maxon motor EPOS4 50/5 Reference Manual

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Page 1

maxon motor control

EPOS4 Positioning Controller

Hardware Reference

Edition May 2017

Positioning Controller

P/N 546047

Hardware Reference

Document ID: rel6852

maxon motor ag Brünigstrasse 220 P.O.Box 263 CH-6072 Sachseln Phone +41 41 666 15 00 Fax +41 41 666 16 50 www.maxonmotor.com

Page 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 Thermal Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.3 Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.4 Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.5 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3Setup 15

3.1 Generally applicable Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.2 Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.3.1 Power Supply (X1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.3.2 Logic Supply (X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.3.3 Motor (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.3.4 Hall Sensor (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.3.5 Encoder (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.3.6 Sensor (X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.3.7 Digital I/O (X7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.3.8 Analog I/O (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.3.9 STO (X9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.3.10 RS232 (X10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3.3.11 CAN 1 (X11) & CAN 2 (X12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3.3.12 USB (X13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.3.13 Extension NET IN (X14) & Extension NET OUT (X15) . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.3.14 Extension Signal (X16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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 EPOS4 50/5 positioning controller 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 com-

pleted machinery or equipment. Therefore, you must not put the device into service,…

• unless you have made completely sure that the ot he r ma chinery 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!

maxon motor control

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3.3.15 Extension Slots (EXT1 & EXT2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.3.16 DIP Switch Configuration (SW1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3.3.17 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3.4 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4Wiring 59

4.1 Possible Combinations to connect a Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 60

4.2 Main Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

4.3 Excerpts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4.3.1 Power & Logic Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4.3.2 DC Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4.3.3 EC (BLDC) Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4.3.4 Hall Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4.3.5 Digital Incremental Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

4.3.6 Digital & Digital Incremental Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

4.3.7 Digital & Analog Incremental Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

4.3.8 Digital Incremental & SSI Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

4.3.9 Analog Incremental Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

4.3.10 SSI Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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1 About

1.1 About this Document

1.1.1 Intended Purpose

Use the document to…

–stay safe, –be fast, –end up with set up and ready-to-go equipment.

The purpose of the present document is to familiarize you with the EPOS4 50/5 positioning 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 present document is part of a documentation set and contains performance data and specifications, information on fulfilled standards, details on connections and pin assignment, and wiring examples. The below overview shows the documentation hierarchy and the interrelationship of its individual parts:

About

About this Document

Figure 1-1 Documentation structure

1.1.2 T arget 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.

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About About this Document

1.1.3 How to use

Throughout the document, the following notations and codes will be used.

Notation Meaning

(n) refers to an item (such as part numbers, list items, etc.)

 denotes “see”, “see also”, “take note of” or “go to”

Table 1-1 Notation used

1.1.4 Symbols & Signs

In the course of the present document, the following symbols and sings will be used.

Type Symbol Meaning

Indicates an imminent hazardous situation. If not avoided, it will result in death or serious in jury.

Indicates a potential hazardous situation. If not avoided, it can result in death or serious injury.

Indicates a probable hazardous situation or calls

the attention to unsafe practices. If not avoided, it

Safety alert

DANGER

WARNING

(typical)

CAUTION

may result in injury.

Prohibited action

Indicates a dangerous action. Hence, you must not!

(typical)

Mandatory action

Indicates a mandatory action. Hence, you must!

(typical)

Requirement / Note / Remark

Information

Best practice

Material Damage

Table 1-2 Symbols and signs

Indicates an activity you must perform prior continuing, or gives information on a particular item you need to observe.

Indicates an advice or recommendation on the easiest and best way to further proceed.

Indicates information particular to possible damage of the equipment.

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About

About the Device

1.1.5 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 list below is not necessarily concluding) are protected by copyright and/or other intellectual property rights even if their legal trademarks are omitted in the later course of this document.

Brand Name Trademark Owner

Adobe® Reader® © Adobe Systems Incorporated, USA-San Jose, CA

BiSS © iC-Haus GmbH, DE-Bodenheim

CANopen® CiA®

CLIK-Mate™ Micro-Fit™ Mini-Fit Jr.™

Mega-Fit®

EnDat © DR. JOHANNES HEIDENHAIN GmbH, DE-Traunreut

EtherCAT®

Linux® © Linus Torvalds (The Linux Foundation, USA-San Francisco CA)

PCI Express® PCIe®

TwinCAT® © Beckhoff Automation GmbH, DE-Verl

Windows® © Microsoft Corporation, USA-Redmond, WA

Table 1-3 Brand names and trademark owners

1.1.6 Copyright

The present document – including all parts thereof – is protected by copyright. Any use (including reproduction, 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 subject to prosecution under the applicable law.

