maxon motor EPOS2 70/10 User manual

maxon motor ag Brünigstrasse 220 P.O.Box 263 CH-6072 Sachseln Phone [phone] Fax [phone] www.maxonmotor.com
Edition May 2016
EPOS2 Positioning Controller
Getting Started
maxon motor control
Positioning Controller
Getting Started
Document ID: rel5892

maxon motor control
A-2 Document ID: rel5892 EPOS2 Positioning Controller
Edition: May 2016 EPOS2 70/10 Getting Started
© 2016 maxon motor. Subject to change without prior notice.
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,
•towrite 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 70/10 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
EPOS2 Positioning Controller Document ID: rel5892 A-3
EPOS2 70/10 Getting Started Edition: May 2016
© 2016 maxon motor. Subject to change without prior notice.
1 About this Document 5
2 Introduction 9
2.1 Documentation Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Installation and Configuration 11
3.1 Important Notice: Prerequisites for Permission to commence Installation. . . 11
3.2 Step 1: Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.1 Minimum System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Step 2: Minimum External Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.1 Minimum Wiring for maxon EC motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3.2 Minimum Wiring for maxon DC motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Step 3: System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4.1 General initial Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4.2 Configuration of EC Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.4.3 Configuration of DC Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.4.4 General closing Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.5 Step 4: Regulation Gains Tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5.1 Starting Regulation Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5.2 Auto Tuning the Current, Velocity and Position Regulators. . . . . . . . . . . . . . . . . . . . . . 24
TABLE OF CONTENTS

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A-4 Document ID: rel5892 EPOS2 Positioning Controller
Edition: May 2016 EPOS2 70/10 Getting Started
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EPOS2 Positioning Controller Document ID: rel5892 1-5
EPOS2 70/10 Getting Started Edition: May 2016
© 2016 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 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”

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1-6 Document ID: rel5892 EPOS2 Positioning Controller
Edition: May 2016 EPOS2 70/10 Getting Started
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1.4 Symbols and Signs
In the course of the present document, the following symbols and sings will be used.
Table 1-2 Symbols & Signs
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.

maxon motor control
EPOS2 Positioning Controller Document ID: rel5892 1-7
EPOS2 70/10 Getting Started Edition: May 2016
© 2016 maxon motor. Subject to change without prior notice.
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
1.6 Copyright
© 2016 maxon motor. All rights reserved.
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 [phone]
Fax [phone]
www.maxonmotor.com
Brand Name Trademark Owner
Adobe® Reader® © Adobe Systems Incorporated, USA-San Jose, CA
CANopen®
CiA® © CiA CAN in Automation e.V, DE-Nuremberg
Internet Explorer® © Microsoft Corporation, USA-Redmond, WA
Pentium® © Intel Corporation, USA-Santa Clara, CA
Windows Vista®
Windows® © Microsoft Corporation, USA-Redmond, WA

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EPOS2 Positioning Controller Document ID: rel5892 2-9
EPOS2 70/10 Getting Started Edition: May 2016
© 2016 maxon motor. Subject to change without prior notice.
2Introduction
The present document provides you with information on the first steps using EPOS2 70/10 Positioning
Controller. It describes the standard procedure when putting the device into operation and is meant to
facilitate installation and configuration of a basic EPOS2 70/10 system.
maxon motor control’s EPOS2 70/10 is a small-sized, full digital smart motion control unit. Due to its
flexible and high efficient power stage, the EPOS2 70/10 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. The EPOS2 70/10 is specially designed being com-
manded and controlled as a slave node in a CANopen network. In addition, the unit can be operated via
any USB or RS232 interface.
Find the latest edition of the present document, as well as additional documentation and software to the
EPOS2 70/10 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 documenta-
tion hierarchy and the interrelationship of its individual parts:
Figure 2-1 Documentation Structure

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2-10 Document ID: rel5892 EPOS2 Positioning Controller
Edition: May 2016 EPOS2 70/10 Getting Started
© 2016 maxon motor. Subject to change without prior notice.
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 Audi-
ence” on page 1-5),
• refer to chapter “1.4 Symbols and Signs” on page 1-6 to understand the subsequently used indi-
cators,
• 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…70 VDC.
• Supply voltages above 75 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!

