Maxon ESCON 24/2 Application guide

ESCON Module 24/2 Servo Controller | P/N 466023
Hardware Reference
CCMC | Edition 2021-08 | DocID rel9004
Hardware Reference

Table of Contents
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TABLE OF CONTENTS 2
1 ABOUT 5
1.1 About this Document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 About the Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 About the Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 SPECIFICATIONS 9
2.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 SETUP 13
3.1 Generally applicable Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 Configuration of Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4 WIRING 27
4.1 DC Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2 EC Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5 MOTHERBOARD DESIGN GUIDE 33
5.1 Requirements for Components of Third-party Suppliers. . . . . . . . . . . . . . . . . . . 33
5.2 Design Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3 THT Footprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.4 Pin Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.5 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
TABLE OF CONTENTS
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.
The ESCON Module 24/2 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.
Therefore, you must not put the device into service, …
• unless you have made completely sure that the other machinery fully complies with the EU directive’s requirements!
• unless the other machinery fulfills all relevant health and safety aspects!
• unless all respective interfaces have been established and fulfill the herein stated requirements!

Table of Contents
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5.6 Dimensional Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.7 ESCON Module 24/2 Motherboard (486400) . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.8 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
LIST OF FIGURES 53
LIST OF TABLES 54
INDEX 55

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About
About this Document
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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 Module 24/2
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.
The document contains performance data and specifications, information on fulfilled standards, details on
connections and pin assignment, and wiring examples. In addition, the document also includes a Mother-
board Design Guide and detailed information on the optionally available «ESCON Module 24/2 Mother-
board».
1.1.2 Target Audience
The present document is intended for trained and skilled personnel. It conveys information on how
to understand and fulfill the respective work and duties.
1.1.3 How to use
Take note of the following notations and codes which will be used throughout the document.
Table 1-1 Notation used
Notation Meaning
(n) refers to an item (such as order number, list item, etc.)
denotes “see”, “see also”, “take note of” or “go to”

About
About this Document
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1.1.4 Symbols & signs
In the course of the present document, the following symbols and signs will be used.
Table 1-2 Symbols & Signs
1.1.5 Trademarks and Brand Names
For easier legibility, registered brand names are listed below and will not be further tagged with their respec-
tive trademark. It must be understood that the brands (the list below is not necessarily concluding) are pro-
tected 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 may result in death or
serious injury.
CAUTION
Indicates a probably 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
to continuing, or gives information on a particular item
you need to observe.
Best Practice Indicates advice or a recommendation on the easiest
and best way to proceed.
Material
Damage
Indicates instructions on how to prevent damage to the
equipment.
Brand Name Trademark Owner
Littelfuse®
SMD NANO2® © Littelfuse, USA-Chicago, IL
Windows® © Microsoft Corporation, USA-Redmond, WA

About
About the Device
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1.1.6 Copyright
The present document – including all parts thereof – is protected by copyright. Any use (including reproduc-
tion, translation, microfilming, and other means of electronic data processing) beyond the narrow restric-
tions of the copyright law without the prior approval of maxon, is not permitted and subject to prosecution
under the applicable law.
© 2021 maxon. All rights reserved. Subject to change without prior notice.
CCMC | ESCON Module 24/2 Hardware Reference | Edition 2021-08 | DocID rel9004
1.2 About the Device
The ESCON Module 24/2 is a small-sized, powerful 4-quadrant PWM servo controller for the highly efficient
control of permanent magnet-activated brushed DC motors or brushless EC motors up to approximately 48
Watts.
The featured operating modes – speed control (closed loop), speed control (open loop), and current control
– meet the highest requirements. The ESCON Module 24/2 is designed being commanded by an analog set
value and features extensive analog and digital I/O functionality.
The miniaturized OEM plug-in module can be seamlessly integrated in complex customer applications. A
suitable motherboard is available for the initial commissioning.
The device is designed to be configured via USB interface using the graphical user interface «ESCON Stu-
dio» for Windows PCs.
You can download the latest ESCON software version (as well as the latest edition of the documentation)
from the Internet under http://escon.maxongroup.com.
maxon motor ag
Brünigstrasse 220
CH-6072 Sachseln
[phone]
www.maxongroup.com

About
About the Safety Precautions
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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 in any work unless you possess the stated skills (chapter “1.1.2 Target Audience”
on page 1-5)!
• Refer to chapter “1.1.4 Symbols & signs” on page 1-6 for explanations of the symbols used in the
following!
• 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!
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 equip-
ment. 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.
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
it with your name!