1.2 About the Device

Capabilities of the device, included features, and supported motors.

maxon motor control’s EPOS4 50/5 is a small-sized, full digital, smart positioning control unit. Its high power density allows flexible use for brushed DC and brushless EC (BLDC) motors up to approximately 250 Watts with various feedback options, such as Hall sensors, incremental encoders as well as absolute sensors in a multitude of drive applications.

The device is specially designed to be commanded and controlled as a slave node in a CANopen network. In addition, the unit can be operated via any USB or RS232 communication port of a Windows or Linux workstation. Moreover, the integrated extension interface allows pooling with optionally available communication interfaces, such as EtherCAT or other additional functionalities.

Latest technology, such as field-oriented control (FOC) and acceleration/velocity feed forward in combination with highest control cycle rates allow sophisticated, ease-of-use motion control.

Find the latest edition of the present document as well as additional documentation and software for EPOS4 positioning controllers also on the Internet: http://epos.maxonmotor.com

maxon motor ag

Brünigstrasse 220 P.O.Box 263 CH-6072 Sachseln

Phone

Fax

Web

+41 41 666 15 00 +41 41 666 16 50 www.maxonmotor.com

maxon motor control EPOS4 Positioning Controller Document ID: rel6852 EPOS4 50/5 Hardware Reference Edition: May 2017

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About About the Safety Precautions

1.3 About the Safety Precautions

Keep in mind: Safety first! Always!

• 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

Audience” on page 1-5)!

• Refer to chapter “1.1.4 Symbols & Signs” on page 1-6 to understand the subsequently used

indicators!

• 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!

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!

Requirements

• Make sure that all associated devices and components are installed according to local regulations.

• Be aware that, by principle, an electronic apparatus cannot 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.

Electrostatic sensitive device (ESD)

• Wear working cloth and use equipment in compliance with ESD protective measures.

• Handle device with extra care.

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2 Specifications

2.1 Technical Data

Nominal power supply voltage +V

Nominal logic supply voltage +V

Absolute supply voltage +V

Output voltage (max.)

Output current I

Pulse Width Modulation frequency 50 kHz

Electrical

Rating

Inputs

Outputs

Continued on next page.

Sampling rate PI current controller 25 kHz (40 μs)

Sampling rate PID speed controller 2.5 kHz (400 μs)

Sampling rate PID positioning controller 2.5 kHz (400 μs)

Max. efficiency 98% (Figure 2-3)

Max. speed DC motor

Max. speed EC motor (block) 100’000 rpm (1 pole pair)

Max. speed EC motor (sinusoidal) 50’000 rpm (1 pole pair)

Built-in motor choke 3 x 15 μH; 5 A

Digital Input 1 (general purpose) Digital Input 2 (general purpose) Digital Input 3 (general purpose) Digital Input 4 (general purpose)

Digital Output 1 (general purpose) Digital Output 2 (general purpose)

STO Input 1 STO Input 2

STO Output

Analog Input 1 Analog Input 2

Analog Output 1 Analog Output 2

Digital Hall sensor signals H1, H2, H3

Digital incremental encoder signals A, A\, B, B\, I, I\

Sensor signals (choice between multiple functions)

• Digital incremental encoder 3-channel, EIA RS422, max. 6.25 MHz

• Analog incremental encoder* 3-channel, resolution 12-bit, ±1.8 V, differential

• SSI absolute encoder configurable, EIA RS422, 5 MHz

• High-speed digital input 1…4 and High-speed digital output 1 EIA RS422, max. 6.25 MHz

cont

/ I

(<15 s)

max

EPOS4 50/5 (546047)

/ +V

min

max

Specifications

Technical Data

10…50 VDC

8 VDC / 56 VDC

0.9 x +V

5 A / 15 A

limited by max. permissible speed (motor) and max. output voltage (controller)

DIP switch-selectable levels:

• Logic: +2.0…+30 VDC

• PLC: +9.0…+30 VDC

max. 36 VDC / IL ≤500 mA (open collector with internal pull-up)

+4.5…+30 VDC (optically isolated)

max. 30 VDC / IL ≤15 mA (optically isolated with self-resetting short-circuit protection)

Resolution 12-bit, −10…+10 V, 10 kHz, differential

Resolution 12-bit, −4…+4 V, 25 kHz, referenced to GND

+2.0…+24 VDC (internal pull-up)

EIA RS422, max. 6.25 MHz

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Specifications Technical Data

Voltage

Outputs

Motor

Connections

Interfaces

Status

Indicators

Physical

Environ-

mental

Conditions

EPOS4 50/5 (546047)

