maxon motor EPOS2 Module 36/2 Hardware Reference Manual

Brand: maxon motor

Model: EPOS2 Module 36/2

Type: Hardware Reference Manual

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

Edition November 2018

EPOS2 Positioning Controller

Hardware Reference

maxon motor control

Hardware Reference

Document ID: rel8458

maxon motor control

A-2 Document ID: rel8458 EPOS2 Positioning Controller

Edition: November 2018 EPOS2 Module 36/2 MoBo Hardware Reference

PLEASE READ THIS FIRST

These instructions are intended for qualified technical personnel. 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 – then go back and continue with

the task!

PREREQUISITES FOR PERMISSION TO COMMENCE INSTALLATION

The EPOS2 Motherboard 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!

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1 About this Document 5

2 Introduction 9

2.1 Documentation Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.3 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3 Motherboard (407582) 13

3.1 Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.1.1 Power Input Connector (J1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.1.2 Coils Output Connector (J2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.1.3 Hall Sensor Input Connector (J3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.1.4 Encoder Input Connector (J4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.1.5 Auxiliary I/O Connector (J5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.1.6 Auxiliary Bay Connector (J6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.1.7 VCC Board-to-Board Powerlink (J7a & J7b) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.1.8 GND Board-to-Board Powerlink (J8a & J8b) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.1.9 CAN Bus Connector (J9 & J10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.1.10 EPOS2 Module 36/2 Connector (J11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.1.11 DIP Switch Bank (Sw) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.2 Attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.2.1 CAN Jumper (Link1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.2.2 Motor+ Link (Link2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.2.3 Motor- Link (Link3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.2.4 Fuse (Fuse1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.2.5 Fuse (Fuse2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.3 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.3.1 Power LED (Pwr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.4 Dimensional Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4 Accessories 25

4.1 Extension Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.1.1 USB Module (407583) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.1.2 RS232 Module (407584) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.1.3 I/O Module (407585) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4.1.4 Dual Encoder Module (423536) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.2 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.2.1 Power Cable (423507) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.2.2 USB Type A - Crimp Cable (423526). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.2.3 RS232-COM Cable (423530). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

TABLE OF CONTENTS

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About this Document

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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 equip-

ment 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 con-

veys information on how to understand and fulfill the respective work and duties.

This document is a reference book. It does require particular knowledge and expertise specific to the

equipment described.

1.3 How to use

Take note of the following notations and codes which will be used throughout the document.

Table 1-1 Notations used in this Document

Notation Explanation

«Abcd» indicating a title or a name (such as of document, product, mode, etc.)

¤Abcd¤

indicating an action to be performed using a software control element

(such as folder, menu, drop-down menu, button, check box, etc.) or a

hardware element (such as switch, DIP switch, etc.)

(n) referring to an item (such as order number, list item, etc.)

 denotes “see”, “see also”, “take note of” or “go to”

About this Document

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1.4 Symbols and Signs

In the course of the present document, the following symbols and signs will be used.

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 conclud-

ing) are protected by copyright and/or other intellectual property rights even if their legal trademarks are

omitted in the later course of this document.

Table 1-3 Brand Names and Trademark Owners

Type Symbol Meaning

Safety Alert

(typical)

DANGER

Indicates an imminent hazardous situation. If not

avoided, it will result in death or serious injury.

WARNING

Indicates a potential hazardous situation. If not

avoided, it can result in death or serious injury.

CAUTION

Indicates a probable hazardous situation or calls

the attention to unsafe practices. If not avoided, it

may result in injury.

Prohibited

Action

(typical)

Indicates a dangerous action. Hence, you must not!

Mandatory

Action

(typical)

Indicates a mandatory action. Hence, you must!

Information

Requirement /

Note / Remark

Indicates an activity you must perform prior

continuing, or gives information on a particular item

you need to observe.

Best Practice

Indicates an advice or recommendation on the

easiest and best way to further proceed.

