Maxon ESCON 36/2 DC Application guide

ESCON 36/2 DC Servo Controller | P/N 403112
Hardware Reference
CCMC | Edition 2021-08 | DocID rel9011
Hardware Reference

Table of Contents
ESCON 36/2 DC Hardware Reference
A-2 CCMC | 2021-08 | rel9011
1 ABOUT 3
1.1 About this Document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 About the Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 About the Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 SPECIFICATIONS 7
2.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 SETUP 11
3.1 Generally applicable Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Determination of Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5 Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.6 Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.7 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4 WIRING 31
LIST OF FIGURES 40
LIST OF TABLES 41
INDEX 42
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 36/2 DC 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!

About
About this Document
ESCON 36/2 DC Hardware Reference
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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 36/2 DC Servo Controller. It will
highlight the tasks for safe and adequate installation and/or commissioning. Follow the described instruc-
tions …
• 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.
1.1.2 Target Audience
The present document is intended for trained and skilled personnel. It conveys information on how to under-
stand 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 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.
Brand Name Trademark Owner
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 36/2 DC Hardware Reference | Edition 2021-08 | DocID rel9011
1.2 About the Device
The ESCON 36/2 DC is a small-sized, powerful 4-quadrant PWM servo controller for the highly efficient
control of permanent magnet-activated DC motors up to approximately 72 Watts.
The featured operating modes – speed control (closed loop), speed control (open loop), and current control
– meet the highest requirements. The ESCON 36/2 DC is designed being commanded by an analog set
value and features extensive analog and digital I/O functionality.
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 with any work unless you possess the stated skills (chapter “1.1.2 Target Audi-
ence” on page 1-3)!
• Refer to chapter “1.1.4 Symbols & Signs” on page 1-4 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!
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 36/2 DC (403112)
Electrical Rating
Nominal operating voltage +VCC 10…36 VDC
Absolute operating voltage
+VCC min / +VCC max
8 VDC / 38 VDC
Output voltage (max.) 0.98 x +VCC
Output current Icont / Imax (<60 s) 2 A / 4 A
Pulse Width Modulation frequency 53.6 kHz
Sampling rate PI current controller 53.6 kHz
Sampling rate PI speed controller 5.36 kHz
Max. efficiency 95%
Max. speed limited by max. permissible speed (motor) and max. output
voltage (controller)
Built-in motor choke 300 μH; 2 A
Inputs & Outputs
Analog Input 1
Analog Input 2 resolution 12-bit; −10…+10 V; differential
Analog Output 1
Analog Output 2 resolution 12-bit; −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)
Encoder signals A, A\, B, B\, (max. 1 MHz)
Voltage Outputs Auxiliary output voltage +5 VDC (IL≤40 mA)
Encoder supply voltage +5 VDC (IL≤70 mA)
Potentiometer Potentiometer P1 (on board) 210°; linear
Motor
Connections
+ Motor
−Motor
Interface USB 2.0 / USB 3.0 full speed
Status Indicators Operation green LED
Error red LED
Physical
Weight approx. 30 g
Dimensions (L x W x H) 55 x 40 x 16.1 mm
Mounting holes for M2.5 screws (max. tightening torque 0.16 Nm)

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…+81 °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 36/2 DC (403112)
Protection functionality Switch-off threshold Recovery threshold
Undervoltage 7.2 V 7.4 V
Overvoltage 43.1 V 41 V
Overcurrent 6.75 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 E207844; 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): 511'401 hours