maxon motor control
EPOS2 Positioning Controller Document ID: rel5892 3-11
EPOS2 70/10 Getting Started Edition: May 2016
© 2016 maxon motor. Subject to change without prior notice.
3 Installation and Configuration
3.1 Important Notice: Prerequisites for Permission to commence Installation
The EPOS2 70/10 is considered as partly completed machinery according to EU directive 2006/42/EC,
Article 2, Clause (g) and therefore is only intended to be incorporated into or assembled with other
machinery or other partly completed machinery or equipment.
3.2 Step 1: Software Installation
Install the software from the «EPOS Positioning Controller» DVD. It contains all necessary information
and tools (such as manuals, firmware, tools, Windows DLLs, drivers) required for installation and opera-
tion of the EPOS2 Positioning Controller.
You can download the latest software version from the Internet (for URLs chapter “2 Introduc-
tion” on page 2-9).
3.2.1 Minimum System Requirements
Table 3-4 Minimum System Requirements
WARNING
Risk of Injury
Operating the device without the full compliance of the surrounding system with EU directive
2006/42/EC may cause serious injuries!
• Do not operate the device, unless you have made sure that the other machinery fulfills the require-
ments stated in the EU directive!
• Do not operate the device, unless the surrounding system fulfills all relevant health and safety
aspects!
• Do not operate the device, unless all respective interfaces have been established and fulfill the
stated requirements!
Component Minimum Requirement
Operating System Windows 10, 8, 7, XP SP3, Vista
Processor Core2Duo 1.5 GHz
Drives Hard disk drive, 1.5 GB available space
DVD drive
Memory 1 GB RAM
Monitor Screen resolution 1024 x 768 pixels at high color (16-Bit)
Web Browser Internet Explorer IE 7.0

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3-12 Document ID: rel5892 EPOS2 Positioning Controller
Edition: May 2016 EPOS2 70/10 Getting Started
© 2016 maxon motor. Subject to change without prior notice.
3.2.2 Installation
1) Insert «EPOS Positioning Controller» DVD into DVD drive of your computer.
Autorun will commence automatically. If autorun should fail to start, find the installation file
named “EPOS Positioning Controller.msi” on your explorer, then doubleclick to start.
2) Follow the instructions during the installation program.
Please read every instruction carefully. Indicate location of working directory when prompted.
Best Practice
We recommend following location as working directory: C:\Program Files\maxon motor ag (note that
designation of program directory may vary depending on the system language installed).
3) View new shortcuts and items in the start menu
• The files have been copied to the menu «maxon motor ag», where you can access the pro-
gram as well as the entire documentation set.
• Clicking the ¤EPOS Studio¤ shortcut on your desktop will launch the program.
4) If needed: Modify or remove the software.
To change application features or to uninstall the software, start the installation program «EPOS
Positioning Controller.msi» anew and follow the instructions given.
3.3 Step 2: Minimum External Wiring
Wiring depends on the type of motor you are using.
1) Decide on type of motor you wish to connect to your EPOS2 70/10 Positioning Controller.
2) Observe notes below.
3) Chose applicable chapter:
“Minimum Wiring for maxon EC motor” on page 3-13.
“Minimum Wiring for maxon DC motor” on page 3-14
Maximal permitted Supply Voltage
• Make sure that supply power is between 11…70 VDC.
• Supply voltages above 75 VDC or wrong polarity will destroy the unit.
• Note that necessary output current is depending on load (continuous max. 10 A; acceleration/short-
time max. 25 A).
Note
• For every motor variant, you will find a table stating type of cable to be used and respective from/to
connections as well as a corresponding illustration (at the end of this chapter).
• If you decide not to use ready-made maxon cables, you must perform wiring according to separate
document «Cable Starting Set».
Note
The first time the device is connected using the USB interface, a respective driver needs to be
installed.
For further information, please consult separate document
 «EPOS2 USB Driver Installation» located
in the folder “…\Driver Packages\EPOS2 USB Driver”.

