maxon motor EPOS 24/5 User manual

maxon motor
maxon motor control EPOS Positioning Controller
Getting Started December 2008 Edition
maxon document number 573050-07
24/5
Positioning Controller
Documentation
Getting Started

maxon motor
EPOS Positioning Controller EPOS 24/5 Getting Started
1Table of contents
1Table of contents ...................................................................................................................2
2Table of figures ......................................................................................................................3
3Introduction ............................................................................................................................4
4How to use this guide ............................................................................................................4
5Safety Instructions .................................................................................................................5
6Installation and Configuration ................................................................................................6
6.1 Step 1: Software Installation................................................................................................6
6.2 Step 2: Hardware Presetting ...............................................................................................7
6.2.1 maxon EC motor..............................................................................................................7
6.2.2 maxon DC motor with separated motor and encoder cable............................................7
6.2.3 maxon DC motor with integrated motor/encoder ribbon cable........................................7
6.3 Step 3: Minimum External Wiring ........................................................................................8
6.3.1 EPOS 24/5 for maxon EC motor .....................................................................................8
6.3.2 EPOS 24/5 for maxon DC motor with separated motor and encoder cable..................10
6.3.3 EPOS 24/5 for maxon DC motor with integrated motor/encoder ribbon cable .............12
6.4 Step 4: System Configuration............................................................................................14
6.5 Step 5: Regulation Gains Tuning.......................................................................................21
6.5.1 Start the Auto-tuning Tool..............................................................................................21
6.5.2 Auto-tuning of the Current Regulator.............................................................................22
6.5.3 Auto-tuning of the Velocity Regulator ............................................................................24
6.5.4 Auto-tuning of the Position Regulator............................................................................26
6.5.5 Manual Tuning...............................................................................................................28
6.5.6 Save all Regulation Gains .............................................................................................29
7Conclusion ...........................................................................................................................29
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EPOS 24/5 Getting Started EPOS Positioning Controller
2Table of figures
Figure 1: EPOS 24/5 photo ..............................................................................................................4
Figure 2: EPOS documentation hierarchy........................................................................................4
Figure 3: EPOS CD-ROM ................................................................................................................6
Figure 4: Location JP2 and JP3 (factory setting) .............................................................................7
Figure 5: Configuration JP2 and JP3 ...............................................................................................7
Figure 6: Minimum wiring for maxon EC motor................................................................................9
Figure 7: Minimum wiring for maxon DC motor with separated motor and encoder cable............11
Figure 8: Minimum wiring for maxon DC motor with integrated motor/encoder ribbon cable........13
Figure 9: Startup wizard dialog for minimum external wiring .........................................................14
Figure 10: Startup wizard dialog for setting RS-232 communication.............................................15
Figure 11: Communication settings found......................................................................................15
Figure 12: Startup wizard dialog for choosing motor type..............................................................15
Figure 13: Startup wizard dialog for choosing EC motor pole pairs...............................................16
Figure 14: Startup wizard dialog for setting DC motor data ...........................................................16
Figure 15: Startup wizard dialog for setting EC motor data ...........................................................16
Figure 16: Startup wizard dialog for choosing DC motor position sensor type ..............................16
Figure 17: Startup wizard dialog for choosing EC motor position sensor type ..............................17
Figure 18: Recommendations for using Hall sensors as position sensors ....................................17
Figure 19: Startup wizard dialog for setting DC motor encoder resolution ....................................17
Figure 20: Startup wizard dialog for setting EC motor encoder resolution ....................................18
Figure 21: Startup wizard configuration summary .........................................................................18
Figure 22: Startup wizard dialog for setting EC motor encoder resolution ....................................19
Figure 23: Save & activate the configured parameters..................................................................19
Figure 24: Confirm parameter activation........................................................................................19