Material

Damage

Indicates information particular to possible damage

of the equipment.

Brand Name Trademark Owner

CANopen®

CiA®

Micro-Fit™

Mini-Fit™

About this Document

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1.6 Copyright

The present document – including all parts thereof – is protected by copyright. Any use (including repro-

duction, translation, microfilming and other means of electronic data processing) beyond the narrow

restrictions of the copyright law without the prior approval of maxon motor ag, is not permitted and sub-

ject to persecution under 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

About this Document

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Introduction

Documentation Structure

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2Introduction

The EPOS2 Motherboard (document identifier is “EPOS2 Module 36/2 MoBo”) offers a smart way to

connect an EPOS2 Module 36/2 positioning controller in a space-saving manner while reducing wiring

effort to an absolute minimum.

The individual EPOS2 Motherboard originates from an eleven-partite array allowing the integration of an

eleven axis system in one single shot. It can easily be cracked along predetermined breaking lines and

is scalable to suit your specific needs.

Remark

Note that the order number 407582 comprises one EPOS2 Motherboard suitable to carry one EPOS2

Module 36/2.

If you wish to order an array of motherboards (up to 11 as one part), you will be required to order the

respective number of EPOS2 Motherboards (407582).

The present document provides you with information on how to employ the EPOS2 Motherboard. It

describes the standard procedure when putting the device into operation and is meant to facilitate instal-

lation and configuration of a multiple axis system comprising up to eleven EPOS2 Module 36/2.

Find the latest edition of the present document, as well as additional documentation and software to the

EPOS2 Motherboard 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 documenta-

tion hierarchy and the interrelationship of its individual parts:

Figure 2-1 Documentation Structure

Introduction

Components

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2.2 Components

The motherboard is available in a harmonized and interoperable set of components:

Table 2-4 EPOS2 Module 36/2 Motherboard

Table 2-5 Modules (optional)

Table 2-6 Cables (optional)

Designation Order # Content

EPOS2 Module 36/2 Motherboard

For details page 3-13.

407582

Motherboard

(for 1 EPOS2 Module 36/2)

1 Powerlink plug (red)

1 Powerlink plug (black)

1 CAN Header

1 CAN Link Cable

Designation Order # Content

EPOS2 Motherboard USB Module

For details page 4-25.

407583

1 USB Module

1 4-way fly lead, l = 0.25m

2 M3x6 mm mounting screw

EPOS2 Motherboard RS232 Module

For details page 4-25.

407584

1 RS232 Module

1 6-way fly lead l = 0.25m

2 M3x6 mm mounting screw

EPOS2 Motherboard I/O Module

For details page 4-25.

407585

1 I/O Module

2 M3x6 mm mounting screw

EPOS2 Motherboard Dual Encoder

Module

For details page 4-25.

423536

1 Dual Encoder Module

2 M3x6 mm mounting screw

Designation Order #

Power Cable

For details page 4-34.

423507

USB Type A - Crimp Cable

For details page 4-34.

423526

RS232-COM Cable

For details page 4-34.

423530

Introduction

Safety Precautions

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2.3 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 Audi-

ence” 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.

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 discon-

nect 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.

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!

Introduction

Safety Precautions

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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.

Motherboard (407582)

Connections

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3 Motherboard (407582)

The EPOS2 Motherboard connects an individual EPOS2 Module 36/2 positioning controller. Further-

more, the motherboard is available as an eleven-partite array capable to integrate up to eleven axis with

the least effort possible. It can easily be cracked along predetermined breaking lines to the desired scale

of your system.

The following information describes both types of use:

• Setup of a motherboard to receive one EPOS2 Module 36/2.

• Use of an motherboard array to receive up to eleven EPOS2 Module 36/2s.

3.1 Connections

Figure 3-2 EPOS2 Module 36/2 Motherboard – Interfaces

Motherboard (407582)

Connections

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3.1.1 Power Input Connector (J1)

Best Practice

Keep the motor mechanically disconnected during setup and adjustment phase.