Specifications
Technical Data
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2 SPECIFICATIONS
2.1 Technical Data
ESCON Module 24/2 (466023)
Electrical Rating
Nominal operating voltage +VCC 10…24 VDC
Absolute operating voltage
+VCC min/+VCC max
8 VDC / 28 VDC
Output voltage (max.) +VCC
Output current Icont/Imax (<4 s) 2 A / 6 A
Pulse width modulation frequency 53.6 kHz
Sampling rate of PI current controller 53.6 kHz
Sampling rate of PI speed controller 5.36 kHz
Max. efficiency 92%
Max. speed of DC motor limited by max. permissible speed (motor) and
max. output voltage (controller)
Max. speed EC motor 150,000 rpm (1 pole pair)
Built-in motor choke –
Inputs & Outputs
Analog input 1
Analog input 2 12-bit resolution; −10…+10 V; differential
Analog output 1
Analog output 2 12-bit resolution ; −4…+4 V; referenced to GND
Digital input 1
Digital input 2 +2.4…+36 VDC (Ri= 38.5 kΩ)
Digital input/output 3
Digital input/output 4 +2.4…+36 VDC (Ri= 38.5 kΩ)/max. 36 VDC (IL<50 mA)
Hall sensor signals H1, H2, H3
Encoder signals A, A\, B, B\, (max. 1 MHz)
Voltage Outputs
Auxiliary output voltage +5 VDC (IL≤10 mA)
Hall sensor supply voltage +5 VDC (IL≤30 mA)
Encoder supply voltage +5 VDC (IL≤70 mA)
Motor
Connections
DC motor + Motor, −Motor
EC motor Motor winding 1, Motor winding 2, Motor winding 3
Interface USB 2.0 / USB 3.0 full speed
Status Indicators Operation green LED
Error red LED

Specifications
Technical Data
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Table 2-4 Technical Data
Figure 2-1 Derating Output Current
Table 2-5 Limitations
Physical
Weight approx. 7 g
Dimensions (L x W x H) 35.6 x 26.7 x 12.7 mm
Connection Plugs into socket headers with 2.54 mm pitch
Environmental
Conditions
Temperature
Operation −30…+60 °C
Extended range *1) +60…+80 °C
Derating Figure 2-1
Storage −40…+85 °C
Altitude *2)
Operation 0…6’000 m MSL
Extended range *1) 6’000…10’000 m MSL
Derating Figure 2-1
Humidity 5…90% (condensation not permitted)
*1) Operation within the extended range (temperature and altitude) is permitted. However, a respective derating (declination
of output current Icont) as to the stated values will apply.
*2) Operating altitude in meters above Mean Sea Level, MSL.
ESCON Module 24/2 (466023)
Protection functionality Switch-off threshold Recovery threshold
Undervoltage 7.2 V 7.4 V
Overvoltage 31 V 29 V
Overcurrent 9.6 A —
Thermal overload 95 °C 85 °C

Specifications
Technical Data
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Figure 2-2 Dimensional Drawing [mm]

Specifications
Standards
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2.2 Standards
The described device has been successfully tested for compliance with the below listed standards. In prac-
tical terms, only the complete system (the fully operational equipment comprising all individual components,
such as motor, servo controller, power supply unit, EMC filter, cabling etc.) can undergo an EMC test to
ensure interference-free operation.
Important Notice
The device’s compliance with the mentioned standards does not imply its compliance within the final, ready
to operate setup. In order to achieve compliance of your operational system, you must perform EMC testing
of the involved equipment as a whole.
Table 2-6 Standards
Electromagnetic compatibility
Generic stan-
dards
IEC/EN 61000-6-2 Immunity for industrial environments
IEC/EN 61000-6-3 Emission standard for residential, commercial and light-
industrial environments
Applied stan-
dards
IEC/EN 61000-6-3
IEC/EN 55022
(CISPR22)
Radio disturbance characteristics/radio interference
IEC/EN 61000-4-3 Radiated, radio-frequency, electromagnetic field immunity test
>10 V/m
IEC/EN 61000-4-4 Electrical fast transient/burst immunity test ±2 kV
IEC/EN 61000-4-6 Immunity to conducted disturbances, induced by radio-
frequency fields 10 Vrms
Others
Environmental
standards
IEC/EN 60068-2-6 Environmental testing – Test Fc: Vibration (sinusoidal,
10…500 Hz, 20 m/s2)
MIL-STD-810F Random transport (10…500 Hz up to 2.53 grms)
Safety standards UL File Number E148881; unassembled printed circuit board
Reliability MIL-HDBK-217F
Reliability prediction of electronic equipment
Environment: Ground, benign (GB)
Ambient temperature: 298 K (25 °C)
Component stress: In accordance with circuit diagram and
nominal power
Mean Time Between Failures (MTBF): 1'044'089 hours

Setup
Generally applicable Rules
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3SETUP
IMPORTANT NOTICE: PREREQUISITES FOR PERMISSION TO COMMENCE INSTALLATION
The ESCON Module 24/2 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.
3.1 Generally applicable Rules
Maximal permitted Supply Voltage
• Make sure that operating voltage is between 10…24 VDC.
• Supply voltages above 28 VDC, or wrong polarity will destroy the unit.
• Note that the necessary output current is depending on the load torque. Yet, the output current limits of
the ESCON Module 24/2 are as follows; continuous max. 2 A / short-time (acceleration) max. 6 A.
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 poten-
tial 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, bal-
ance them.
• Insert the USB connector first, then switch on the power supply of the controller.
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 completely sure that the other machinery fully com-
plies with the EU directive’s requirements!
• Do not operate the device, unless the other machinery fulfills all relevant health and safety aspects!
• Do not operate the device, unless all respective interfaces have been established and fulfill the
requirements stated in this document!