Figure 25: Clear CAN error ............................................................................................................20
Figure 26: Start regulation tuning...................................................................................................21
Figure 27: Auto-tuning of current regulator ....................................................................................22
Figure 28: Auto-tuning button.........................................................................................................22
Figure 29: Confirm motor shaft blocking ........................................................................................22
Figure 30: Confirm end of tuning....................................................................................................23
Figure 31: Confirm tuning error ......................................................................................................23
Figure 32: Clear tuning error ..........................................................................................................23
Figure 33: Auto-tuning of velocity regulator ...................................................................................24
Figure 34: Auto-tuning button.........................................................................................................24
Figure 35: Confirm free running of motor.......................................................................................24
Figure 36: Confirm end of tuning....................................................................................................25
Figure 37: Confirm tuning error ......................................................................................................25
Figure 38: Clear tuning error ..........................................................................................................25
Figure 39: Auto-tuning of position regulator...................................................................................26
Figure 40: Auto-tuning button.........................................................................................................26
Figure 41: Confirm free running of motor.......................................................................................26
Figure 42: Confirm end of tuning....................................................................................................27
Figure 43: Confirm tuning error ......................................................................................................27
Figure 44: Clear tuning error ..........................................................................................................27
Figure 45: Manual tuning mode .....................................................................................................28
Figure 46: Manual tuning mode .....................................................................................................28
Figure 47: Next tuning step ............................................................................................................28
Figure 48: Save button...................................................................................................................29
Figure 49: Confirm regulation gains saving....................................................................................29
Figure 50: Confirm saving of all parameters ..................................................................................29
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EPOS Positioning Controller EPOS 24/5 Getting Started
3Introduction
This documentation ‘Getting Started’ provides the first steps in using EPOS positioning controller. It
describes the standard procedure when the device is put into operation. The document facilitates the
installation and configuration of a basic EPOS 24/5 system.
maxon motor EPOS 24/5 is a small-sized full digital smart motion
controller. Due to the flexible and high efficient power stage the
EPOS 24/5 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 to
drive brushless EC motors with minimal torque ripple and low noise.
The integrated position-, velocity- and current control functionality
allows sophisticated positioning applications. It is specially designed
being commanded and controlled as a slave node in the CANopen
network. In addition the unit can be operated through any RS-232 communication port.
Figure 1: EPOS 24/5 photo
The latest edition of these ‘Getting Started’, additional documentation and software to the EPOS
positioning controller may also be found in the internet under http://www.maxonmotor.com category
<Service & Downloads>.
4How to use this guide
Setup
Getting Started
Installation Configuration Programming Application
•Cable Starting Set
•Hardware
Reference
•Graphical User
Interface
•Windows DLL
•IEC1131 libraries
•Firmware
Specification
•Communication
Guide
•Application Notes
•Application
Samples
Figure 2: EPOS documentation hierarchy
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EPOS 24/5 Getting Started EPOS Positioning Controller
5Safety Instructions
Skilled Personnel
Installation and starting of the equipment shall only be performed by experienced,
skilled personnel.
Statutory Regulations
The user must ensure that the positioning controller and the components belonging
to it are assembled and connected according to local statutory regulations.
Load Disconnected
For primary operation the motor should be free running, i.e. with the load
disconnected.
Additional Safety Equipment
An electronic apparatus is not fail-safe in principle. Machines and apparatus must
therefore be fitted with independent monitoring and safety equipment. If the
equipment breaks down, if it is operated incorrectly, if the control unit breaks down
or if the cables break, etc., it must be ensured that the drive or the complete
apparatus is kept in a safe operating mode.
Repairs
Repairs may be made by authorized personnel only or by the manufacturer. It is
dangerous for the user to open the unit or make repairs to it.
Danger
Do ensure that during the installation of the EPOS 24/5 no apparatus is connected
to the electrical supply. After switching on, do not touch any live parts!