Figure 3-3 Power Input Connector (J1)

3.1.2 Coils Output Connector (J2)

Figure 3-4 Coils Output Connector (J2)

Pin Signal Description

1 Power_Gnd Ground of supply voltage

Power supply voltage +11…+36 VDC

Accessories Cables

Power Cable (423507)

Power Cable (275829)

Notes

Suitable connector

Suitable crimp terminals

Suitable hand crimper

Molex Mini-Fit Jr. 2 poles (39-01-2020)

Molex Mini-Fit Jr. female crimp terminals (44476-xxxx)

Molex hand crimper (63819-0900)

maxon EC motor

maxon DC motor

with separated motor/encoder cable

Signal Description Signal Description

1 Motor winding 1 EC motor: Winding 1 Motor (+M) DC motor: Motor +

2 Motor winding 2 EC motor: Winding 2 Motor (+M) DC motor: Motor −

3 Motor winding 3 EC motor: Winding 3 do not connect

4 not connected — — —

Accessories Cable Motor Cable (275851)

Notes

Suitable connector

Suitable crimp terminals

Suitable hand crimper

Molex Mini-Fit Jr. 4 poles (39-01-2040)

Molex Mini-Fit Jr. female crimp terminals (44476-xxxx)

Molex hand crimper (63819-0900)

Motherboard (407582)

Connections

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3.1.3 Hall Sensor Input Connector (J3)

Figure 3-5 Hall Sensor Input Connector (J3)

3.1.4 Encoder Input Connector (J4)

Figure 3-6 Encoder Input Connector (J4)

Pin Signal Description

1 Hall sensor 1 Hall sensor 1 Input

2 Hall sensor 2 Hall sensor 2 Input

3 Hall sensor 3 Hall sensor 3 Input

4 GND Ground of Hall sensor supply

5 +VHall Hall sensor supply voltage +5 VDC / 30 mA

6 not connected —

Accessories Cable Hall Sensor Cable (275878)

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)

Pin Signal Description

EC motor: not connected

DC motor: Motor +

EC motor: −

DC motor: + Motor (“Motor+ Link (Link2)” on page 3-23)

2 +5 VDC / 100 mA Encoder supply voltage

3 GND Ground

EC motor: not connected

DC motor: Motor −

EC motor: −

DC motor: − Motor (“Motor- Link (Link3)” on page 3-23)

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

Motherboard (407582)

Connections

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3.1.5 Auxiliary I/O Connector (J5)

Figure 3-7 Auxiliary I/O Connector (J5)

Pin Array / Signal Description

1 GND Signal ground

2 B22 DigOUT1 Digital Output 1

3 GND Signal ground

4 B16 DigIN4 Digital Input 4

5 GND Signal ground

6 B15 DigIN3 Digital Input 3

Notes

Suitable connector

Suitable crimp terminals

Suitable hand crimper

JST PHR-6

JST SPH-002T-P0.5L

JST YRS-241

Motherboard (407582)

Connections

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3.1.6 Auxiliary Bay Connector (J6)

Used to communicate with auxiliary modules. In some cases, it also provides necessary power supply.

Figure 3-8 Auxiliary Bay Connector (J6)

Maximal permitted electrical Load

• Max. current (track handling): 1.0 A.

