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2.4 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.3 Schematic Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.3.1 Minimum External Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.3.2 Separate Logic Supply Voltage and CAN Communication . . . . . . . . . . . . . . . . . . . . . . 42
5.3.3 USB Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.3.4 Wiring Example: Low Supply Voltage Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.3.5 Wiring Example: Two Axes with RS232 to CAN Gateway. . . . . . . . . . . . . . . . . . . . . . . 45
maxon motor control
A-4 Document ID: rel7050 EPOS2 Positioning Controller
Edition: May 2017 EPOS2 Module 36/2 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
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.
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
maxon motor control
EPOS2 Positioning Controller Document ID: rel7050
EPOS2 Module 36/2 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
1-5
About this Document
1.4 Symbols and Signs
In the course of the present document, the following symbols and sings will be used.
Type Symbol Meaning
Safety Alert
Prohibited
Action
Mandatory
Action
Information
(typical)
(typical)
(typical)
DANGER
WARNING
CAUTION
Indicates a dangerous action. Hence, you must not!
Indicates a mandatory action. Hence, you must!
Requirement /
Note / Remark
Best Practice
Indicates an imminent hazardous situation. If not
avoided, it will result in death or serious in jury.
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.
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.
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
OMNI-BLOK®
SMD NANO2®
Pentium® © Intel Corporation, USA-Santa Clara, CA
Windows® © Microsoft Corporation, USA-Redmond, WA
Table 1-3 Brand Names and Trademark Owners
Material
Damage
© Littelfuse, USA-Chicago, IL
Indicates information particular to possible damage
of the equipment.
maxon motor control
1-6 Document ID: rel7050 EPOS2 Positioning Controller
Edition: May 2017 EPOS2 Module 36/2 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
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
maxon motor control
EPOS2 Positioning Controller Document ID: rel7050
EPOS2 Module 36/2 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
1-7
About this Document
••page intentionally left blank••
maxon motor control
1-8 Document ID: rel7050 EPOS2 Positioning Controller
Edition: May 2017 EPOS2 Module 36/2 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
2Introduction
The present document provides you with information on the EPOS2 Module 36/2 Positioning Controller’s hardware. It contains…
• performance data and specifications,
• information on connections and pin assignment and
• wiring examples.
maxon motor control’s EPOS2 Module 36/2 is a small-sized, full digital, smart motion controller. It is designated for the use as plug-in module in customer-specific motherboards for single axis or multi axes
motion control systems. Due to its flexible and high efficient power stage, the EPOS2 Module 36/2
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 Module 36/2 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 (external transceiver necessary) or RS232 interface.
Find the latest edition of the present document, as well as additional documentation and software to the
EPOS2 Module 36/2 Positioning Controller also on the Internet: www.maxonmotor.com
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
maxon motor control
EPOS2 Positioning Controller Document ID: rel7050
EPOS2 Module 36/2 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
2-9
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 1-6 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 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 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 11…36 VDC.
• Supply voltages above 40 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.
maxon motor control
2-10 Document ID: rel7050 EPOS2 Positioning Controller
Edition: May 2017 EPOS2 Module 36/2 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
3Technical Data
3.1 Electrical Data
Rating
Nominal power supply voltage V
Nominal logic supply voltage VC (optional)
Absolute minimum supply voltage 10 VDC
Absolute max. supply voltage 40 VDC
Max. output voltage
Max. output current I
Continuous output current I
Switching frequency 50 kHz
Max. efficiency 93%
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) 25 000 rpm
Max. speed @ block commutation (motors with 1 pole pair) 100 000 rpm
Built-in motor choke per phase 10 μH / 2 A
Table 3-4 Electrical Data – Rating
max
(<1sec)
cont
CC
11…36 VDC
11…36 VDC
0.9 • V
CC
4 A
2 A
Inputs
Hall sensor 1, Hall sensor 2 and Hall sensor 3
Hall sensor signals
Encoder signals
Digital Input 1 (“General Purpose”) +3…+36 VDC (Ri = 12 kΩ)
Digital Input 2 (“General Purpose”) +3…+36 VDC (Ri = 12 kΩ)
Digital Input 3 (“General Purpose”) +3…+36 VDC (Ri = 12 kΩ)
Digital Input 4 (“General Purpose”) +3…+36 VDC (Ri = 12 kΩ)
Digital Input 7 (“High Speed Command”) internal line receiver EIA RS422 Standard
Digital Input 8 (“High Speed Command”) internal line receiver EIA RS422 Standard
Analog Input 1 resolution 11-bit 0…+5 V (Ri = 34 kΩ)
Analog Input 2 resolution 11-bit 0…+5 V (Ri = 34 kΩ)
CAN ID (CAN identification) ID 1…127 configurable by external wiring
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 1 (“General Purpose”), open collector
Digital Output 2 (“General Purpose”), open collector
Digital Output 5 (“High Speed Command”), push-pull
max. 36 VDC (IL <50 mA)
max. 36 VDC (IL <50 mA)
max. 3.3 VDC (IL <10 mA)
Table 3-6 Electrical Data – Outputs
maxon motor control
EPOS2 Positioning Controller Document ID: rel7050
EPOS2 Module 36/2 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
3-11
Technical Data
Mechanical Data
Voltage Outputs
Encoder supply voltage
Hall sensors supply voltage
+5 VDC (IL <100 mA)
+5 VDC (IL <30 mA)
Table 3-7 Electrical Data – Voltage Outputs
Motor Connections
maxon EC motor maxon DC motor
Motor winding 1 + Motor
Motor winding 2 − Motor
Motor winding 3
Table 3-8 Electrical Data – Motor Connections
Interfaces
RS232 RxD; TxD max. 115 200 bit/s
USB 2.0 /
USB 3.0
CAN CAN_H (high); CAN_L (low) max.1 Mbit/s
external transceiver necessary
Table 3-9 Electrical Data – Interfaces
Status Indicators
Operation green LED
Error red LED
Table 3-10 Electrical Data – LEDs
Connections
On board:
Suitable plug:
Suitable retainer:
Table 3-11 Electrical Data – Connections
3.2 Mechanical Data
Mechanical Data
Weight approx. 10 g
Dimensions (L x W x H) 54.5 x 28.2 x 9 mm
Mounting
Card edge connector
PCI Express (PCIe) Connector 2x32 Pin vertical or horizontal, 1 mm pitch
Tyco 2-1775801-1 (vertical) / Tyco 1761465-2 (horizontal)
FCI 10018783-11111TLF (vertical)
Meritec 983172-064-2MMF (horizontal)
FCI PCI express retainer, blue, 10042618-002LF
pluggable card edge connector
with optional PCB support brackets
Table 3-12 Mechanical Data
maxon motor control
3-12 Document ID: rel7050 EPOS2 Positioning Controller
Edition: May 2017 EPOS2 Module 36/2 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
3.3 Dimensional Drawings
VERTICAL CONNECTOR
Figure 3-2 Dimensional Drawing (with vertical Connector) [mm]
H
ORIZONTAL CONNECTOR
Figure 3-3 Dimensional Drawing (with horizontal connector Meritec 983172-064-2MMF) [mm]
ETAINER
R
Figure 3-4 Footprint of Retainer (Meritec 983172-064-2MMF connector) [mm]
maxon motor control
EPOS2 Positioning Controller Document ID: rel7050
EPOS2 Module 36/2 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
3-13
Technical Data
Environmental Conditions
3.4 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
(declination of output current I
Operation −10…+45 °C
Extended Range
Storage −40…+85 °C
Operation 0…6’000 m MSL
Extended Range
) as to the stated values will apply.
