Maxon ESCON 50/4 EC-S Application guide

ESCON Module 50/4 EC-S Servo Controller | P/N 446925
Hardware Reference
CCMC | Edition 2021-08 | DocID rel9026
Hardware Reference

Table of Contents
ESCON Module 50/4 EC-S Hardware Reference
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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 Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Configuration of Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5 Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.6 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4 WIRING 25
5 MOTHERBOARD DESIGN GUIDE 27
5.1 Requirements for Components of Third-party Suppliers. . . . . . . . . . . . . . . . . . . 27
5.2 Design Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3 THT Footprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4 Pin Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.5 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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 50/4 EC-S 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.7 ESCON Module Motherboard Sensorless (450237) . . . . . . . . . . . . . . . . . . . . . 31
5.8 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
LIST OF FIGURES 39
LIST OF TABLES 40
INDEX 41

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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 50/4 EC-S
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 Motherboard
Sensorless».
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 50/4 EC-S Hardware Reference | Edition 2021-08 | DocID rel9026
1.2 About the Device
The ESCON Module 50/4 EC-S is a small-sized, powerful 4-quadrant PWM servo controller for the highly
efficient control of permanent magnet-activated brushless, sensorless EC motors without Hall sensors up to
approximately 200 Watts.
The featured operating modes – speed control (closed loop) and speed control (open loop) – meet the high-
est requirements. The ESCON Module 50/4 EC-S 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 50/4 EC-S (446925)
Electrical Rating
Nominal operating voltage +VCC 10…50 VDC
Absolute operating voltage
+VCC min/+VCC max
8 VDC / 56 VDC
Output voltage (max.) 0.96 x +VCC
Output current Icont/Imax (<30 s) 4 A / 12 A
Pulse width modulation frequency 53.6 kHz
Sampling rate of PI speed controller 5.36 kHz
Max. efficiency 97%
Max. speed EC motor 120,000 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<500 mA)
BEMF signals BEMF-W1, BEMF-W2, BEMF-W3
Voltage Outputs Auxiliary output voltage +5 VDC (IL≤110 mA)
Potentiometer Potentiometer P1 (on board) 210°; linear
Motor Connec-
tions 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
Physical
Weight approx. 11 g
Dimensions (L x W x H) 43.2 x 31.8 x 12.7 mm
Connection Plugs into socket headers with 2.54 mm pitch

Specifications
Technical Data
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Table 2-4 Technical Data
Figure 2-1 Derating Output Current
Table 2-5 Limitations
Environmental
Conditions
Temperature
Operation −30…+45 °C
Extended range *1) +45…+65 °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 50/4 EC-S (446925)
Protection functionality Switch-off threshold Recovery threshold
Undervoltage 7.2 V 7.4 V
Overvoltage 58 V 55 V
Overcurrent 22.5 A —
Thermal overload 100 °C 90 °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 Environmental testing – Test Fc: Vibration (sinusoidal,
10…500 Hz, 20 m/s2)
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,
sinusförmig, 10…500 Hz, 20 m/s2)
MIL-STD-810F Random transport (10…500 Hz up to 2.53 grms)
Safety standards UL File Number E76251; 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): 634'498 hours

Setup
Generally applicable Rules
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3SETUP
IMPORTANT NOTICE: PREREQUISITES FOR PERMISSION TO COMMENCE INSTALLATION
The ESCON Module 50/4 EC-S 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…50 VDC.
• Supply voltages above 56 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 50/4 EC-S are as follows; continuous max. 4 A / short-time (acceleration) max. 12 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
Start-up Procedure
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3.2 Start-up Procedure
A successful sensorless start-up procedure consists of two phases; the alignment phase and the accelera-
tion phase.
ALIGNMENT PHASE
The motor shaft will be brought to and stabilized in a defined rotor position. This will be accomplished by
applying a motor current ramp with a fixed step configuration without rotating stator field. During the align-
ment phase the motor current Istart rises.
ACCELERATION PHASE
A synchronous rotation of the motor with a constant acceleration αis being forced until the speed is suffi-
ciently high for Back-EMF sampling. The motor current is limited to Istart.
Note
Under unfavorable conditions, the sensorless commutation principle can lead to start-up problems.
Thereby, the following aspects can have a negative effect on the reliable start-up:
• high friction torques
• high moment of inertia in combination with low friction
• unsuitably defined start-up parameter
CAUTION
Risk of injury
During the starting operation, the motor shaft will temporarily move in both directions
• Do not take the device into operation unless all protective devices on moving parts have been com-
pletely attached and checked for proper function.
• Make sure that no loose objects are in the vicinity of any moving parts. Keep any objects which could
get caught away.

