maxon motor control ESCON Servo Controller Hardware Reference Edition November 2015 ESCON 50/5 Servo Controller P/N 409510 Hardware Reference Document ID: rel5536 maxon motor ag Brünigstrasse 220 P.O.Box 263 CH-6072 Sachseln Phone +41 41 666 15 00 Fax +41 41 666 16 50 www.maxonmotor.
TABLE OF CONTENTS 1 2 3 About 3 1.1 1.2 1.3 About this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 About the Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 About the Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Specifications 7 2.1 2.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About About this Document 1 About 1.1 About this Document 1.1.1 Intended Purpose The purpose of the present document is to familiarize you with the ESCON 50/5 Servo Controller. It will highlight the tasks for safe and adequate installation and/or commissioning. Follow the described instructions … • to avoid dangerous situations, • to keep installation and/or commissioning time at a minimum, • to increase reliability and service life of the described equipment.
About About the Device Type Symbol Information Table 1-2 1.1.5 Meaning 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.
About About the Safety Precautions 1.3 About the Safety Precautions • Make sure that you have read and understood the note “READ THIS FIRST” on page A-2! • Do not engage with any work unless you possess the stated skills (chapter “1.1.2 Target Audience” on page 1-3)! • Refer to chapter “1.1.
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Specifications Technical Data 2 Specifications 2.1 Technical Data ESCON 50/5 (409510) Electrical Rating Inputs & Outputs Voltage Outputs Potentiometers Motor Connections Interface Status Indicators Nominal operating voltage +VCC 10…50 VDC Absolute operating voltage +VCC min / +VCC max 8 VDC / 56 VDC Output voltage (max.) 0.98 x +VCC Output current Icont / Imax (<20 s) 5 A / 15 A Pulse Width Modulation frequency 53.6 kHz Sampling rate PI current controller 53.
Specifications Technical Data ESCON 50/5 (409510) Physical Weight approx. 204 g Dimensions (L x W x H) 115 x 75.5 x 24 mm Mounting holes for M4 screws Operation −30…+45 °C Extended range *1) +45…+85 °C Derating Figure 2-1 Storage −40…+85 °C Altitude *2) Operation 0…10’000 m MSL Humidity 5…90% (condensation not permitted) Temperature Environmental Conditions *1) *2) 2-8 Operation within the extended range (temperature and altitude) is permitted.
Specifications Technical Data Figure 2-2 maxon motor control ESCON Servo Controller ESCON 50/5 Hardware Reference Dimensional Drawing [mm] Document ID: rel5536 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Specifications Standards 2.2 Standards The described device has been successfully tested for compliance with the below listed standards. In practical terms, only the complete system (the fully operational equipment comprising all individual components, such as motor, servo controller, power supply unit, EMC filter, cabling etc.) can undergo an EMC test to ensure interference-free operation.
Setup Generally applicable Rules 3 Setup IMPORTANT NOTICE: PREREQUISITES FOR PERMISSION TO COMMENCE INSTALLATION The ESCON 50/5 is considered as partly completed machinery according to EU Directive 2006/42/EC, Article 2, Clause (g) and is intended to be incorporated into or assembled with other machinery or other partly completed machinery or equipment.
Setup Determination of Power Supply 3.2 Determination of Power Supply Basically, any power supply may be used, provided it meets the minimal requirements stated below. Power Supply Requirements Output voltage +VCC 10…50 VDC Absolute output voltage min. 8 VDC; max. 56 VDC Output current Depending on load • continuous max. 5 A • short-time (acceleration, <20 s) max. 15 A 1) Use the formula below to calculate the required voltage under load.
Setup Connections 3.3 Connections The actual connection will depend on the overall configuration of your drive system and the type of motor you will be using. Follow the description in given order and choose the connection scheme that suits the respective components you are using. For corresponding wiring diagrams chapter “4 Wiring” on page 4-29. 3.3.
Setup Connections 3.3.2 Motor (J2) The servo controller is set to drive either maxon DC motor (brushed) or maxon EC motor (brushless).
Setup Connections 3.3.3 Hall Sensor (J3) Suitable Hall effect sensors IC use «Schmitt trigger» with open collector output.