cont
*1)
*1)
+45…+75 °C / Derating: Figure 3-5
6’000…10’000 m MSL / Derating: Figure 3-5
Figure 3-5 Derating Output Current
3.5 Order Details
Order Details
EPOS2 Module 36/2 Order number 360665
Table 3-14 Order Details
Accessories
EPOS2 Module Evaluation Board Order number 361435
EPOS2 Module Starter Kit
(including EPOS2 Module 36/2, EPOS2 Module
Evaluation Board and necessary cables)
Table 3-15 Accessories
Note
Accessories are not part of the delivery. You will need to order them separately.
Order number 363407
maxon motor control
3-14 Document ID: rel7050 EPOS2 Positioning Controller
Edition: May 2017 EPOS2 Module 36/2 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
3.6 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 ±1 kV/±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 1.05 g
rms
)
Safety Standards UL File Number E172472 or E92481; unassembled printed circuit board
Reliability prediction of electronic equipment
Environment: Ground, benign
Reliability MIL-HDBK-217F
Ambient temperature: 298 K (25 °C)
Component stress: In accordance with circuit diagram and
nominal power
Mean Time Between Failures (MTBF): 610'435 hours
Table 3-16 Standards
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Technical Data
Standards
••page intentionally left blank••
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4 Connections
Figure 4-6 EPOS2 Module 36/2 – PCB with Connector Array
4.1 Pin Assignment
ARRAY A
Pin Signal Description
A1 Power_GND Ground of supply voltage
A2
A4
A5
A6 Power_GND Ground of supply voltage
A7 Hall sensor 1 Hall sensor 1 input
A8 Hall sensor 2 Hall sensor 2 input
A9 Hall sensor 3 Hall sensor 3 input
A10
A11 GND
A12 Channel A Encoder channel A
A13 Channel A\ Encoder channel A complement
A14 Channel B Encoder channel B
A15 Channel B\ Encoder channel B complement
A16 Channel I Encoder index
A17 Channel I\ Encoder index complement
A18 GND Ground of analog inputs
A19 AnIN1 Analog Input 1
A20 AnIN2 Analog Input 2
A21 GND Ground of digital output
A22 DigOUT5 Digital Output 5
A23 not connected
A24 EPOS SCI RTS Serial communication interface handshake
A25 EPOS SCI RxD Serial communication interface receive
A26 EPOS SCI TxD Serial communication interface transmit
A27 EPOS RxD EPOS RS232 receive
A28 EPOS TxD EPOS RS232 transmit
A29 GND Ground of SCI and RS232
V
V
V
V
+V
+V
CC
CC
CC
C
aux
DDin
Power supply voltage +0…+36 VDCA3
Logic supply voltage 11…36 VDC (optional)
Auxiliary voltage output +5 VDC
Auxiliary supply voltage input +5 VDC (optional)
Ground of Hall sensor supply and
Ground of encoder supply
*1)
*1)
*1)
*2)
*2)
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Connections
Pin Assignment
Pin Signal Description
A30 CAN low CAN low bus line
A31 CAN high CAN high bus line
A32 GND Ground of CAN bus
Note
*1) Voltage level “low” = 0V, “high” = 3.3V, connected directly to the DSP
*2) EIA RS232 Standard
Table 4-17 EPOS2 Module 36/2 – Pin Assignment Array A
RRAY B
A
Pin Signal Description
B1 Power_GND Ground of supply voltage
B2
B3
B4
B5
B6
B7
B8
B9
B10
EC: Motor winding 1
DC: Motor +
EC: Motor winding 1
DC: Motor +
EC: Motor winding 1
DC: Motor +
EC: Motor winding 2
DC: Motor −
EC: Motor winding 2
DC: Motor −
EC: Motor winding 2
DC: Motor −
EC: Motor winding 3
DC: not connected
EC: Motor winding 3
DC: not connected
EC: Motor winding 3
DC: not connected
EC motor: Motor winding 1
DC motor: Motor +
EC motor: Motor winding 2
DC motor: Motor −
EC motor: Motor winding 3
DC motor: not connected
B11 Power_GND Ground of supply voltage
B12 GND Ground of digital input
B13 DigIN1 Digital Input 1
B14 DigIN2 Digital Input 2
B15 DigIN3 Digital Input 3
B16 DigIN4 Digital Input 4
B17 GND Ground of digital input
B18 DigIN7 Digital Input 7 “High Speed Command”
B19 DigIN7\ Digital Input 7 “High Speed Command” complement
B20 DigIN8 Digital Input 8 “High Speed Command”
B21 DigIN8\ Digital Input 8 “High Speed Command” complement
B22 DigOUT1 Digital Output 1
B23 DigOUT2 Digital Output 2
B24 GND Ground of CAN ID setting
B25 CAN ID 1 CAN ID 1 (valence = 1)
B26 CAN ID 2 CAN ID 2 (valence = 2)
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Pin Signal Description
B27 CAN ID 3 CAN ID 3 (valence = 4)
B28 CAN ID 4 CAN ID 4 (valence = 8)
B29 CAN ID 5 CAN ID 5 (valence = 16)
B30 CAN ID 6 CAN ID 6 (valence = 32)
B31 CAN ID 7 CAN ID 7 (valence = 64)
B32 Auto bit rate Automatic bit rate detection of CAN bus
Table 4-18 EPOS2 Module 36/2 – Pin Assignment Array B
4.2 Minimum external Wiring
Figure 4-7 Minimum external Wiring
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4-19
Connections
V
CC
U
N
n
O
-------
n
B
Δn
ΔM
-------- -
MB⋅+
1
0.9
-------
⋅⋅ 1 V[]+=
Power Supply
4.3 Power Supply
Best Practice
Keep the motor mechanically disconnected during setup and adjustment phase.