• Max. current (supplied by EPOS2 Module 36/2):

Note

*1) Voltage level “low” = 0 V, “high” = 3.3 V, connected directly to the DSP

*2) EIA RS232 Standard

*3)Total ampacity on voltage supply +5 VDC is 150 mA and divides as follows:

• Encoder supply voltage +5 VDC/100 mA

• Hall sensor supply voltage +5 VDC/30 mA

• Auxiliary output voltage +5 VDC/20 mA

Pin Array / Signal Description

1 B13 DigIN1 Digital Input 1

2 A19 AnIN1 Analog Input 1

3 B19 DigIN7\ Digital Input 7 “High Speed Command” complement

4 B18 DigIN7 Digital Input 7 “High Speed Command”

5 A20 AnIN2 Analog Input 2

Power supply voltage

7 GND Ground

8 GND Ground

+5 VDC/20 A

Auxiliary output voltage +5 VDC

*3)

11 B20 DigIN8 Digital Input 8 “High Speed Command”

12 B21 DigIN8\ Digital Input 8 “High Speed Command” complement

13 A28 EPOS TxD

EPOS RS232 transmit

*2)

14 A26 EPOS SCI TxD

Serial communication interface transmit

*1)

15 A27 EPOS RxD

EPOS RS232 receive

*2)

16 A24 EPOS SCI RTS

Serial communication interface handshake

*1)

17 A25 EPOS SCI RxD

Serial communication interface receive

*1)

18 B14 DigIN2 Digital Input 2

19 B23 DigOUT2 Digital Output 2

20 A22 DigOUT5 Digital Output 5

Motherboard (407582)

Connections

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3.1.7 VCC Board-to-Board Powerlink (J7a & J7b)

Used to bridge V

between adjacent boards. Bridges J7a / J7b / J1 [Pin 2].

Figure 3-9 VCC Board-to-Board Powerlink (J7a & J7b)

Maximal permitted electrical Load

• Max. current powerlink (J7a/J7b): 10 A @ 20C°

• Max. current power input connector (J1): 13 A

3.1.8 GND Board-to-Board Powerlink (J8a & J8b)

Used to bridge GND between adjacent boards. Bridges J8a / J8b / J1 [Pin 1].

Figure 3-10 GND Board-to-Board Powerlink (J8a & J8b)

Maximal permitted electrical Load

• Max. current powerlink (J8a/J8b): 10 A @ 20C°

• Max. current power input connector (J1): 13 A

Motherboard (407582)

Connections

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3.1.9 CAN Bus Connector (J9 & J10)

Used to pass CAN data between adjacent boards on CAN bus. Both links can be used for CAN in &

CAN out.

Figure 3-11 CAN Bus Connector (J9 & J10)

Table 3-7 CAN Bus Connector – CAN Link Cable

Pin Signal Description

1 CAN GND CAN Ground

2 CAN low CAN low bus line

3 CAN high CAN high bus line

CAN Link Cable

Type 3 x AWG 26

Length 75 mm

Head A 3-way JST PH connector

Head B 3-way JST PH connector

Motherboard (407582)

Connections

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3.1.10 EPOS2 Module 36/2 Connector (J11)

Figure 3-12 EPOS2 Module 36/2 Connector (J11)

Array A

Pin Signal Description

A1 Power_GND Ground of supply voltage

Power supply voltage +0…+36 VDC

Logic supply voltage 11…36 VDC (optional)

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

aux

DDin

Auxiliary voltage output +5 VDC

*3)

Auxiliary supply voltage input +5 VDC (optional)

A11 GND

Ground of Hall sensor supply and

Ground of encoder supply

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

*1)

A25 EPOS SCI RxD

Serial communication interface receive

*1)

A26 EPOS SCI TxD

Serial communication interface transmit

*1)

A27 EPOS RxD

EPOS RS232 receive

*2)

A28 EPOS TxD

EPOS RS232 transmit

*2)

A29 GND Ground of SCI and RS232

A30 CAN low CAN low bus line

A31 CAN high CAN high bus line

A32 GND Ground of CAN bus

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maxon motor EPOS2 Module 36/2 Hardware Reference Manual

Brand: maxon motor

Model: EPOS2 Module 36/2

Type: Hardware Reference Manual

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maxon motor EPOS2 Module 36/2 Hardware Reference Manual

maxon motor EPOS2 Module 36/2 Hardware Reference Manual

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