Sensor supply voltage V

Auxiliary output voltage V

+5 VDC / IL ≤100 mA

Sensor

+5 VDC / IL ≤150 mA

Aux

DC motor + Motor, − Motor

EC motor Motor winding 1, Motor winding 2, Motor winding 3

RS232 max. 115’200 bit/s

USB 2.0 / USB 3.0 Full Speed

CAN max. 1 Mbit/s

EtherCAT 3) Full duplex (100 Mbit/s) as to IEEE 802.3 100 Base T

Operation green LED

Device Status

Error red LED

RUN state green LED

NET Status

Error red LED

NET Port Link activity green LED

Weight approx. 206 g

Dimensions (L x W x H) 105.0 x 83.0 x 38.7 mm

Mounting mounting holes for M4 screws

Operation −30…+50 °C

+50…+80 °C; Derating: −0.167 A/°C (Figure 2-2)

Temperature

Extended range 1)

Additional derating with inserted extension card: Ambient temperature

less 5 °C (Figure 2-2)

Storage −40…+85 °C

Altitude 2) Operation 0…10’000 m MSL

Humidity 5…90% (condensation not permitted)

Legend

* Available with an upcoming firmware release.

1) Operation within the extended range is permitted. However, a respective derating (declination of output current I

cont

)

as to the stated values will apply.

2) Operating altitude in meters above Mean Sea Level, MSL.

3) Available with optional EPOS4 EtherCAT Card.

4) Derating further increases with an inserted extension card. For the actual value, consult Figure 2-2 and shift the

graph horizontally to the left by the specified value.

Table 2-4 Technical data

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2.2 Thermal Data

2.2.1 Derating of Output Current

Specifications

Thermal Data

Figure 2-2 Derating of output current

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Specifications Limitations

2.2.2 Power Dissipation and Efficiency

Figure 2-3 Power dissipation and efficiency

2.3 Limitations

Table 2-5 Limitations

Protection functionality Switch-off threshold Recovery threshold

Undervoltage 8.0 V 8.5 V

Overvoltage 58 V 56 V

Overcurrent 20 A —

Thermal overload 100 °C 90 °C

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2.4 Dimensional Drawing

Specifications

Dimensional Drawing

Figure 2-4 Dimensional drawing [mm]

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Specifications Standards

2.5 Standards

The described device has been successfully tested for compliance with the below listed standards. In practical 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.

Generic

Applied

Electromagnetic Compatibility

IEC/EN 61000-6-2 Immunity for industrial environments

IEC/EN 61000-6-3

IEC/EN 55022 (CISPR22)

IEC/EN 61000-4-3

Emission standard for residential, commercial and lightindustrial environments

Radio disturbance characteristics / radio interference

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 radiofrequency fields 10 Vrms

Others

Environment

IEC/EN 60068-2-6

MIL-STD-810F

Environmental testing – Test Fc: Vibration (sinusoidal,

10…500 Hz, 20 m/s

)

Random transport (10…500 Hz up to 2.53 g

Safety UL File Number Unassembled printed circuit board: E229342

Reliability prediction of electronic equipment Environment: Ground, benign (GB)

Reliability MIL-HDBK-217F

Ambient temperature: 298 K (25 °C) Component stress: In accordance with circuit diagram and nominal power Mean Time Between Failures (MTBF): 296'741 hours

Table 2-6 Standards

rms

)

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3Setup

IMPORTANT NOTICE: PREREQUISITES FOR PERMISSION TO COMMENCE INST ALLATION The EPOS4 50/5 positioning controller 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 equipm en t.

WARNING

Risk of injury Operating the device without the full compliance of the surrounding system with the EU Direc-

tive 2006/42/EC may cause serious injuries!

• Do not operate the device, unless you have made completely sure that the other machinery fully complies 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!

3.1 Generally applicable Rules

Setup

Generally applicable Rules

Maximal permitted supply voltage

• Make sure that supply power 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 are as follows: – continuous max. 5 A – short-time (acceleration) max. 15 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 potential 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, balance them.

• Insert the USB connector first, then switch on the power supply of the controller.

Hot plugging/hot swapping the extension slots may cause hardware damage

Switch off the controller’s power supply before removing or inserting an extension card.

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Setup Cabling

3.2 Cabling

PLUG&PLAY

Take advantage of maxon’s prefab cable assemblies. They come as ready-to-use parts and will help to reduce commissioning time to a minimum.

a) Check the following table and find the part number of the cable assembly that matches the

setup you will be using.

b) Follow the cross-reference to get the cable’s pin assignment.

Prefab Cable Assembly

Connector

X1 Power Cable 275829 3-19

X2 Power Cable 275829 3-19

X3 Motor Cable 275851 3-22

X4 Hall Sensor Cable 275878 3-23

X5 Encoder Cable 275934 3-26

X6 Sensor Cable 5x2core 520852 3-29

X7 Signal Cable 8core 520853 3-38

X8 Signal Cable 7core 520854 3-42

X9 Signal Cable 8core 520853 3-38

X10 RS232-COM Cable 520856 3-46

X11

X12

X13 USB Type A - micro B Cable 403968 3-49

X14 Ethernet Cable 422827 3-51

X15 Ethernet Cable 422827 3-51

X16 Sensor Cable 5x2core 520852 3-29

Designation

CAN-COM Cable CAN-CAN Cable

Part

Number

520857 520858

Page

3-47 3-48

Table 3-7 Prefab maxon cables

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Setup

Cabling

MAKE&BAKE YOUR OWN

If you decide not to employ maxon motor’s prefab cable assemblies, you might wish to use the prepackaged kit that contains all connectors required to make up your own cabling.