External Protection
Supply voltages above 40 VDC will destroy the unit.
To prevent damage to the EPOS2 Module 36/2, we recommend to install two upstream fuses – a tran-
sient voltage suppressor diode (TVS diode) and a capacitor in the power supply voltage line (for details
chapter “5.1.2 Power Supply Voltage” on page 5-37).
4.3.1 Determination 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
Output current Depending on load (continuous max. 2 A / acceleration, short-time max. 4 A <1 s)
VCC min. 11 VDC; VCC max. 36 VDC
min. 0 V (VCC below 11 V is only possible with separate logic supply voltage!) /
max. 40 VDC
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 Module 36/2 into account):
NOWN VALUES:
K
• Operating torque MB [mNm]
• Operating speed n
• Nominal motor voltage U
• Motor no-load speed at U
• Speed/torque gradient of the motor Δn/ΔM [min
OUGHT VALUE:
S
• Supply voltage V
S
OLUTION:
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 or shunt regulator (309687).
b) When using an electronically stabilized power supply, observe that the overcurrent protec-
tion must not be activated in any operating state.
[min−1]
B
[Volt]
CC
[Volt]
N
, n0 [min−1]
N
−1
mNm−1]
Pin Signal Description
A1/6
B1/11
A2/3/4
Limited Current Rating per Pin
Due to the limited current rating per pin (1.1 A), you must connect all pins!
Power_Gnd Ground of supply voltage
V
CC
Power supply voltage +11…+36 VDC
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Edition: May 2017 EPOS2 Module 36/2 Hardware Reference
4.3.2 Use of separate Logic Supply (optional)
By default, the logic must be powered by (connected to) the regular supply voltage. Optionally, you may
wish to feed the logic supply voltage separately, permitting a safe and economical power backup feature. For connection chapter “4.2 Minimum external Wiring” on page 4-19).
External Protection
Supply voltages above 40 VDC will destroy the unit.
To prevent damage to the EPOS2 Module 36/2, we recommend to install two upstream fuses – a tran-
sient voltage suppressor diode (TVS diode) and a capacitor in the power supply voltage line (for details
chapter “5.1.2 Power Supply Voltage” on page 5-37).
Basically, any power supply may be used, provided it meets below stated minimal requirements.
Logic Power Supply Requirements
Output voltage
Absolute output voltage min. 9 VDC; max. 40 VDC
Min. output power
Pin Signal Description
A1/6
B1/11
A5
Power_Gnd Ground of supply voltage
V
C
VC min. 11 VDC; VC max. 36 VDC
PC min. 3 W
Logic supply voltage +11…+36 VDC
4.3.3 Low Supply Voltage Operation (optional)
For low voltage applications, you may supply the power stage separately with voltages lower than +11V.
PPLICATION EXAMPLE:
A
Operation with a Li-Ion battery 3.6 V:
• Power supply voltage direct via accumulator.
• An external step-up converter produces 5 V for logic supply voltage.
The low supply voltage operation for logic and power supply is possible, as long as the following conditions are met (for further details chapter “5.3.4 Wiring Example: Low Supply Voltage Operation” on
page 5-44):
• Supply the logic part via +V
• Supply the power part via V
(pin A10). The voltage range must be 4.75…5.25 V.
DDin
(pins A2, A3 and A4). The voltage range must be 0…40 V.
CC
• Deactivate undervoltage control using «EPOS Studio». Do so by opening the Object Dictionary
and set the object with Index 0x2008 (Miscellaneous Configuration) to 32 (decimal format).
Best Practice
We strongly recommend to use separate voltage supplies for logic part and power part.
• Using a common supply, it will be very difficult to maintain the logic voltage range condition
(4.75…5.25 V).
• Voltage drops during acceleration, as well as the fed back energy during breaking may cause signifi-
cant voltage variations on the power supply voltage.
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Connections
Motor Connection
Following requirements must be met:
Supply Voltage Requirements
Output voltage
Absolute output voltage min. 4.75 VDC; max. 5.25 VDC
Power Supply Requirements
Output voltage
Absolute output voltage min. 0 V / max. 40 VDC
Pin Signal Description
A1/6
B1/11
A2/3/4
A10
Power_Gnd Ground of supply voltage
V
CC
+V
DD
VDD +5 VDC
VCC min. 0 VDC; max. 36 VDC
Power supply voltage 0…+36 VDC
+5 V voltage supply
Limited Current Rating per Pin
Due to the limited current rating per pin (1.1 A), you must connect all pins!
4.4 Motor Connection
Limited Current Rating per Pin
Due to the limited current rating per pin (1.1 A), you must connect all pins!
4.4.1 maxon EC motor (brushless)
Pin Signal Description
B2/3/4 Motor winding 1 EC motor: Winding 1
B5/6/7 Motor winding 2 EC motor: Winding 2
B8/9/10 Motor winding 3 EC motor: Winding 3
4.4.2 maxon DC motor (brushed)
Pin Signal Description
B2/3/4 Motor (+M) DC motor: Motor +
B5/6/7 Motor (−M) DC motor: Motor −
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4.5 Hall Sensor Connection
Hall sensors are required to detect the rotor position of maxon EC motors (brushless).