Setup
Configuration of Power Supply
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3.2 Configuration of Power Supply
Basically, any power supply may be used, provided it meets the minimal requirements stated below.
1) Use the formula below to calculate the required voltage under load.
2) Choose a power supply according to the calculated voltage. Thereby consider:
a) During braking of the load, the power supply must be capable of buffering the recovered
kinetic energy (for example, in a capacitor).
b) If you are using an electronically stabilized power supply, make sure that the overcurrent pro-
tection circuit is configured inoperative within the operating range.
Note
The formula already takes the following into account:
• Maximum PWM duty cycle of 100%
• Controller’s max. voltage drop of 1 V @ 2 A
KNOWN VALUES:
• Operating torque M [mNm]
• Operating speed n [rpm]
• Nominal motor voltage UN[Volt]
• Motor no-load speed at UN, n0[rpm]
• Speed/torque gradient of the motor Δn/ΔM [rpm/mNm]
SOUGHT VALUE:
• Supply voltage +VCC [Volt]
SOLUTION:
Power Supply Requirements
Output voltage +VCC 10…24 VDC
Absolute output voltage min. 8 VDC; max. 28 VDC
Output current
Depending on load
• continuous max. 2 A
• short-time (acceleration, <4 s) max. 6 A
VCC UN
nO
------- nΔn
ΔM
---------M⋅+


⋅1V[]+≥

Setup
Connections
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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 the given order and choose the wiring diagram that best suits the components you
are using. For corresponding wiring diagrams chapter “4 Wiring” on page 4-27.
3.3.1 Pin Assignment
Figure 3-3 Pin Assignment
Table 3-7 Pin Assignment (Pins 1-13)
Pin Signal Description
1Motor (+M)
Motor winding 1
DC motor: Motor +
EC motor: Winding 1
2Motor (−M)
Motor winding 2
DC motor: Motor −
EC motor: Winding 2
3Motor winding 3 EC motor: Winding 3
4+VCC Nominal operating voltage (+10…+24 VDC)
5Power_GND
GND
Ground of operating voltage
Ground
6+5 VDC
Hall sensor supply voltage (+5 VDC; ≤30 mA)
Encoder supply voltage (+5 VDC; ≤70 mA)
Auxiliary output voltage (+5 VDC; ≤10 mA)
7Hall sensor 1 Hall sensor 1 input
8Hall sensor 2 Hall sensor 2 input
9Hall sensor 3 Hall sensor 3 input
10 Channel A Encoder channel A
11 Channel A\ Encoder channel A complement
12 Channel B Encoder channel B
13 Channel B\ Encoder channel B complement

Setup
Connections
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Figure 3-4 Pin Assignment
Table 3-8 Pin Assignment (Pins 14-24)
Pin Signal Description
14 DigIN/DigOUT4 Digital input/output 4
15 DigIN/DigOUT3 Digital input/output 3
16 DigIN2 Digital input 2
17 DigIN1 Digital input 1
18 GND Ground
19 AnOUT2 Analog output 2
20 AnOUT1 Analog output 1
21 AnIN2−Analog input 2, negative signal
22 AnIN2+ Analog input 2, positive signal
23 AnIN1−Analog input 1, negative signal
24 AnIN1+ Analog input 1, positive signal

Setup
Connections
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3.3.2 Hall Sensor
Figure 3-5 Hall Sensor 1 Input Circuit (analogously valid also for Hall Sensors 2 & 3)
Hall sensor supply voltage +5 VDC
Max. Hall sensor supply current 30 mA
Input voltage 0…5.5 VDC
Max. input voltage ±5.5 VDC
Logic 0 typically <1.0 V
Logic 1 typically >2.4 V
Internal pull-up resistor 10 kΩ (referenced to +5.45 V)

Setup
Connections
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3.3.3 Encoder
Best practice
• Differential signals offer good resistance against electrical interference. Therefore we recommend
using a differential scheme. Nevertheless, the controller supports both schemes – differential and sin-
gle-ended (unsymmetrical).
• The controller does not require an index impulse (Ch I, Ch I\).
• For best performance, we strongly recommend using encoders with a line driver. Otherwise, speed
limitations may apply due to slow switching edges.
Figure 3-6 Encoder Input Circuit Ch A “Differential” (analogously valid also for Ch B)
Differential
Min. differential input voltage ±200 mV
Max. input voltage +12 VDC/−12 VDC
Line receiver (internal) EIA RS422 standard
Max. input frequency 1 MHz

Setup
Connections
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Figure 3-7 Encoder Input Circuit Ch A “Single-ended” (analogously valid also for Ch B)
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 +420 μA @ 5 V
Input low current IIL = typically −170 μA @ 0 V
Max. input frequency 100 kHz

Setup
Connections
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3.3.4 Digital I/Os
3.3.4.1 Digital Input 1
Figure 3-8 DigIN1 Circuit
Input voltage 0…28 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%
PWM accuracy
typically 0.1% @ 10 Hz
typically 0.5% @ 1 kHz
typically 2.5% @ 5 kHz
RC Servo cycle duration 3…30 ms
RC Servo pulse length 1…2 ms