Max. Supply Voltage
Make sure that the supply voltage is between 11 and 24 VDC. Voltages higher than
27 VDC or of wrong polarity will destroy the unit.
Electrostatic Sensitive Device (ESD)
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EPOS Positioning Controller EPOS 24/5 Getting Started
6Installation and Configuration
6.1 Step 1: Software Installation
Install the software from the EPOS CD-ROM. The CD-ROM contains all
necessary information and tools for installation and operation of the EPOS
controllers (Manuals, Firmware, Tools and Windows DLLs).
Figure 3: EPOS CD-ROM
The latest edition of the software to the EPOS positioning controller may be
downloaded from the internet under http://www.maxonmotor.com category
<Service & Downloads>.
Minimum system requirements:
Windows ME, Windows NT 4.0, Windows 2000, XP
486 processor, 128 MB RAM
200 MB free storage space on hard drive
Screen resolution 1024 x 768 pixels at 256 colours
Follow the next instructions to install the whole software on your computer:
1. Insert CD-ROM
Insert the EPOS CD-ROM into the CD-ROM drive of your computer.
2. Start the installation program ‘EPOS_CD-ROM.exe’
Normally the installation program starts automatically after inserting
EPOS CD-ROM. Alternatively, double click the item in the explorer to
start the installation program ‘EPOS_CD-ROM.exe’
3. Follow the instructions during the installation program
Please read each instruction carefully. During the installation
procedure you will be asked for a working directory. (Recommendation:
C:\Programme\maxon motor EPOS CD-ROM)
4. Check the new shortcuts and items in the start menu
All necessary files are copied to the hard drive ‘maxon motor EPOS
CD-ROM’ item allows accessibility to all ‘Contents’. On the desktop, a
new shortcut to the ‘EPOS_UserInterface.exe‘ will be added. Check
the new shortcuts in the start menu and on the desktop.
5. Modify or remove the EPOS software
To change application features or to uninstall the EPOS software, start
the installation program ‘EPOS_CD-ROM.exe’ and follow the
instructions.
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EPOS 24/5 Getting Started EPOS Positioning Controller
6.2 Step 2: Hardware Presetting
6.2.1 maxon EC motor
Using EPOS 24/5 for maxon EC motor, no presetting is necessary.
6.2.2 maxon DC motor with separated motor and encoder cable
Using EPOS 24/5 for maxon DC motor with separated motor and encoder
cable, no presetting is necessary.
6.2.3 maxon DC motor with integrated motor/encoder ribbon cable
Using EPOS 24/5 for maxon DC motor with integrated motor/encoder
ribbon cable an additional presetting has to be done.
The jumper JP2 and JP3 can be found on board by opening the housing
cover.
Figure 4: Location JP2 and JP3 (factory setting)
maxon DC motor with separated
motor and encoder cable
maxon DC motor with integrated
motor/encoder ribbon cable
JP2 open JP2 closed
JP3 open JP3 closed
Motor (J2): motor cable Motor (J2): not connected
Encoder (J4): encoder cable Encoder (J4): motor/encoder
ribbon cable
Figure 5: Configuration JP2 and JP3
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EPOS Positioning Controll
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6.3 Step 3: Minimum External Wiring
Select the motor variant used with EPOS 24/5 for minimum wiring:
•‘6.3.1 EPOS 24/5 for maxon EC motor’
•‘6.3.2 EPOS 24/5 for maxon DC motor with separated motor and encoder cable’
•‘6.3.3 EPOS 24/5 for maxon DC motor with integrated motor/encoder ribbon cable’
6.3.1 EPOS 24/5 for maxon EC motor
Install the EPOS 24/5 hardware. Use the maxon cable assemblies below
for wiring.
You should have:
EPOS 24/5 positioning controller ..................... order number 275512
EPOS power cable (Connector J1) .................. order number 275829
EPOS motor cable (Connector J2) .................. order number 275851
EPOS Hall sensor cable (Connector J3) ......... order number 275878
EPOS encoder cable (Connector J4) .............. order number 275934
EPOS RS232-COM cable (Connector J6) ....... order number 275900
Follow the steps and see also figure 6.