Suitable Hall effect sensors IC use «Schmitt trigger» with open collector output.
Hall sensor supply voltage +5 VDC
Max. Hall sensor supply current 30 mA
Input voltage 0…+24 VDC
Logic 0 typical <0.8 VDC
Logic 1 typical >2.4 VDC
Internal pull-up resistor 2.7 kΩ (against +5 VDC)
Figure 4-8 Hall Sensor Input Circuit
Pin Signal Description
A7 Hall sensor 1 Hall sensor 1 Input
A8 Hall sensor 2 Hall sensor 2 Input
A9 Hall sensor 3 Hall sensor 3 Input
A10
A11 GND Ground of Hall sensor/encoder supply
+V
aux
Auxiliary output voltage for Hall sensors and encoder +5 VDC
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Connections
Encoder Connection
4.6 Encoder Connection
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 4-9 Encoder Input Circuit
Pin Signal Description
A10
A11 GND Ground of Hall sensor/encoder supply
A12 Channel A Channel A
A13 Channel A\ Channel A complement
A14 Channel B Channel B
A15 Channel B\ Channel B complement
A16 Channel I Index
A17 Channel I\ Index complement
+V
aux
Auxiliary output voltage for Hall sensors and encoder +5 VDC
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4.7 Digital Input Connection
Contains four smart multi-purpose digital inputs configurable as “Positive Limit Switch”, “Negative Limit
Switch”, “Home Switch” and “General Purpose”.
Additionally offered are two “High Speed Command” inputs.
4.7.1 Digital Inputs 1, 2, 3 and 4
By default, the digital input is defined as “General Purpose” and may be configured via software.
DigIN1 “General Purpose”
DigIN2 “Home Switch”
DigIN3 “Positive Limit Switch”
DigIN4 “Negative Limit Switch”
GND
Type of input single-ended
Input voltage 0…36 VDC
Max. input voltage ±36 VDC
Logic 0
Logic 1
Input resistance
Input current at logic 1 typical 270 µA @ 5 VDC
Switching delay <300 µs
Pin [B13]
Pin [B14]
Pin [B15]
Pin [B16]
Pin [B12]
Uin <0.8 VDC
Uin >2.0 VDC
typical 22 kΩ (<3.3 V)
typical 18 kΩ (@ 5 V)
typical 12 kΩ (@ 24 V)
Figure 4-10 DigIN1 Circuit (analogously valid also for DigIN2…4)
For wiring examples page 4-26.
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Connections
R
ext
RINVSVIN–()⋅
V
IN
-------------------------------------- -
=
Digital Input Connection
WIRING EXAMPLE: “PROXIMITY SWITCH TYPE PNP 3-WIRE MODEL”
Figure 4-11 DigIN2 – Wiring Example for Type PNP Proximity Switch
W
IRING EXAMPLE: “SLOTTED OPTICAL SENSOR”
Figure 4-12 DigIN2 – Wiring Example for slotted optical Sensor
Note
Logic level threshold VIN assumed to be 5 V.
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4.7.2 Digital Inputs 7 and 8
The “High Speed Command” differential inputs are set by default and may be configured via software.
Differential
DigIN7 “High Speed Command”
DigIN8 “High Speed Command”
Min. differential input voltage ±200 mV
Line receiver (internal) EIA RS422 Standard
Max. input frequency 5 MHz
Pins [B18] / [B19]
Pins [B20] / [B21]
Figure 4-13 DigIN7 “Differential” Circuit (analogously valid also for DigIN8)
Single-ended
DigIN7 “High Speed Command”
DigIN8 “High Speed Command”
Input voltage 0…5 VDC
Max. input voltage −7.5…+12.5 VDC
Logic 0 <0.8 V
Logic 1 >2.0 V
Input resistance typical 20 kΩ (referenced to D_GND)
Max. input frequency 2.5 MHz
Pins [B18]
Pins [B20]
Note
Do not connect DigIN’s complements!
Figure 4-14 DigIN7 “Single-ended” Circuit (analogously valid also for DigIN8)
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Connections
Analog Input Connection
4.8 Analog Input Connection
4.8.1 Analog Inputs 1 and 2
By default, the analog inputs are defined as “General Purpose” and may be configured via software.
AnIN1 “General Purpose”
AnIN2 “General Purpose”
GND
Input voltage 0…5 VDC
Max. input voltage 0…10 VDC
Input resistance typical 34 kΩ (referenced to GND)
Resolution 2.49 mV
Bandwidth 250 Hz
Pin [A19]
Pin [A20]
Pin [A18]
Figure 4-15 AnIN1 Circuit (analogously valid also for AnIN2)
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4.9 Digital Output Connection
Contains two “General Purpose” open collector (5 V) and one “High speed” push-pull (3.3 V) digital outputs.
4.9.1 Digital Outputs 1 and 2
By default, the digital outputs are defined as “General Purpose” and may be configured via software.
DigOUT1
DigOUT2
GND
Circuit
Switching delay <3 µs
Pin [B22]
Pin [B23]
Pin [A21]
Open collector (internal pull-up resistor 2k2 and
diode to +5 VDC
Figure 4-16 DigOUT1 Circuit (analogously valid also for DigOUT2)
DigOUT “Sinks”
Max. input voltage +36 VDC
Max. load current 50 mA
Max. voltage drop <1.0 V @ 50 mA
Figure 4-17 DigOUT1 “Sinks” Circuit (analogously valid also for DigOUT2)
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Connections
Digital Output Connection
Output voltage
Max. load current
Figure 4-18 DigOUT1 “Source” Circuit (analogously valid also for DigOUT2)
DigOUT “Source”
U
≈5 V − 0.75 V − (I
out
I
≤2 mA
load
× 2200 Ω)
load
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4.9.2 Digital Output 5
The digital output is defined as “High Speed” and may be configured via software.