EPOS4 Connector Set (520859)

Connector Specification Quantity

Connectors

Molex Mega-Fit, 2 poles (171692-0102) 1

X1 / X2 Molex Mini-Fit Jr., 2 poles (39-01-2020) 2

X3 Molex Mini-Fit Jr., 4 poles (39-01-2040) 1

Molex Mega-Fit, 4 poles (171692-0104) 1

X4 Molex Micro-Fit 3.0, 6 poles (430-25-0600) 1

X6 / X16 Molex CLIK-Mate, dual row, 10 poles (503149-1000) 1

X7 / X9 Molex CLIK-Mate, single row, 8 poles (502578-0800) 2

X8 Molex CLIK-Mate, single row, 7 poles (502578-0700) 1

X10 Molex CLIK-Mate, single row, 5 poles (502578-0500) 1

X11 / X12 Molex CLIK-Mate, single row, 4 poles (502578-0400) 2

Crimp Te rminals

Molex Mega-Fit, female crimp terminal (172063-0311) 7

X1 / X2 / X3 Molex Mini-Fit Jr. female crimp terminal (45750-1111) 9

X4 Molex Micro-Fit 3.0 female crimp terminal (43030-0010) 7

X6…X12 /

X16

Molex CLIK-Mate crimp terminal (502579-0100) 44

Accessories

X5 3M Retainer Clip with strain relief, height 13.5 mm (3505-8110) 1

Table 3-8 EPOS4 Connector Set – Content

OOLS

Tool Manufacturer Part Number

Hand crimper for CLIK-Mate crimp terminals Molex 63819-4600

Hand crimper for Micro-Fit 3.0 crimp terminals Molex 63819-0000

Hand crimper for Mini-Fit crimp terminals Molex 63819-0900

Table 3-9 Recommended tools

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Setup Connections

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.

For each connector you will find detailed information on the pin assignment, the available accessories and prefab cable assemblies, the requirements that must be met, if any, and the circuitry.

How to read pin assignment tables

In the later course of the document you will find tables containing information on the EPOS4’s hardware connectors, their wired signals and assigned pins as well as details on the available prefab cables.

• The first column describes both the pin number of the connector and of the matching prefab maxon cable’s Head A.

• The second column describes the cable core color of the prefab maxon cable.

• The third column describes the pin number of the prefab maxon cable’s Head B.

Follow the description in given order and choose the wiring diagram (as of page 4-59) that best suits the components you are using.

X10

X11

X12

X13

X14

Power Supply page 3-19

Logic Supply page 3-21

Motor page 3-22

Hall Sensor page 3-23

Encoder page 3-25

Sensor page 3-28

Digital I/O page 3-38

Analog I/O page 3-42

STO page 3-44

RS232 page 3-46

CAN 1 page 3-47

CAN 2 page 3-47

USB page 3-49

Extension NET IN page 3-50

X15

X16

Extension NET OUT page 3-50

Extension Signal page 3-52

5) Requires an optionally available maxon Extension Card

Figure 3-5 Connectors

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Connections

3.3.1 Power Supply (X1)

Basically, any power supply may be used provided that it meets the stated minimum requirements.

Best practice

Keep the motor mechanically disconnected during the setup and adjustment phase.

Figure 3-6 Power supply connector X1

Setup

Head A

Prefab

Cable

Head B

Signal Description

Pin Color Pin

1black− GND Ground

2 black +

Nominal power supply voltage (+10…+50 VDC)

Table 3-10 Power supply connector X1 – Pin assignment

Power Cable (275829)

Cross-section

2 x 0.75 mm2, grey

Length 3 m

Plug Molex Mini-Fit Jr., 2 poles (39-01-2020)

Head A

Contacts Molex Mini-Fit Jr. female crimp terminals (45750)

Head B

Wire end sleeves 0.75 mm

Table 3-11 Power Cable

Power supply requirements

Output voltage

+VCC 10…50 VDC

Absolute output voltage min. 8 VDC; max. 56 VDC

Depending on load

Output current

• continuous max. 5 A

• short-time (acceleration, <15 s) max. 15 A

Continued on next page.

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Setup

-------

Δn

ΔM

-------- -

M⋅+





0.9

-------

⋅⋅1 V[]+≥

Connections

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

protection circuit is configured inoperative within the operating range.