maxon motor control
EPOS2 Positioning Controller Document ID: rel5892 3-13
EPOS2 70/10 Getting Started Edition: May 2016
© 2016 maxon motor. Subject to change without prior notice.
3.3.1 Minimum Wiring for maxon EC motor
1) Install «EPOS2 70/10 Positioning Controller» (375711).
2) Connect maxon cable assemblies (Table 3-5 and Figure 3-2).
Table 3-5 Minimum Wiring: maxon EC motor
Figure 3-2 Minimum Wiring: maxon EC motor
Cable Connection
Designation Order # from … … to
Power Cable 275829 J1 power supply
+11…+70 VDC
Motor Cable 275851 J2 terminal blocks
Hall Sensor Cable 275878 J3 terminal blocks
Encoder Cable 275934 J4 encoder of the motor
USB Type A - mini B Cable 370513 J9 an available USB port
of your computer

maxon motor control
3-14 Document ID: rel5892 EPOS2 Positioning Controller
Edition: May 2016 EPOS2 70/10 Getting Started
© 2016 maxon motor. Subject to change without prior notice.
3.3.2 Minimum Wiring for maxon DC motor
1) Install «EPOS2 70/10 Positioning Controller» (375711).
2) Connect maxon cable assemblies (Table 3-6 and Figure 3-3).
Table 3-6 Minimum Wiring: maxon DC motor
Figure 3-3 Minimum Wiring: maxon DC motor
Cable Connection
Designation Order # from … … to
Power Cable 275829 J1 power supply
+11…+70 VDC
Motor Cable 275851 J2 terminal blocks
Encoder Cable 275934 J4 encoder of the motor
USB Type A - mini B Cable 350392 J9 an available USB port
of your computer

maxon motor control
EPOS2 Positioning Controller Document ID: rel5892 3-15
EPOS2 70/10 Getting Started Edition: May 2016
© 2016 maxon motor. Subject to change without prior notice.
3.4 Step 3: System Configuration
Read separate Instructions
You will need to know certain technical data of your system.
Refer to maxon catalog or respective data sheets of components used.
3.4.1 General initial Steps
1) Switch on EPOS2 70/10 power supply.
2) Doubleclick ¤EPOS Studio.exe¤ shortcut on your desktop.
«EPOS Studio» will start and the “New Project Wizard” will automatically be launched.
3) Make sure that you are using the latest version of «EPOS Studio». If you are in doubt on the ver-
sion you are currently using, proceed as follows:
a) Click menu ¤Help¤, then select menu ¤About EPOS Studio¤. The currently installed version
will be displayed.
b) Click one of the displayed hyperlinks to find out on the latest version available. Download the
latest version, if needed.
4) Load an existing EPOS2 Project:
a) Select ¤EPOS2 Project¤ from list.
b) Click ¤Next¤ to proceed.
Figure 3-4 Project Configuration Dialog
5) Set project settings:
a) Click browse icon (arrow) to set path and project name for your project.
b) Click ¤Finish¤ to create new project.
Figure 3-5 Project Path and Name

maxon motor control
3-16 Document ID: rel5892 EPOS2 Positioning Controller
Edition: May 2016 EPOS2 70/10 Getting Started
© 2016 maxon motor. Subject to change without prior notice.
6) Clear CAN Warning:
The Project Tree will be displayed in the “Page Navigator Window”. If CAN is not connected, the
warning “CanPassiveError on CAN Port” will appear (arrow).
a) Click right on warning.
b) Click ¤Clear All Entries¤.
c) If other errors or warnings appear, check wiring and startup configuration (for details on
errors and warnings separate document «EPOS2 Firmware Specification»).
Figure 3-6 Warning “CAN Passive Mode Error”
7) Start “Startup Wizard”:
a) Click ¤Wizards¤.
b) Select ¤EPOS2¤ from Device Selection Combo Box.
c) Doubleclick ¤Startup Wizard¤ item in Wizard Tree (arrow).
Figure 3-7 Page Navigator Window
8) Startup Wizard (Step 1): Minimum External Wiring:
a) Verify correct hardware installation (chapter “3.3 Step 2: Minimum External Wiring” on
page 3-12).
b) Make sure you have read “Getting Started” and confirm by clicking ¤Confirm that you’ve read
the “Getting Started” document¤.
c) Click ¤Next¤ to proceed.
Figure 3-8 Startup Wizard Dialog: Minimum external Wiring