DigOUT5
GND
Pin [A22]
Pin [A21]
Circuit Push-pull stage
Switching delay <10 ns
Figure 4-19 DigOUT5 Circuit
DigOUT “Sinks”
Max. input voltage
Max. load current
Max. voltage drop
Uin ≤3.3 VDC
I
≤24 mA
max
U
<0.55 V + (I
drop
x 100 Ω)
max
Figure 4-20 DigOUT5 “Sinks” Circuit
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Connections
RS232 Connection
Output voltage
Max. load current
Figure 4-21 DigOUT5 “Source” Circuit
4.10 RS232 Connection
The EPOS2 Module 36/2 can be configured via RS232 communication port. The software «EPOS Studio» provides a graphical user interface to setup all features via the PC’s serial port.
DigOUT “Source”
U
≈3.3 V − 0.75 V − (I
out
I
≤24 mA
load
× 100 Ω)
load
Max. input voltage ±30 V
Output voltage typical ±9 V @ 3 kΩ to Ground
Max. bit rate 115 200 bit/s
Internal RS232 driver/receiver EIA RS232 Standard
Note
• Consider your PC's serial port maximal baud rate.
• The standard baud rate setting (factory setting) is 115'200 bauds.
ONNECTION OF POSITIONING CONTROLLER TO PC
C
EPOS2 Module 36/2 PC Interface (RS232), DIN41652
Pin [A27] “EPOS RxD” Pin 3 “PC TxD”
Pin [A28] “EPOS TxD” Pin 2 “PC RxD”
Pin [A29] “GND” Pin 5 “GND”
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4.11 SCI Interface Connection
The serial communications interface (SCI) is a two-wire asynchronous serial port, commonly known as a
UART. The SCI modules support digital communication between the CPU and other asynchronous
peripherals that use the standard non-return-to-zero (NRZ) format.
As a common application for EPOS2 Module 36/2’s SCI interface, it can be wired to an USB-to-UART
converter to built an USB interface. For further details chapter “5.1.6 USB” on page 5-40.
Max. input voltage 3.3 VDC
High-level input voltage >2.0 VDC
Low-level input voltage <0.8 VDC
High-level output voltage >2.4 VDC
Low-level output voltage <0.4 VDC
Bit rate 1 Mbit/s
Data format NRZ (non-return-to-zero)
Pin Signal Description
A24 DSP_RTS2 Serial communication interface handshake
A25 DSP_RxD2 Serial communication interface receive
A26 DSP_TxD2 Serial communication interface transmit
A29 GND Ground
4.12 CAN Connection
The EPOS2 Module 36/2 is specially designed being commanded and controlled via a Controller Area
Network (CAN), an highly efficient data bus, very common in all fields of automation and motion control.
The EPOS2 Module 36/2 is preferably used as a slave node in the CANopen network.
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 by external wiring or software
Pin Signal Description
A30 CAN_L CAN low bus line
A31 CAN_H CAN high bus line
A32 GND Ground
Note
• Consider CAN Master’s maximal baud rate.
• The standard baud rate setting (factory setting) is “Auto Bit Rate”.
• Use 120
• For detailed CAN information separate document «EPOS2 Communication Guide».
Ω
termination resistor at both ends of the CAN bus.
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Connections
CAN Configuration
4.13 CAN Configuration
4.13.1 CAN ID (Node Address)
The CAN ID is set with input lines CAN ID1…CAN ID7. Addresses (1…127) may be coded using binary
code.
Logic 1 typical <0.8 VDC
Logic 0 typical >2.4 VDC
Internal pull-up resistor 4.7 kΩ (against +3.3 VDC)
Figure 4-22 CAN ID Input Circuit
Pin Signal Description Binary Code Valence
B24 GND Ground for CAN ID settings – –
B25 CANID1 CAN ID 1 2
B26 CANID2 CAN ID 2 2
B27 CANID3 CAN ID 3 2
B28 CANID4 CAN ID 4 2
B29 CANID5 CAN ID 5 2
B30 CANID6 CAN ID 6 2
B31 CANID7 CAN ID 7 2
0
1
2
3
4
5
6
1
2
4
8
16
32
64
Table 4-19 CAN ID – Binary Code Values
The set CAN ID (node address) can be observed by adding the valences of all inputs connected externally to GND.
XAMPLES:
E
Use following table as a (non-concluding) guide:
CAN ID/Switch 1234567
Valence 1 2 4 8 16 32 64
CAN ID Calculation
1 1*0**00000 1
2 0100000 2
32 0000010 32
35 1100010 1 + 2 + 32
127 1 1 1 1 1 1 1 1 + 2 + 4 + 8 + 16 + 32 + 64
Legend:
* 1 = CAN ID input line externally connected to GND
** 0 = CAN ID input line open or externally connected to +3.3 VDC
Table 4-20 CAN ID – Examples
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Note
The Node ID set by software is valid, if CAN ID is set “0” (all CAN ID input lines open or externally connected to +3.3 VDC).
4.13.2 CAN automatic Bit Rate Detection
By using this function, the CANopen interface can be put in a “listen only” mode. For further details
separate document «EPOS2 Firmware Specification».
The automatic bit rate detection is activated when the input line is connected externally to GND.
Auto Bit Rate
GND
Logic 0 typical <0.8 VDC
Logic 1 typical >2.4 VDC
Internal pull-up resistor 4.7 kΩ (against +3.3 VDC)
Pin [B32]
Pin [B24]
Figure 4-23 CAN automatic Bit Rate Detection Circuit
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Connections
Status LEDs
4.14 Status LEDs
The LEDs display the current status of the EPOS2 Module 36/2, as well as possible errors:
For detailed information separate document «EPOS2 Firmware Specification».
• Green LED shows the operating status
• Red LED indicates errors
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 4-21 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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5 Motherboard Design Guide
The «Motherboard Design Guide» provides helpful information on the implementation of the EPOS2
Module 36/2 into an electronics board. It contains external component requirements, routing instructions, pin assignment, mechanical dimensions and wiring examples.
CAUTION
Hazardous
Incorrect Design can lead to serious injuries!
• Do not further proceed if you are not familiar with electronic design!
• Designing an electronic board requires specific skills and must only be performed by experienced
electronic engineers!
• This short guide must only be considered as a help and does not by itself lead to a working design!
Get assistance:
If you are not familiar with electronic design, you might wish to seek assistance.
maxon motor ag’s specialists will be glad to offer you a customized motherboard design that suits your
particular application.