The formula already takes the following into account:

• Maximum PWM duty cycle of 90%

• Controller’s max. voltage drop of 1 V @ 5 A

NOWN VALUES:

• Operating torque M [mNm]

• Operating speed n [rpm]

• Nominal motor voltage U

• Motor no-load speed at U

• Speed/torque gradient of the motor Δn/ΔM [rpm/mNm]

OUGHT VALUE:

• Supply voltage +VCC [Volt]

[Volt]

; nO [rpm]

OLUTION:

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Setup

Connections

3.3.2 Logic Supply (X2)

Separate power supply

The logic part of the controller may be supplied by a separate supply voltage provided that it meets the below stated minimum requirement:

If not supplied separately, the logic supply is internally connected to the power supply.

Figure 3-7 Logic supply connector X2

Head A

Prefab

Cable

Head B

Signal Description

Pin Color Pin

1black− GND Ground

2 black +

Nominal logic supply voltage (+10…+50 VDC)

Table 3-12 Logic supply connector X2 – Pin assignment

For the matching prefab cable assembly Table 3-11.

Power supply requirement s

Output voltage

+VC 10…50 VDC

Absolute supply voltage min. 8 VDC; max. 56 VDC

Min. output power

PC min. 3.5 W

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Setup Connections

3.3.3 Motor (X3)

The controller is set to drive either maxon DC motors (brushed DC motor) or maxon EC motors (BLDC, brushless DC motor).

Figure 3-8 Motor connectors X3

Head A

Prefab

Cable

Head B

Signal Description

Pin Color Pin

1 white Motor (+M) DC motor: Motor +

2 brown Motor (−M) DC motor: Motor −

3 green – not connected

4 black Motor shield Cable shield

Table 3-13 Motor connector X3 – Pin assignment for maxon DC motor

Head A

Prefab

Cable

Head B

Signal Description

Pin Color Pin

1 white Motor winding 1 EC motor: Winding 1

2 brown Motor winding 2 EC motor: Winding 2

3 green Motor winding 3 EC motor: Winding 3

4 black Motor shield Cable shield

Table 3-14 Motor connector X3– Pin assignment for maxon EC motor

Motor Cable (275851)

Cross-section

3 x 0.75 mm2, shielded, grey

Length 3 m

Plug Molex Mini-Fit Jr., 4 poles (39-01-2040)

Head A

Contacts Molex Mini-Fit Jr. female crimp terminals (45750)

Head B

Wire end sleeves 0.75 mm

Table 3-15 Motor Cable

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3.3.4 Hall Sensor (X4)

Suitable Hall effect sensors IC use «Schmitt trigger» with open collector output.

Figure 3-9 Hall sensor connector X4

Setup

Connections

Head A

Prefab

Cable

Head B

Signal Description

Pin Color Pin

1 green Hall sensor 1 Hall sensor 1 input

2 brown Hall sensor 2 Hall sensor 2 input

3 white Hall sensor 3 Hall sensor 3 input

4 yellow GND Ground

5grey

Sensor supply voltage (+5 VDC; IL ≤100 mA)

Sensor

6 black Hall shield Cable shield

Table 3-16 Hall sensor connector X4 – Pin assignment

Hall Sensor Cable (275878)

Cross-section

5 x 0.14 mm

, shielded, grey

Length 3 m

Plug Molex Micro-Fit 3.0, 6 poles (430-25-0600)

Head A

Contacts Molex Micro-Fit 3.0 female crimp terminals (430-30-xxxx)

Head B

Wire end sleeves 0.14 mm

Table 3-17 Hall Sensor Cable

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Setup Connections

Hall sensor

Sensor supply voltage (V

Sensor

)

+5 VDC

Max. Hall sensor supply current 30 mA

Input voltage 0…24 VDC

Max. input voltage +24 VDC

Logic 0 typically <0.8 V

Logic 1 typically >2.0 V

Internal pull-up resistor 10 kΩ (referenced to +5.45 V)

Figure 3-10 Hall sensor 1 input circuit (analogously valid for Hall sensors 2 & 3)

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Setup

Connections

3.3.5 Encoder (X5)

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

single-ended (unsymmetrical).

• For best performance, we strongly recommend using encoders with a line driver. Otherwise, limitations may apply due to slow switching edges.

• Even though 2-channel will do, we strongly recommend to use only 3-channel versions.