Setup Connections 3.3.4 Encoder (J4) Figure 3-7 Encoder Socket J4 J4 Signal Description Pin 1 not connected – 2 +5 VDC Encoder supply voltage (+5 VDC; ≤70 mA) 3 GND Ground 4 not connected – 5 Channel A\ Channel A complement 6 Channel A Channel A 7 Channel B\ Channel B complement 8 Channel B Channel B 9 not connected – 10 not connected – Table 3-13 Encoder Socket J4 – Pin Assignment Accessories Suitable strain relief Retainer Latch Table 3-14 3-16 For sockets with s
Setup Connections Encoder Cable (275934) Cable cross-section 10 x AWG28, round-jacket, twisted pair flat cable, pitch 1.27 mm Length 3.20 m Head A DIN 41651 female, pitch 2.54 mm, 10 poles, with strain relief Head B DIN 41651 Plug, pitch 2.54 mm, 10 poles, with strain relief Table 3-15 Encoder Cable Best Practice • Because of its resistance against electrical interferences, we recommend using differential scheme. Nevertheless, the controller supports both schemes – differential and single-ended.
Setup Connections Single-ended Input voltage 0…5 VDC Max. input voltage +12 VDC / −12 VDC Logic 0 <1.0 V Logic 1 >2.4 V Input high current IIH = typically −50 μA @ 5 V Input low current IIL = typically −550 μA @ 0 V Max. input frequency 100 kHz Figure 3-9 3-18 Encoder Input Circuit Ch A “Single-ended” (analogously valid also for Ch B) Document ID: rel5536 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Setup Connections 3.3.5 Digital I/Os (J5) Figure 3-10 Digital I/Os Plug J5 J5 Signal Description Pin 1 DigIN1 Digital input 1 2 DigIN2 Digital input 2 3 DigIN/DigOUT3 Digital input/output 3 4 DigIN/DigOUT4 Digital input/output 4 5 GND Signal ground 6 +5 VDC Auxiliary output voltage (+5 VDC; ≤10 mA) Table 3-16 Digital I/Os Plug J5 – Pin Assignment & Cabling Specification / Accessories Type Pluggable screw-type terminal block, 6 poles, pitch 3.5 mm Suitable cables 0.14…1.
Setup Connections 3.3.5.1 Digital Input 1 Input voltage 0…36 VDC Max. input voltage +36 VDC / −36 VDC Logic 0 typically <1.0 V Logic 1 typically >2.4 V Input resistance typically 47 kΩ (<3.3 V) typically 38.5 kΩ (@ 5 V) typically 25.5 kΩ (@ 24 V) Input current at logic 1 typically 130 µA @ +5 VDC Switching delay <8 ms PWM frequency range 10 Hz…5 kHz PWM duty cycle range (resolution) 10...90% (0.1%) RC Servo cycle duration 3…30 ms RC Servo pulse length 1…2 ms Figure 3-11 3.3.5.
Setup Connections 3.3.5.3 Digital Inputs/Outputs 3 and 4 DigIN Input voltage 0…36 VDC Max. input voltage +36 VDC Logic 0 typically <1.0 V Logic 1 typically >2.4 V Input resistance typically 47 kΩ (<3.3 V) typically 38.5 kΩ (@ 5 V) typically 25.5 kΩ (@ 24 V) Input current at logic 1 typically 130 µA @ +5 VDC Switching delay <8 ms Figure 3-13 DigIN3 Circuit (analogously valid also for DigIN4) DigOUT Max. input voltage +36 VDC Max. load current 500 mA Max. voltage drop 0.
Setup Connections Figure 3-15 3-22 DigOUT3 Wiring Examples (analogously valid also for DigOUT4) Document ID: rel5536 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Setup Connections 3.3.6 Analog I/Os (J6) Figure 3-16 Analog I/Os Plug J6 J6 Signal Description Pin 1 AnIN1+ Analog input 1, positive signal 2 AnIN1− Analog input 1, negative signal 3 AnIN2+ Analog input 2, positive signal 4 AnIN2− Analog input 2, negative signal 5 AnOUT1 Analog output 1 6 AnOUT2 Analog output 2 7 GND Signal ground Table 3-18 Analog I/Os Plug J6 – Pin Assignment & Cabling Specification / Accessories Type Pluggable screw-type terminal block, 7 poles, pitch 3.
Setup Connections 3.3.6.1 Analog Inputs 1 and 2 Input voltage −10…+10 VDC (differential) Max. input voltage +24 VDC / −24 VDC Common mode voltage −5…+10 VDC (referenced to GND) Input resistance 100 kΩ (differential) 50 kΩ (referenced to GND) A/D converter 12-bit Resolution 5.07 mV Bandwidth 10 kHz Figure 3-17 3.3.6.2 Analog Outputs 1 and 2 Output voltage −4…+4 VDC D/A converter 12-bit Resolution 2.30 mV Refresh rate AnOUT1: 26.8 kHz AnOUT2: 5.