5.1 Requirements for external Components
For correct and save function of the EPOS2 Module 36/2, the following external components will be
required. Function and key data of each component is noted and completed with examples.
5.1.1 Card Edge Connector
The EPOS2 Module 36/2 is designed to plug into a card edge connector that is mounted on an application-specific PCB. This connector must be a 2x32 way vertical or horizontal type with at rated current per
pin of at least 1 A. In case of high vibration in your application, the EPOS2 Module 36/2 must be locked
with an additional PCB retainer (for details and references “Connections” on page 3-12.
5.1.2 Power Supply Voltage
Due to limited current rating of 1.1 A per pin, all pins of the power supply voltage V
To protect the module from damage, two fuses – a transient voltage suppressor diode (TVS diode) and
a capacitor in the power supply voltage line – are recommended.
Figure 5-24 Recommended Protection for Power Supply
must be connected.
CC
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Motherboard Design Guide
Requirements for external Components
5.1.2.1 Capacitor C1
An external capacitor is not mandatory for the function of the module, but – during braking of the load –
the power supply must be capable to buffer the fed back energy. Hence, connect an electrolytic capacitor to the power supply voltage. The capacity needed depends on the following items:
• Power supply voltage
• Speed at the beginning of the braking
• Total mass inertia
• Deceleration rate
• Number of modules
For recommended types (supplying one EPOS2 Module 36/2) “Supplier Reference” on page 5-39.
5.1.2.2 Fuse FU1
Place a fuse at the power supply’s entry to protect against reverse polarity. Together with the TVS
diode, the fuse breaks an occurring reverse current. The continuous current of the fuse depends on the
number of modules supplied and how much current each module needs. For recommended types
“Supplier Reference” on page 5-39.
5.1.2.3 Fuse FU2
For protection against short circuit of the motor winding connections, it is recommended to place additionally one fuse per module. The fuse must withstand 2 A continuously and 4 A during 5 seconds with a
2
typical melt I
t smaller than 0.05 A2s. For recommended types “Supplier Reference” on page 5-39.
5.1.2.4 TVS Diode D1
To protect against overvoltage due to supply transients or the braking energy, connect a transient voltage suppressor diode to the power supply voltage. For recommended types “Supplier Reference” on
page 5-39.
5.1.3 Logic Supply Voltage
The EPOS2 Module 36/2 features a logic supply voltage input and a +V
output. The logic supply volt-
aux
age input has a voltage range of 9…40 V and can be sourced separately or by the power supply voltage
(chapter “4.2 Minimum external Wiring” on page 4-19).
• If the logic supply voltage is sourced, the +V
can be used as +5 VDC supply output for Hall
aux
sensors and encoder.
• If the logic supply voltage is sourced separately, a transient voltage suppressor diode at the
logic supply voltage input can be connected to protect the module against overvoltage. For references on the TVS diode “Supplier Reference” on page 5-39.
maxon motor control
5-38 Document ID: rel7050 EPOS2 Positioning Controller
Edition: May 2017 EPOS2 Module 36/2 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
5.1.4 Motor Phase
L
ext
V
cc
6 INf
pwm
⋅⋅
----------------------------
L
int
0.3 L
mot
⋅()–()–=
L
extVcc
INf
pwmLint
L
mot
L
ext
0≤
L
ext
0>
The EPOS2 Module 36/2 features a built-in choke of 10 μH per phase. For most motors and applications
this will be sufficient. In case of high power supply voltage and for motors with very low inductance, the
current ripple will become too high thus, requiring additional chokes on the motherboard.
The minimum inductance of each choke can be calculated as to below formula.
• If the result is negative, no additional chokes will be needed.
• If the result is positive, additional chokes will be required.
The chokes must have an electromagnetic shield, high saturation current, low losses and a
rated current higher than the continuous motor current. For recommended types “Supplier
Reference” on page 5-39.
[H]
[V]
[A]
[Hz]
[H]
[H]
External inductance per phase
Power supply voltage
Nominal motor current (consult maxon catalog for applicable data)
PWM frequency = 50000 Hz
EPOS2 Module 36/2’s built-in inductance per phase = 10
Terminal inductance phase to phases of the motor
No additional motor choke necessary
Additional motor choke recommended
5.1.5 Supplier Reference Recommended Components
Panasonic (EEUFC1H221)
C=220 uF / UDC=50 V / IAC=1030 mA @ 100kHz, low impedance /
T=−55…105 °C
Capacitor C1
Rubicon (50ZL220M10X16)
C=220 uF / U
T=−55…105 °C
Littelfuse, 154 Series OMNI-BLOK fuse holder with SMD NANO2 fuse installed.
Fuse FU1
– 3 A very fast-acting (154003) when employing 1 EPOS2 Module 36/2
– 5 A very fast-acting (154005) when employing 2 EPOS2 Module 36/2
– 10 A very fast-acting (154010) when employing 4 EPOS2 Module 36/2
Fuse FU2
Bussmann, 3216FF Series (3216FF-2A), fast-acting, 2 A
Wickmann, SMD 0805 Series (FCD081200), quick-acting, 2 A
Vishay (SMBJ43A)
TVS diode D1
Motor choke
Diotec(P6KE51A)
=43 V / UBR=47.8…52.8 V @ 1 m A / UC=69.4 V @ 8.6 A
U
R
Würth Elektronik, WE-PD-XXL (7447709101)
LN=100 μH / RDC=100 mΩ / IDC=2.5 A / I
−5
H
=50 V / IAC=1370 mA @ 100kHz, low impedance /
DC
= 3.1A, shielded
sat
Table 5-22 Recommended Components
maxon motor control
EPOS2 Positioning Controller Document ID: rel7050
EPOS2 Module 36/2 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
5-39
Motherboard Design Guide
Requirements for external Components
5.1.6 USB
5.1.6.1 General Requirements
USB offers an easy way to configure and command the EPOS2 Module 36/2. The module itself does not
possess an USB interface, but an USB to UART converter placed on the motherboard can be wired to
the module’s SCI interface pins. It will be sufficient to place only one USB converter on the motherboard.
The modules among themselves communicate via the CAN bus. For a schematic example of the USB to
UART converter chapter “5.3.3 USB Interface” on page 5-43.