1. Connect EPOS power cable
Connect the power cable (Order No. 275829) to the connector J1 of
the EPOS 24/5. On the opposite side connect to a power supply
(+11 … +24 VDC).
The necessary output current is depending on load. (Continuous max.
5 A; acceleration, short-time max. 10 A)
Note! Make sure that the supply voltage is between +11 and
+24 VDC. Voltages higher than +27 VDC or of wrong polarity will
destroy the unit.
2. Connect EPOS motor cable
Connect the motor cable (Order No. 275851) to the connector J2 of the
EPOS 24/5. On the opposite side connect to terminal blocks. Connect
the motor power lines to the opposite side of the terminal blocks.
3. Connect EPOS Hall sensor cable
Connect the Hall sensor cable (Order No. 275878) to the connector J3
of the EPOS 24/5. On the opposite side connect to terminal blocks.
Connect the motor Hall sensor lines to the opposite side of the terminal
blocks.
4. Connect EPOS encoder cable
Connect the encoder cable (Order No. 275934) to the connector J4 of
the EPOS 24/5. On the opposite side connect to the encoder of the
motor.
5. Connect EPOS RS232-COM cable
Connect the RS232-COM cable (Order No. 275900) to the connector
J6 of the EPOS 24/5. On the opposite side connect to a free RS-232
port of your computer.
Note! If you do not use the maxon cables, you have to do the wiring using
the ‘Cable Starting Set’ manual.

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EPOS Positioning Controll
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Figure 6: Minimum wiring for maxon EC motor

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EPOS Positioning Controller EPOS 24/5 Getting Started
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6.3.2 EPOS 24/5 for maxon DC motor with separated motor and encoder cable
Next option allows hardware installation of EPOS 24/5 for maxon DC
motor with separated motor and encoder cable. Use the maxon cable
assemblies below for wiring.
You should have:
EPOS 24/5 positioning controller .................... order number 275512
EPOS power cable (Connector J1) ................. order number 275829
EPOS motor cable (Connector J2) .................. order number 275851
EPOS encoder cable (Connector J4) .............. order number 275934
EPOS RS232-COM cable (Connector J6) ...... order number 275900
Follow the steps and see also figure 7.
1. Connect EPOS power cable
Connect the power cable (Order No. 275829) to the connector J1
of the EPOS 24/5. On the opposite side connect to a power
supply (+11 … +24 VDC).
The necessary output current is depending on load. (Continuous
max. 5 A; acceleration, short-time max. 10 A)
Note! Make sure that the supply voltage is between +11 and
+24 VDC. Voltages higher than +27 VDC or of wrong polarity will
destroy the unit.
2. Connect EPOS motor cable
Connect the motor cable (Order No. 275851) to the connector J2
of the EPOS 24/5. On the opposite side connect to a terminal
blocks. Connect the motor power lines to the opposite side of the
terminal blocks.
3. Connect EPOS encoder cable
Connect the encoder cable (Order No. 275934) to the connector
J4 of the EPOS 24/5. On the opposite side connect to the encoder
of the motor.
4. Connect EPOS RS232-COM cable
Connect the RS232-COM cable (Order No. 275900) to the
connector J6 of the EPOS 24/5. On the opposite side connect to a
free RS-232 port of your computer.
Note! If you do not use the maxon cables, you have to do the wiring
using the ‘Cable Starting Set’ manual.

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Figure 7: Minimum wiring for maxon DC motor with separated motor and encoder cable

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EPOS Positioning Controller EPOS 24/5 Getting Started
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6.3.3 EPOS 24/5 for maxon DC motor with integrated motor/encoder ribbon cable
Next option allows hardware installation of EPOS for maxon DC motor
with integrated motor/encoder ribbon cable. Use the maxon cable
assemblies below for wiring.
You should have:
EPOS 24/5 positioning controller ..................... order number 275512
EPOS power cable (Connector J1) .................. order number 275829
EPOS encoder cable (Connector J4) ............... order number 275934
EPOS RS232-COM cable (Connector J6) ....... order number 275900
Follow the steps and see also figure 8.