Figure 3-11 Encoder connector X5

Head A

Prefab

Cable

Head B

Signal Description

Pin Color Pin

1 brown 1 – not connected

2white2

Sensor supply voltage (+5 VDC; IL ≤100 mA)

Sensor

3 red 3 GND Ground

4 white 4 – not connected

5 orange 5 Channel A\ Channel A complement

6 white 6 Channel A Channel A

7 yellow 7 Channel B\ Channel B complement

8 white 8 Channel B Channel B

9 green 9 Channel I\ Channel I complement

10 white 10 Channel I Channel I

Table 3-18 Encoder connector X5 – Pin assignment

Accessories

For sockets with strain relief:

1 retainer clip, height 13.5 mm, 3M (3505-8110) Suitable strain relief

Retainer

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)

Table 3-19 Encoder connector X5 – Accessories

Continued on next page.

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Setup Connections

Encoder Cable (275934)

Cross-section 10 x AWG28, round-jacket, twisted pair flat cable, pitch 1.27 mm, grey

Length 3.2 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

Table 3-20 Encoder Cable

Encoder (differential)

Sensor supply voltage (V

Sensor

)

+5 VDC

Max. encoder supply current 70 mA

Min. differential input voltage ±200 mV

Max. input voltage ±12 VDC

Line receiver (internal) EIA RS422 standard

Max. input frequency 6.25 MHz

Figure 3-12 Encoder input circuit Ch A “differential” (analogously valid for Ch B & Ch I)

Continued on next page.

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Encoder (single-ended)

Sensor supply voltage (V

Sensor

)

+5 VDC

Max. encoder supply current 70 mA

Input voltage 0…5 VDC

Max. input voltage ±12 VDC

Logic 0 <1.0 V

Logic 1 >2.4 V

Input high current

Input low current

IIH = typically +420 μA @ 5 V

IIL = typically −170 μA @ 0 V

Push-pull Open collector

Max. input frequency

6.25 MHz

Setup

Connections

40 kHz (internal pull-up only)

150 kHz (additional external 3k3 pull-up)

Figure 3-13 Encoder input circuit Ch A “single-ended” (analogously valid for Ch B & Ch I)

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Setup Connections

3.3.6 Sensor (X6)

Additional sensors, both incremental and serial encoders, can be connected.

Check on the applied sensor’s data sheet

If the specified inrush current or the maximum continuous current of the sensor should exceed 150 mA, you can connect the sensor supply voltage (V

) in parallel to the auxiliary output voltage (V

Sensor

Aux

Figure 3-14 Sensor connector X6

Head A

Prefab

Cable

Head B

Signal Description

Pin Color Pin

1white1

Channel A HsDigIN1

Channel A\

2brown2

HsDigIN1\

3 green 3

Channel B HsDigIN2

Channel B\

4 yellow 4

HsDigIN2\

Channel I

5grey5

HsDigIN3 Clock HsDigOUT1

Channel I\

6pink6

HsDigIN3\ Clock\ HsDigOUT1\

7blue7

8red8

Data HsDigIN4

Data\ HsDigIN4\

9 black 9 GND Ground

Auxiliary output voltage (+5 VDC; IL ≤150 mA)

10 violet 10

Aux

Digital/analog incremental encoder channel A High-speed digital input 1

Digital/analog incremental encoder channel A complement High-speed digital input 1 complement

Digital/analog incremental encoder channel B High-speed digital input 2

Digital/analog incremental encoder channel B complement High-speed digital input 2 complement

Digital/analog incremental encoder channel I High-speed digital input 3 Clock (SSI) High-speed digital output 1

Digital/analog incremental encoder channel I complement High-speed digital input 3 complement Clock (SSI) complement High-speed digital output 1 complement

Data (SSI) High-speed digital input 4

Data (SSI) complement High-speed digital input 4 complement

Table 3-21 Sensor connector X6 – Pin assignment

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Sensor Cable 5x2core (520852)

Setup

Connections

Cross-section

5 x 2 x 0.14 mm

, twisted pair, grey

Length 3 m

Plug Molex CLIK-Mate, dual row, 10 poles (503149-1000)

Head A

Contacts Molex CLIK-Mate crimp terminals (502579)

Head B

Wire end sleeves 0.14 mm

Table 3-22 Sensor Cable 5x2core

3.3.6.1 Incremental Encoder

Digital incremental encoder (differential)

Auxiliary output voltage (V

Aux

)

+5 VDC

Max. auxiliary supply current 150 mA

Min. differential input voltage ±200 mV

Max. input voltage +12 VDC

Line receiver (internal) EIA RS422 standard

Max. input frequency 6.25 MHz

Figure 3-15 Digital incremental encoder input circuit Ch A “differential” (analogously valid for Ch B)

Continued on next page.

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Setup Connections

Figure 3-16 Digital incremental encoder input circuit Ch I

Continued on next page.