5.1.6.2 USB to UART Converter Configuration
1) Connect the USB cable to an USB port of a PC.
2) Install and start the «EPOS Studio» software.
The provided USB driver supports only the USB to UART converter “FT232RQ” by FTDI. It
must be configured with FTDI’s utility software «MProg» before communication between
«EPOS Studio» and the EPOS2 Module 36/2 will be available.
3) Download and install «D2XX drivers» from www.ftdichip.com – category «Drivers» / category
«D2XX» / column «Comments» / link «setup executable».
4) Download and install «MProg» from www.ftdichip.com – category «Resources» / category «Util-
ities» / heading «MProg - EEPROM Programming Utility».
5) Connect FT232RQ with an USB cable to your computer. The FT232RQ will be powered via
USB.
6) Start the software utility «MProg» and click in menu “Tools” / “Read and Parse”. The default
configuration will be read-out and displayed.
7) Change values as follows:
Name Change from… …to
USB VID/PID FTDI Default FTDI Supplied PID
Product ID 6001 A8B0
Manufacturer FTDI maxon motor ag
Description FT232R USB UART maxon motor EPOS2
Check box “Load D2XX driver” ticked
Table 5-23 USB to UART Converter Configuration – Settings
8) Select menu “File” / “Save As…” and assign a name.
9) Select menu “Device” / “Program”.
10) The “Programmed Serial Number: …” will now be displayed in the text box at the bottom. Leave
this number unchanged.
11) Close «MProg» utility and disconnect the USB cable.
Now, the converter is configured and the communication between «EPOS Studio» and the EPOS2 Module 36/2 via USB is established.
maxon motor control
5-40 Document ID: rel7050 EPOS2 Positioning Controller
Edition: May 2017 EPOS2 Module 36/2 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
5.2 Design Rules
Follow below rules to design your application-specific motherboard and to provide correct and save
function of the EPOS2 Module 36/2.
Before continuing, make sure to consult the following sections:
5.2.1 Ground
The ground pins (GND) are internally connected, but each ground pin is assigned to a functional block.
It is common practice to place a ground plane on the motherboard and will be required to connect pins
A1, A6, B1 and B11 with thick tracks to the power supply voltage ground.The ground pins of each functional block are as follows:
Use Pin(s)… …to connect this Functional Block to Ground:
A1/6
B1/11
A11 Encoder
A18 Analog inputs
A21
B12/17
A29 USB and RS232
A32 CAN bus
B24 CAN ID settings
•For Pin Description chapter “4.1 Pin Assignment” on page 4-17.
•For Performance Data chapter “3 Technical Data” on page 3-11 and chapter “4.3.3 Low
Supply Voltage Operation (optional)” on page 4-21.
•For Dimensional Drawings chapter “3.3 Dimensional Drawings” on page 3-13.
Power supply voltage
Digital inputs and outputs
Table 5-24 Functional Blocks – Ground Connections
If ground safety earth is available, connect the ground plane over some parallel capacitors to the ground
safety earth. We recommend the use of capacitors with 47 nF and 100 V.
5.2.2 Communication Interfaces
•For RS232 chapter “4.10 RS232 Connection” on page 4-32.
•For CAN chapter “4.12 CAN Connection” on page 4-33.
5.2.3 I/Os
•For Digital inputs chapter “4.7 Digital Input Connection” on page 4-25.
•For Analog Inputs chapter “4.8 Analog Input Connection” on page 4-28.
•For Digital Outputs chapter “4.9 Digital Output Connection” on page 4-29.
maxon motor control
EPOS2 Positioning Controller Document ID: rel7050
EPOS2 Module 36/2 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
5-41
Motherboard Design Guide
Schematic Examples
5.2.4 Layout
Follow these rules:
• Connect pins A2, A3 and A4 (power supply voltage V
• Connect pins A1, A6, B1 and B11 (Power_GND) with thick tracks to the ground of supply voltage.
• Copper plating’s width and thickness of traces for power supply voltage and motor winding
depend on the maximum current expected in the application. We recommend a minimum width
of 50 mil at a thickness of 35 µm.
• Route fast signal wire pairs (encoder, differential inputs, CAN, USB) close to the return wire in
order to minimize the area of the loop enclosed by the corresponding current.
5.3 Schematic Examples
5.3.1 Minimum External Wiring
Logic supply is sourced by the power supply voltage. The EPOS2 Module 36/2 is configured by RS232.
For details chapter “4.2 Minimum external Wiring” on page 4-19.
5.3.2 Separate Logic Supply Voltage and CAN Communication
Power and logic supply voltage are sourced separately. The EPOS2 Module 36/2 is configured and
commanded by CAN.
) with a thick track to the fuse.
CC
Figure 5-25 Separate Logic Supply Voltage and CAN Communication – Wiring Diagram
maxon motor control
5-42 Document ID: rel7050 EPOS2 Positioning Controller
Edition: May 2017 EPOS2 Module 36/2 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
5.3.3 USB Interface
If an external USB to UART converter is connected to the EPOS SCI, the module can be configured and
commanded by a PC through USB.
Figure 5-26 USB Interface – Wiring Diagram
maxon motor control
EPOS2 Positioning Controller Document ID: rel7050
EPOS2 Module 36/2 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
5-43
Motherboard Design Guide
Schematic Examples
5.3.4 Wiring Example: Low Supply Voltage Operation
The power stage is powered separately with a voltage between 0 and 36 VDC. The logic part must be
supplied with +5 VDC connected to V
supply voltage by an appropriate voltage converter (step-up-converter or step-down-converter).
It is recommended to use this operation mode only with power supply voltages below 11 VDC.
. As a possibility, this voltage can be produced out of the power
DDin
Figure 5-27 Low Supply Voltage Operation – Wiring Diagram
maxon motor control
5-44 Document ID: rel7050 EPOS2 Positioning Controller
Edition: May 2017 EPOS2 Module 36/2 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
5.3.5 Wiring Example: Two Axes with RS232 to CAN Gateway
The logic supply is sourced by the power supply voltage and the module is configured by RS232.