Setup
Generally applicable Rules
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3SETUP
IMPORTANT NOTICE: PREREQUISITES FOR PERMISSION TO COMMENCE INSTALLATION
The ESCON 36/2 DC 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
For each possible motor variant you will find information on the from/to connections and the cables you will
require. If you should decide not to use the ready-made maxon cables, you must establish the respective
connections as to chapter “3.4.7 ESCON 36/2 DC Connector Set” on page 3-28 and chapter “4 Wiring”
on page 4-31.
Maximal permitted Supply Voltage
• Make sure that supply power is between 10…36 VDC.
• Supply voltages above 38 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 36/2 DC are as follows; continuous max. 2 A / short-time (acceleration) max. 4 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.
How to read the Wiring Details
The subsequent description follows this scheme:
• Column “J… & Head A”: Pin number…
– of the socket,
– of the corresponding plug, and
– of Head A of the matching prefab maxon cable.
• Column “Prefab Cable”: Wire color of the prefab maxon cable.
• Column “Head B”: Pin number of Head B of the matching prefab maxon cable.
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
Determination of Power Supply
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3.2 Determination 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 98%
• 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…36 VDC
Absolute output voltage min. 8 VDC; max. 38 VDC
Output current
Depending on load
• continuous max. 2 A
• short-time (acceleration, <60 s) max. 4 A
VCC UN
nO
------- nΔn
ΔM
---------M⋅+


1
0.98
----------
⋅⋅1V[]+≥

Setup
Cabling
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3.3 Cabling
Here you can get the connection information required to commission your ESCON 36/2 DC. You will find all
details for both approaches, Plug&Play and making your own cables.
PLUG&PLAY
Take advantage of maxon’s prefab cable assemblies. They come as ready-to-use parts and will help you to
reduce commissioning time to a minimum.
a) Check the «Cable Selector» (Table 3-7) to find the cable assemblies’ order number matching
the setup you will be using.
b) Follow the cross-reference to get the cable assemblies’ pin assignment.
MAKE&BAKE YOUR OWN
a) Check the «Cable Selector» (Table 3-7) to find the required cables for the setup you will be
using.
b) Follow the cross-reference to get the cable’s specification and pin assignment.
c) Utilize the installation kit (page 3-28) containing plugs and terminals that will fit the control-
ler’s sockets.
Table 3-7 Cable Selector
Cable
Socket
DC Motor
with…
Designation Order
number

page
Separated
Motor/Encoder
Cable
Integrated
Motor/Encoder
Ribbon Cable
Power Cable 403957 3-14 J1 X X
DC Motor Cable 403962 3-15 J2 X
Encoder Cable 275934 3-18 J4 O O
I/O Cable 6core 403965 3-21 J5 X X
I/O Cable 7core 403964 3-25 J6 O O
USB Type A - micro B Cable 403968 3-27 J7 X X
Legend: X = required / O = optional

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. Some connections must be established in a given way, while for motor (J2/J2A and
encoder (J4/J4A) alternative plug-in locations can be chosen from.
Follow the description in given order and choose the connection scheme that suits the respective compo-
nents you are using. For corresponding wiring diagrams chapter “4 Wiring” on page 4-31.
3.4.1 Power (J1)
Figure 3-3 Power Socket J1
Table 3-8 Power Socket J1 – Pin Assignment & Cabling
Table 3-9 Power Cable
J1 &
Head A Prefab Cable Head B Signal Description
Pin Color Pin
1white −Power_GND Ground of supply voltage
2brown ++VCC Power supply voltage (+10…+36 VDC)
Power Cable (403957)
Cable cross-section 2 x 0.34 mm2
Length 1.5 m
Head A Suitable plugs
Suitable contacts
Hirose DF3-2S-2C
Hirose DF3-22SC…
Head B Cable end sleeves 0.34 mm2

Setup
Connections
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3.4.2 Motor (J2 / J2A)
Potential Destruction
Use only one of the two sockets – either J2 or J2A!
SOCKET J2
Figure 3-4 Motor Socket J2
Table 3-10 Motor Socket J2 – Pin Assignment & Cabling
Table 3-11 DC Motor Cable
J2 &
Head A Prefab Cable Head B Signal Description
Pin Color Pin
1white Motor (+M) Motor +
2brown Motor (−M) Motor −
3black Motor shield Cable shield
DC Motor Cable (403962)
Cable cross-section 2 x 0.34 mm2shielded
Length 1.5 m
Head A Suitable plugs
Suitable contacts
Hirose DF3-3S-2C
Hirose DF3-22SC…
Head B Cable end sleeves 0.34 mm2