1. Check jumper presetting
Be sure you have done the jumper presetting as described in
chapter ‘6.2.3 maxon DC motor with integrated motor/encoder
ribbon cable’.
2. Connect EPOS power cable
Connect the power cable (Order No. 275829) to the connector J1
of the EPOS 24/5. On the opposite side connect to a power
supply (+11 … +24 VDC).
The necessary output current is depending on load. (Continuous
max. 5 A; acceleration, short-time max. 10 A)
Note! Make sure that the supply voltage is between +11 and
+24 VDC. Voltages higher than +27 VDC or of wrong polarity will
destroy the unit.
3. Connect EPOS encoder cable
Connect the encoder cable (Order No. 275934) to the connector
J4 of the EPOS 24/5. On the opposite side connect to the encoder
of the motor.
4. Connect EPOS RS232-COM cable
Connect the RS232-COM cable (Order No. 275900) to the
connector J6 of the EPOS 24/5. On the opposite side connect to a
free RS-232 port of your computer.
Note! If you do not use the maxon cables, you have to do the wiring
using the ‘Cable Starting Set’ manual.

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Figure 8: Minimum wiring for maxon DC motor with integrated motor/encoder ribbon cable

maxon motor
EPOS Positioning Controller EPOS 24/5 Getting Started
6.4 Step 4: System Configuration
In this section you will configure the EPOS 24/5 for your drive system.
Please note:
•The EPOS User Interface provides an online help. It contains all
available documentation.
To open online help functions:
- press F1
-or use the help buttons
-or click the right mouse button
•You have to know some technical data about your system. Use the
maxon catalogue or the datasheets of the components used.
To configure your drive system:
1. Power-up
Switch on the EPOS 24/5 power supply.
2. Start the ‘EPOS User Interface’ Version 2.00 or higher
Double click on the item ‘EPOS UserInterface.exe’ on the desktop to
start the graphical user interface (GUI). By starting the ‘EPOS User
Interface’ the ‘Startup Wizard’ will be started automatically.
3. ‘Startup Wizard’ Step 1: Minimum External Wiring
a) Verify that your hardware installation is correct. Please refer to
chapter ‘6.3 Step 3: Minimum External Wiring’.
b) If you have already read the ‘Getting Started’ document, click on
the button ‘Confirm that you’ve read the ‘Getting Started’
document’. Otherwise it is possible to display the document online
by clicking on the button ‘Show Getting Started’.
Figure 9: Startup wizard dialog for minimum external wiring
c) Click on the button ‘Weiter’ for the next step.
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EPOS 24/5 Getting Started EPOS Positioning Controller
4. ‘Startup Wizard’ Step 2: Communication Setting!
a) Verify that your RS-232 wiring is correct.1Please refer to chapter
‘6.3 Step 3: Minimum External Wiring’.
b) Click on the button ‘Search Communication Setting’ to search the
used COM port and the adjusted baudrate automatically.
Figure 10: Startup wizard dialog for setting RS-232 communication
c) If a correct communication setting is found, the following dialog is
displayed.
Figure 11: Communication settings found
d) Click on the ‘OK’ button to confirm and accept the values.
e) Click on the button ‘Weiter’ for the next step.
5. ‘Startup Wizard’ Step 3: Motor Type
a) Select the used motor type.
Figure 12: Startup wizard dialog for choosing motor type
b) Click on the button ‘Weiter’ for the next step.
1It is also possible to run ‘EPOS User Interface’ via CANopen communication. In this case, a PC CAN- interface card from IXXAT or
Vector has to be used.
For correct wiring please see ‘EPOS 24/5 Hardware Reference’ document.
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EPOS Positioning Controller EPOS 24/5 Getting Started
6. ‘Startup Wizard’
Step 4 for EC motors: Motor Pole Pair
a) Select the correct number of pole pairs.
Figure 13: Startup wizard dialog for choosing
EC motor pole pairs
b) Click on the button ‘Weiter’ for the next
step.