Both modules are configured and commanded by a PC via RS232. The upper module is used as RS232
to CAN gateway. Further modules can be connected and commanded to the CAN bus accordingly.
Figure 5-28 Two Axes with RS232 to CAN Gateway – Wiring Diagram
maxon motor control
EPOS2 Positioning Controller Document ID: rel7050
EPOS2 Module 36/2 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
5-45
Motherboard Design Guide
Schematic Examples
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5-46 Document ID: rel7050 EPOS2 Positioning Controller
Edition: May 2017 EPOS2 Module 36/2 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
LIST OF FIGURES
Figure 2-1 Documentation Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Figure 3-2 Dimensional Drawing (with vertical Connector) [mm] . . . . . . . . . . . . . . . . . . . . . . . . . .13
Figure 3-3 Dimensional Drawing (with horizontal connector Meritec 983172-064-2MMF) [mm] . .13
Figure 3-4 Footprint of Retainer (Meritec 983172-064-2MMF connector) [mm] . . . . . . . . . . . . . .13
Figure 3-5 Derating Output Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Figure 4-6 EPOS2 Module 36/2 – PCB with Connector Array . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Figure 4-7 Minimum external Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Figure 4-8 Hall Sensor Input Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Figure 4-9 Encoder Input Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Figure 4-10 DigIN1 Circuit (analogously valid also for DigIN2…4) . . . . . . . . . . . . . . . . . . . . . . . . .25
Figure 4-11 DigIN2 – Wiring Example for Type PNP Proximity Switch . . . . . . . . . . . . . . . . . . . . . .26
Figure 4-12 DigIN2 – Wiring Example for slotted optical Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Figure 4-13 DigIN7 “Differential” Circuit (analogously valid also for DigIN8) . . . . . . . . . . . . . . . . . .27
Figure 4-14 DigIN7 “Single-ended” Circuit (analogously valid also for DigIN8) . . . . . . . . . . . . . . . .27
Figure 4-15 AnIN1 Circuit (analogously valid also for AnIN2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Figure 4-16 DigOUT1 Circuit (analogously valid also for DigOUT2) . . . . . . . . . . . . . . . . . . . . . . . .29
Figure 4-17 DigOUT1 “Sinks” Circuit (analogously valid also for DigOUT2) . . . . . . . . . . . . . . . . . .29
Figure 4-18 DigOUT1 “Source” Circuit (analogously valid also for DigOUT2) . . . . . . . . . . . . . . . . .30
Figure 4-19 DigOUT5 Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Figure 4-20 DigOUT5 “Sinks” Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Figure 4-21 DigOUT5 “Source” Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Figure 4-22 CAN ID Input Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Figure 4-23 CAN automatic Bit Rate Detection Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Figure 5-24 Recommended Protection for Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Figure 5-25 Separate Logic Supply Voltage and CAN Communication – Wiring Diagram . . . . . . .42
Figure 5-26 USB Interface – Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Figure 5-27 Low Supply Voltage Operation – Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Figure 5-28 Two Axes with RS232 to CAN Gateway – Wiring Diagram . . . . . . . . . . . . . . . . . . . . .45
maxon motor control
EPOS2 Positioning Controller Document ID: rel7050
EPOS2 Module 36/2 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
Z-47
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Table 3-5 Electrical Data – Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Table 3-6 Electrical Data – Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Table 3-7 Electrical Data – Voltage Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Table 3-8 Electrical Data – Motor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Table 3-9 Electrical Data – Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Table 3-10 Electrical Data – LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Table 3-11 Electrical Data – Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Table 3-12 Mechanical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Table 3-13 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Table 3-14 Order Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Table 3-15 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Table 3-16 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Table 4-17 EPOS2 Module 36/2 – Pin Assignment Array A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Table 4-18 EPOS2 Module 36/2 – Pin Assignment Array B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Table 4-19 CAN ID – Binary Code Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Table 4-20 CAN ID – Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Table 4-21 LEDs – Interpretation of Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Table 5-22 Recommended Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Table 5-23 USB to UART Converter Configuration – Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Table 5-24 Functional Blocks – Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
maxon motor control
Z-48 Document ID: rel7050 EPOS2 Positioning Controller
Edition: May 2017 EPOS2 Module 36/2 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
INDEX
A
additionally applicable regulations 10
alerts
6
analog inputs
28
B
backup power 21
bit rate detection, automatic
35
C
C1 38
calculation of required supply voltage
CAN
example of communication
interface
RS232 to CAN gateway 45
CAN ID settings
choke
country-specific regulations
33
34
39
10
20
42
D
D1 38
digital inputs
digital outputs
25
29, 31
E
electrical data 11
environmental conditions, permitted
error display
ESD
10
example
2 axes with RS232 to CAN gateway
CAN communication
Low Supply Voltage Operation
separate Logic Supply Voltage
setting CAN IDs
USB interface
wiring proximity switches 26
36
42
34
43
14
45
44
42
F
FU1 38
FU2
38
H
how to
calculate minimum inductance
calculate required supply voltage
configure CAN ID 34
get help in designing the motherboard
get MProg
interpret icons (and signs) used in the document 6
40
39
20
37
I
informatory signs 6
intended purpose
interface
CAN
33
RS232 32
9
L
LEDs 36
M
mandatory action signs 6
mechanical data
motherboard, requirements
motor choke
12
37
39
N
Node Address, configuration 34
O
operating status, display 36
P
performance data 11
power backup
precautions
prohibitive signs
purpose
of the device
of this document
21
10
6
9
5
R
recommended components (suppliers) 39
regulations, additionally applicable
RS232
interface 32
to CAN gateway
rules for motherboard design
45
10
41
S
safety alerts 6
safety first!
SCI
interface
signs used
standards, fulfilled
status display
status LEDs
suppliers of recommended components
supply voltage, required
symbols used 6
10
33
6
15
36
36
39
20
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EPOS2 Positioning Controller Document ID: rel7050
EPOS2 Module 36/2 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
Z-49
T
technical data 11
U
UART 40
USB
example for interface
to UART converter 40
43
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© 2017 maxon motor. Subject to change without prior notice.
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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
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Z-52 Document ID: rel7050 EPOS2 Positioning Controller
Edition: May 2017 EPOS2 Module 36/2 Hardware Reference
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