Setup
Configuration of Power Supply
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3.3 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 96%
• Controller’s max. voltage drop of 1 V @ 4 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…50 VDC
Absolute output voltage min. 8 VDC; max. 56 VDC
Output current
Depending on load
• continuous max. 4 A
• short-time (acceleration, <30 s) max. 12 A
VCC UN
nO
------- nΔn
ΔM
---------M⋅+


1
0.96
----------
⋅⋅1V[]+≥

Setup
Connections
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3.4 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 4-25.
3.4.1 Pin Assignment
Figure 3-3 Pin Assignment
Table 3-7 Pin Assignment & Wiring
Pin Signal Description
1 / 2 Motor winding 1 EC motor: Winding 1
3 / 4 Motor winding 2 EC motor: Winding 2
5 / 6 Motor winding 3 EC motor: Winding 3
7 / 8 +VCC Nominal operating voltage (+10…+50 VDC)
9 / 10 Power_GND
GND
Ground of operating voltage
Ground
11 +5 VDC Auxiliary output voltage (+5 VDC; ≤110 mA)
12 BEMF-W3 Back-EMF signal of winding 3
13 BEMF-W1 Back-EMF signal of winding 1
14 BEMF-W2 Back-EMF signal of winding 2
19 DigIN/DigOUT4 Digital input/output 4
20 DigIN/DigOUT3 Digital input/output 3
21 DigIN2 Digital input 2
22 DigIN1 Digital input 1
23 GND Ground
24 AnOUT2 Analog output 2
25 AnOUT1 Analog output 1
26 AnIN2−Analog input 2, negative signal
27 AnIN2+ Analog input 2, positive signal
28 AnIN1−Analog input 1, negative signal
29 AnIN1+ Analog input 1, positive signal

Setup
Connections
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3.4.2 Back-EMF Signals
Best Practice
• Make sure that all three Back-EMF signal leads are of identical length and that they are being routed in
parallel. Thereby, keep the leads as short as possible.
• The Back-EMF signal leads must be connected with the corresponding motor winding terminals.
• If no motor output filter is used, the Back-EMF signal leads may be connected directly to the motor wind-
ing terminals:
– Pin [13] BEMF-W1 with pins [1/2] motor winding 1
– Pin [14] BEMF-W2 with pins [3/4] motor winding 2
– Pin [12] BEMF-W3 with pins [5/6] motor winding 3
• If a motor output filter is used, the Back-EMF signal leads should be connected to the filter’s motor exit
side.
• For further details  “Motherboard Design Guide” on page 5-27.
Figure 3-4 Back-EMF Signal Circuit
Input voltage 0…50 VDC
Max. input voltage ±100 VDC

Setup
Connections
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3.4.3 Digital I/Os
3.4.3.1 Digital Input 1
Figure 3-5 DigIN1 Circuit
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 25 Hz…5 kHz
PWM duty cycle range (resolution) 10...90% (0.1%)
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

Setup
Connections
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3.4.3.2 Digital Input 2
Figure 3-6 DigIN2 Circuit
3.4.3.3 Digital Inputs/Outputs 3 and 4
Figure 3-7 DigIN3 Circuit (analogously valid also for DigIN4)
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
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

Setup
Connections
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Figure 3-8 DigOUT3 Circuit (analogously valid also for DigOUT4)
Figure 3-9 DigOUT3 Wiring Examples (analogously valid also for DigOUT4)
DigOUT
Max. input voltage +36 VDC
Max. load current 500 mA
Max. voltage drop 0.5 V @ 500 mA
Max. load inductance 100 mH @ 24 VDC; 500 mA