maxon motor control
EPOS2 Positioning Controller Document ID: rel5892 3-17
EPOS2 70/10 Getting Started Edition: May 2016
© 2016 maxon motor. Subject to change without prior notice.
9) Startup Wizard (Step 2): Communication Setting:
a) Verify correct wiring to USB interface (chapter “3.3 Step 2: Minimum External Wiring” on
page 3-12).
b) Click ¤Search Communication Setting¤ to search USB port and to automatically adjust trans-
fer rate (arrow).
Figure 3-9 Startup Wizard Dialog: USB Communication
c) If correct communication settings were found, a respective message will be displayed.
Figure 3-10 Communication Settings
d) Click ¤OK¤ to confirm settings.
e) Click ¤Next¤ to proceed.
10)Startup Wizard (Step 3): Auxiliary Regulation
a) By default, no auxiliary regulation will be used.
Select ¤None¤.
b) Click ¤Next¤ to proceed.
Figure 3-11 Startup Wizard Dialog: Auxiliary Regulation

maxon motor control
3-18 Document ID: rel5892 EPOS2 Positioning Controller
Edition: May 2016 EPOS2 70/10 Getting Started
© 2016 maxon motor. Subject to change without prior notice.
11) Startup Wizard (Step 4): Motor Type
a) Select used motor type.
b) Click ¤Next¤ to proceed.
Figure 3-12 Startup Wizard Dialog: Motor Type
12)Decide on how to further proceed:
For EC motors:
Proceed to chapter “3.4.2 Configuration of EC Motors” on page 3-19,
then continue with chapter “3.4.4 General closing Steps” on page 3-23.
For DC motors:
Proceed to chapter “3.4.3 Configuration of DC Motors” on page 3-21,
then continue with chapter “3.4.4 General closing Steps” on page 3-23.

maxon motor control
EPOS2 Positioning Controller Document ID: rel5892 3-19
EPOS2 70/10 Getting Started Edition: May 2016
© 2016 maxon motor. Subject to change without prior notice.
3.4.2 Configuration of EC Motors
1) Startup Wizard for EC motors (Step 5): Commutation
a) Select type of commutation (example: “Sinusoidal Commutation”).
b) Click ¤Next¤ to proceed.
Figure 3-13 Startup Wizard Dialog for EC Motors: Commutation Type
2) Startup Wizard for EC motors (Step 6): Main Sensor Type
a) Select type of main sensor (example: “Incremental Encoder”).
b) Click ¤Next¤ to proceed.
Figure 3-14 Startup Wizard Dialog for EC Motors: Main Sensor Type
3) Startup Wizard for EC motors (Step 7): Motor Data
a) Enter maximum permissible speed.
b) Enter nominal (maximum continuous) current.
c) Enter thermal time constant of motor winding.
d) Enter number of pole pairs.
e) Click ¤Next¤ to proceed.
Figure 3-15 Startup Wizard Dialog for EC Motors: Motor Data

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3-20 Document ID: rel5892 EPOS2 Positioning Controller
Edition: May 2016 EPOS2 70/10 Getting Started
© 2016 maxon motor. Subject to change without prior notice.
4) Startup Wizard for EC motors (Step 8): Incremental Encoder 1 Settings
a) Enter resolution of encoder used.
b) Click ¤Next¤ to proceed.
Figure 3-16 Startup Wizard Dialog for EC Motors: Incremental Encoder 1 Settings
5) Startup Wizard for EC motors (Step 9): Safety Parameter Position
a) Enter maximum permitted following error.
b) Click ¤Next¤ to proceed.
Figure 3-17 Startup Wizard Dialog for EC Motors: Safety Parameter Position
6) Startup Wizard for EC motors (Step 10): Configuration Summary
A short summary of most important configuration values will be displayed.
a) If configuration is not correct: Click ¤Back¤ to modify settings.
b) If configuration is correct: Click ¤Finish¤ to close the startup wizard.
Figure 3-18 Startup Wizard Dialog for EC Motors: Configuration Summary