Setup
Connections
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SOCKET J2A
Figure 3-5 Motor Socket J2A
Table 3-12 Motor Socket J2A – Pin Assignment
Table 3-13 Motor Socket J2A – Specification & Accessories
J2A &
Head A Prefab Cable Head B Signal Description
Pin Color Pin
1Motor (+M) Motor +
2Motor (−M) Motor −
Specification / Accessories
Type 2 poles, spring-loaded contacts, pitch 2.5 mm
Suitable cables
Rigid 0.14…0.5 mm2, AWG 26-20 / wire stripping length 6 mm
Flexible
0.2…0.5 mm2, AWG 24-20 / wire stripping length 6 mm
0.25…0.5 mm2, AWG 24-20 / wire stripping length 6 mm, cable
end sleeves
Suitable tools Miniature screwdriver, size “00”

Setup
Connections
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3.4.3 Encoder (J4 / J4A)
Potential Destruction
Use only one of the two sockets – either J4 or J4A!
SOCKET J4
Figure 3-6 Encoder Socket J4
Table 3-14 Encoder Socket J4 – Pin Assignment & Cabling
Note
If you are using a maxon DC motor with integrated Motor/Encoder Ribbon Cable, make sure to close
both JP1 jumpers (  chapter “3.5 Jumpers” on page 3-29).
Table 3-15 Encoder Socket J4 – Accessories
J4 &
Head A Prefab Cable Head B Signal Description
Pin Color Pin
1Motor (+M) Motor +M (note below)
2+5 VDC Encoder supply voltage (+5 VDC; ≤70 mA)
3GND Ground
4Motor (−M) Motor −M (note below)
5Channel A\ Channel A complement
6Channel A Channel A
7Channel B\ Channel B complement
8Channel B Channel B
9not connected –
10 not connected –
Accessories
Suitable strain
relief
Lock 2 levers, Harting (09 18 000 9905)
Retainer
For sockets with strain relief:
1 retainer clip, height 13.5 mm, 3M (3505-8110)
For sockets without strain relief:
1 retainer clip, height 7.9 mm, 3M (3505-8010)
Latch For sockets with strain relief: 2 pieces, 3M (3505-33B)

Setup
Connections
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Table 3-16 Encoder Cable
SOCKET J4A
Figure 3-7 Encoder Socket J4A
Table 3-17 Encoder Socket J4A – Pin Assignment
Encoder Cable (275934)
Cable cross-section 10 x AWG28, round-jacket, flat cable, pitch 1.27 mm
Length 3 m
Head A DIN 41651 female, pitch 2.54 mm, 10 poles, with strain relief
Head B DIN 41651 Plug, pitch 2.54 mm, 10 poles, with strain relief
J4A &
Head A Prefab Cable Head B Signal Description
Pin Color Pin
1not connected –
2+5 VDC Encoder supply voltage (+5 VDC; ≤70 mA)
3GND Ground
4not connected –
5Channel A\ Channel A complement
6Channel A Channel A
7Channel B\ Channel B complement
8Channel B Channel B
9not connected –
10 not connected –

Setup
Connections
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Table 3-18 Encoder Socket J4A – Specification & Accessories
Best Practice
• Because of its resistance against electrical interferences, we recommend using differential scheme.
Nevertheless, the controller supports both schemes – differential and single-ended.
• The controller does not require an index impulse (Ch I, Ch I\).
• For best performance, we strongly recommend using encoders with line driver. Otherwise, speed
limitations may apply due to slow switching edges.
Figure 3-8 Encoder Input Circuit Ch A “Differential” (analogously valid also for Ch B)
Specification / Accessories
Type 2 x 5 poles, half pitch box header, pitch 1.27/1.27 mm
Suitable plugs
Samtec: FFSD series
W+P Products: 376 series
Elcotron: IDC32 series
Suitable cables Flat ribbon cable AWG 30
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 3-9 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 −50 μA @ 5 V
Input low current IIL = typically −550 μA @ 0 V
Max. input frequency 100 kHz