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Digital incremental encoder (single-ended)

Auxiliary output voltage (V

Aux

)

+5 VDC

Max. auxiliary supply current 150 mA

Input voltage 0…5 VDC

Max. input voltage ±12 VDC

Logic 0 <1.0 V

Logic 1 >2.4 V

Input high current

Input low current

typically 210 μA @ +5 VDC (channel A, B) typically 60 μA @ +5 VDC (channel I)

typically −80 μA @ 0 VDC (channel A, B) typically −7 μA @ 0 VDC (channel I)

Push-pull Open collector

Max. input frequency

6.25 MHz

Setup

Connections

100 kHz (additional external 3k3 pull-up)

Figure 3-17 Digital incremental encoder input circuit Ch A “single-ended” (analogously valid for Ch B)

Continued on next page.

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Setup Connections

Figure 3-18 Digital incremental encoder input circuit Ch I

Continued on next page.

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Analog incremental encoder (differential)

Auxiliary output voltage (V

Aux

)

+5 VDC

Max. auxiliary supply current 150 mA

Input voltage ±1.8 V (differential)

Max. input voltage ±12 VDC

Common mode voltage −9…+4 VDC (referenced to GND)

Input resistance typically 10 kΩ

A/D converter 12-bit

Resolution 0.88 mV

Bandwidth 10 kHz

Setup

Connections

Figure 3-19 Analog incremental encoder input circuit Ch A “differential” (analogously valid for Ch B)

Continued on next page.

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Setup Connections

Figure 3-20 Analog incremental encoder input circuit Ch I (digital evaluation)

Continued on next page.

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3.3.6.2 SSI Absolute Encoder

SSI absolute encoder

Auxiliary output voltage (V

Aux

)

+5 VDC

Max. auxiliary supply current 150 mA

Min. differential input voltage ±200 mV

Min. differential output voltage ±1.8 V @ external load R=54 Ω

Max. output current 40 mA

Line receiver (internal) EIA RS422 standard

Max. encoder input/output frequency 5 MHz

Setup

Connections

Figure 3-21 SSI absolute encoder data input

Figure 3-22 SSI absolute encoder clock output

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Setup Connections

3.3.6.3 High-speed Digital I/Os

Alternatively, the sensor interface can be used for high-speed digital I/O operation.

High-speed digital input 1…4 (differential)

Max. input voltage ±12 VDC

Min. differential input voltage ±200 mV

Line receiver (internal) EIA RS422 standard

Max. input frequency 6.25 MHz

Figure 3-23 HsDigIN1 circuit “differential” (analogously valid for HsDigIN2…4)

High-speed digital input 1…4 (single-ended)

Input voltage 0…5 VDC

Max. input voltage ±12 VDC

Logic 0 <1.0 V

Logic 1 >2.4 V

Input high current

Input low current

typically 210 μA @ +5 VDC (HsDigIN1, 2) typically 60 μA @ +5 VDC (HsDigIN3, 4)

typically −80 μA @ 0 VDC (HsDigIN1, 2) typically −7 μA @ 0 VDC (HsDigIN3, 4)

Max. input frequency 6.25 MHz

Figure 3-24 HsDigIN1 circuit “single-ended” (analogously valid for HsDigIN2…4)

Continued on next page.

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High-speed digital output 1

Min. differential output voltage ±1.8 V @ external load R=54 Ω

Max. output current 40 mA

Line transceiver (internal) EIA RS422 standard

Max. output frequency 6.25 MHz

Setup

Connections

Figure 3-25 HsDigOUT1 output circuit

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Setup Connections

3.3.7 Digital I/O (X7)

Figure 3-26 Digital I/O connector X7

Head A

Prefab

Cable

Head B

Signal Description

Pin Color Pin

1 white 1 DigIN1 Digital input 1

2 brown 2 DigIN2 Digital input 2

3 green 3 DigIN3 Digital input 3

4 yellow 4 DigIN4 Digital input 4

5 grey 5 DigOUT1 Digital output 1

6 pink 6 DigOUT2 Digital output 2

7 blue 7 GND Ground

8red8

Auxiliary output voltage (+5 VDC; IL ≤150 mA)

Aux

Table 3-23 Digital I/O connector X7 – Pin assignment

Signal Cable 8core (520853)

Cross-section

8 x 0.14 mm

, grey

Length 3 m

Plug Molex CLIK-Mate, single row, 8 poles (502578-0800)

Head A

Contacts Molex CLIK-Mate crimp terminals (502579)

Head B

Wire end sleeves 0.14 mm

Table 3-24 Signal Cable 8core

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Digital inputs 1…4 (Logic level setting)

Input voltage 0…30 VDC

Max. input voltage ±30 VDC

Logic 0 <0.8 V

Logic 1 >2.0 V

Input current at logic 1 250 µA @ 5 VDC

Switching delay <300 μs @ 5 VDC

Figure 3-27 DigIN1 circuit (analogously valid for DigIN2…4) – Logic level setting

Setup

Connections

Digital inputs 1…4 (PLC level setting)

Input voltage 0…30 VDC

Max. input voltage ±30 VDC

Logic 0 <5.5 V

Logic 1 >9 V

Input current at logic 1

>2 mA @ 9 VDC typically 3.5 mA @ 24 VDC

Switching delay <300 μs @ 24 VDC

Figure 3-28 DigIN1 circuit (analogously valid for DigIN2…4) – PLC level setting

Continued on next page.