Setup Connections 3.3.7 USB (J7) Figure 3-19 USB Socket J7 Note Column “Head B” (Table 3-20) refers to USB terminals of your PC. J7 & Head A Head B Pin Pin 1 1 VBUS USB BUS supply voltage input +5 VDC 2 2 D− USB Data− (twisted pair with Data+) 3 3 D+ USB Data+ (twisted pair with Data−) 4 – ID not connected 5 4 GND USB ground Signal Table 3-20 Description USB Socket J7 – Pin Assignment & Cabling USB Type A - micro B Cable (403968) Cable cross-section According to USB 2.
Setup Potentiometers 3.4 Potentiometers POTENTIOMETERS P1 & P2 Adjustment angle 240° Type Linear Figure 3-20 3.5 Potentiometers – Location & Adjustment Range Status Indicators Light-emitting diodes (LEDs) indicate the actual operating status (green) and possible errors (red). Figure 3-21 3-26 LEDs – Location Document ID: rel5536 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Setup Status Indicators LED Status / Error Green Red off off INIT slow off DISABLE on off ENABLE 2x off STOPPING; STOP STANDSTILL off 1x ERROR • +Vcc Overvoltage Error • +Vcc Undervoltage Error • +5 VDC Undervoltage Error off 2x ERROR • Thermal Overload Error • Overcurrent Error • Power Stage Protection Error • • • • Encoder Cable Break Error Encoder Polarity Error DC Tacho Cable Break Error DC Tacho Polarity Error off 3x ERROR off 4x ERROR • PWM Set Value Input out of Range
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Wiring 4 Wiring Figure 4-22 Interfaces – Designations and Location Remark The subsequent diagrams feature this sign: • maxon motor control ESCON Servo Controller ESCON 50/5 Hardware Reference Ground safety earth connection (optional) Document ID: rel5536 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Wiring DC Motors 4.1 DC Motors MAXON DC MOTOR Figure 4-23 4-30 maxon DC motor (J2) Document ID: rel5536 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Wiring DC Motors MAXON DC MOTOR WITH DC TACHO Figure 4-24 maxon motor control ESCON Servo Controller ESCON 50/5 Hardware Reference maxon DC motor with DC Tacho (J2) Document ID: rel5536 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Wiring DC Motors MAXON DC MOTOR WITH ENCODER Figure 4-25 4-32 maxon DC motor with Encoder (J2 / J4) Document ID: rel5536 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Wiring EC Motors 4.2 EC Motors MAXON EC MOTOR WITH HALL SENSORS Figure 4-26 maxon motor control ESCON Servo Controller ESCON 50/5 Hardware Reference maxon EC motor with Hall Sensors (J2 / J3) Document ID: rel5536 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Wiring EC Motors MAXON EC MOTOR WITH HALL SENSORS & ENCODER Figure 4-27 4-34 maxon EC motor with Hall Sensors & Encoder (J2 / J3 / J4) Document ID: rel5536 Edition: November 2015 © 2015 maxon motor. Subject to change without prior notice.
Spare Parts 5 Spare Parts Order number Description 425562 2 poles pluggable screw-type terminal block, pitch 3.5 mm, labeled 1…2 425563 4 poles pluggable screw-type terminal block, pitch 3.5 mm, labeled 1…4 425564 5 poles pluggable screw-type terminal block, pitch 3.5 mm, labeled 1…5 425565 6 poles pluggable screw-type terminal block, pitch 3.5 mm, labeled 1…6 425566 7 poles pluggable screw-type terminal block, pitch 3.
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LIST OF FIGURES Figure 2-1 Derating Output Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Figure 2-2 Dimensional Drawing [mm]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Figure 3-3 Power Plug J1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Figure 3-4 Motor Plug J2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF TABLES Z-38 Table 1-1 Notation used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Table 1-2 Symbols & Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Table 1-3 Brand Names and Trademark Owners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Table 2-4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX order numbers 275934 17 403112 7 403968 25 425562 35 425563 35 425564 35 425565 35 425566 35 A additionally applicable regulations 5 alerts 3 analog inputs 24 applicable EU directive 11 C cables (prefab) Encoder Cable 17 USB Type A - micro B Cable 25 country-specific regulations 5 P performance data 7 potentiometers 26 precautions 5 prerequisites prior installation 11 prohibitive signs 3 purpose of the device 4 of this document 3 D digital inputs 20, 21 E error display 26 ESD 5 EU directive, appl
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