6. ‘Startup Wizard’
Step 4 for DC motors: Motor Data
a) Select the maximum permissible speed.
b) Select the nominal current (maximum
continuous current).
c) Select the thermal time constant of the
winding.
Figure 14: Startup wizard dialog for setting
DC motor data
d) Click the button ‘Weiter’ for the next step.
7. ‘Startup Wizard’
Step 5 for EC motors: Motor Data
a) Select the maximum permissible speed.
b) Select the nominal current (maximum
continuous current).
c) Select the thermal time constant of the
winding.
Figure 15: Startup wizard dialog for setting
EC motor data
d) Click the button ‘Weiter’ for the next step.
7. ‘Startup Wizard’
Step 5 for DC motors: Position Sensor
Type
a) Select the used position sensor type
Figure 16: Startup wizard dialog for choosing
DC motor position senso typer
b) Click the button ‘Weiter’ for the next step.
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EPOS 24/5 Getting Started EPOS Positioning Controller
8. ‘Startup Wizard’
Step 6 for EC motors: Position Sensor
Type
a) Select the used position sensor type
Figure 17: Startup wizard dialog for choosing
EC moto position sensor type r
b) Click the button ‘Weiter’ for the next step.
c) Important remarks for using Hall
sensors: For a proper function of the
regulation, please be aware of the
following restrictions.
Figure 18: Recommendations for using Hall
sensors as position sensors
d) Please consider this warning carefully
before clicking the ‘Accept’ button for the
next step.
8. ‘Startup Wizard’
Step 6 for DC motors: Position
Resolution
a) Enter the resolution of the used encoder.
Figure 19: Startup wizard dialog for setting
DC motor encoder resolution
b) Click the button ‘Weiter’ for the next step.
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EPOS Positioning Controller EPOS 24/5 Getting Started
9. ‘Startup Wizard’
Step 7 for EC motors: Position
Resolution
a) Enter the resolution of the used encoder.
Figure 20: Startup wizard dialog for setting
EC motor encoder resolution
b) Click the button ‘Weiter’ for the next step.
9. ‘Startup Wizard’
Step 7 for DC motors: Summary
a) A short summary of the most important
configuration values is displayed in this
window.
b) If there are any mistakes in the
configuration, you can go back and modify
the values by clicking on the button
‘Zurück’.
c) If you will not start the startup wizard at the
beginning of every EPOS user interface
session, you have to deselect the option
‘Always start this wizard after program
start’.
Figure 21: Startup wizard configuration
summary
d) If all settings are correct, click the button
‘Fertig stellen’ to close the startup wizard.
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10. ‘Startup Wizard’
Step 8 for EC motors: Summary
a) A short summary of the most important
configuration values is displayed in this
window.
b) If there are any mistakes in the
configuration, you can go back and modify
the values by clicking on the button
‘Zurück’.
c) If you will not start the startup wizard at the
beginning of every EPOS user interface
session, you have to deselect the option
‘Always start this wizard after program
start’.
Figure 22: Startup wizard dialog for setting
EC motor encoder resolution
d) If all settings are correct, click the button
‘Fertig stellen’ to close the startup wizard.
11. Save and activate parameters
Figure 23: Save & activate the configured parameters
a) Click the button ‘Yes’ to accept the parameters.
Figure 24: Confirm parameter activation
b) Confirm by clicking the ‘OK’ button.
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12. Clear CAN error
Now, the object dictionary will be loaded. In case of not connected
CAN communication, the error ‘CAN in Error Passive Mode’ appears.1
a) Click on button ‘Clear Errors’ to clear the error ‘CAN in Passive
Error Mode’.
Figure 25: Clear CAN error
b) If other errors occurred, please check wiring and startup
configuration. For more information’s about errors, refer to EPOS
firmware documentation.
c) Your EPOS is now ready for regulation gains tuning.
1If the 'EPOS User Interface' is communicating via CANopen, this error will not appear.
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