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Setup Connections

Digital outputs 1…2

Circuit

Open drain (internal pull-up resistor 2k2 and diode to +5.45 VDC

Figure 3-29 DigOUT1 circuit (analogously valid for DigOUT2)

Continued on next page.

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WIRING EXAMPLES

DigOUT “sinks”

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

Setup

Connections

Figure 3-30 DigOUT1 “sinks” (analogously valid for DigOUT2)

DigOUT “source”

Output voltage

Max. load current

= 5.45 V − 0.75 V − (I

Out

≤2 mA

Load

Figure 3-31 DigOUT1 “source” (analogously valid for DigOUT2)

x 2200 Ω)

Load

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Setup Connections

3.3.8 Analog I/O (X8)

Figure 3-32 Analog I/O connector X8

Head A

Prefab

Cable

Head B

Signal Description

Pin Color Pin

1 white 1 AnIN1+ Analog input 1, positive signal

2 brown 2 AnIN1− Analog input 1, negative signal

3 green 3 AnIN2+ Analog input 2, positive signal

4 yellow 4 AnIN2− Analog input 2, negative signal

5 grey 5 AnOUT1 Analog output 1

6 pink 6 AnOUT2 Analog output 2

7 blue 7 GND Ground

Table 3-25 Analog I/O connector X8 – Pin assignment

Signal Cable 7core (520854)

Cross-section

7 x 0.14 mm

, grey

Length 3 m

Plug Molex CLIK-Mate, single row, 7 poles (502578-0700)

Head A

Contacts Molex CLIK-Mate crimp terminals (502579)

Head B

Wire end sleeves 0.14 mm

Table 3-26 Signal Cable 7core

Continued on next page.

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Analog inputs 1…2

Input voltage ±10 VDC (differential)

Max. input voltage ±24 VDC

Common mode voltage −5…+10 VDC (referenced to GND)

Input resistance

80 kΩ (differential) 65 kΩ (referenced to GND)

A/D converter 12-bit

Resolution 5.64 mV

Bandwidth 10 kHz

Setup

Connections

Figure 3-33 AnIN1 circuit (analogously valid for AnIN2)

Analog outputs 1…2

Output voltage ±4 VDC

D/A converter 12-bit

Resolution 2.42 mV

Refresh rate 2.5 kHz

Analog bandwidth of output amplifier 25 kHz

300 nF

Max. capacitive load

Note: The increase rate is limited in proportion to the capacitive load (e.g. 5 V/ms @ 300 nF)

Max. output current limit 1 mA

Figure 3-34 AnOUT1 circuit (analogously valid for AnOUT2)

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Setup Connections

3.3.9 STO (X9)

The STO (Safe Torque Off) function can be utilized to bring the drive to a torque-free, safe condition via two independent inputs. The drive output power stage is switched off if either one of the inputs is not powered. For in-depth details on the STO functionality separate document «EPOS4 Application Notes».

Figure 3-35 STO connector X9

Activation of power stage

In order to activate the power stage, either both STO inputs must be powered or the «STO Idle Connector» (Table 3-28) must be plugged.

Head A

Prefab

Cable

Head B

Signal Description

Pin Color Pin

1 white 1 STO-IN1+ Safe Torque Off input 1, positive signal

2 brown 2 STO-IN1− Safe Torque Off input 1, negative signal

3 green 3 STO-IN2+ Safe Torque Off input 2, positive signal

4 yellow 4 STO-IN2− Safe Torque Off input 2, negative signal

5 grey 5 STO-OUT+ Safe Torque Off output, positive signal

6pink6STO-OUT− Safe Torque Off output, negative signal

7 blue 7 GND Ground

Activation voltage for STO inputs (+5 VDC)

8red8

STO

Note: Do not use this voltage for any other purpose

Table 3-27 STO connector X9 – Pin assignment

For the matching prefab cable assembly Table 3-24 on page 3-38.

STO Idle Connector (520860)

—included with every delivery—

Plug Molex CLIK-Mate, single row, 8 poles (502578-0800) with cable bridges

Table 3-28 STO Idle Connector

Continued on next page.

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Safe Torque Off inputs 1…2

Circuit type Optically isolated input

Input voltage 0…+30 VDC

Max. input voltage ±30 VDC

Logic 0 <1.0 VDC

Logic 1 >4.5 VDC

Input current at logic 1

>2 mA @ 5 VDC typically 3.2 mA @ 24 VDC

Reaction time <25 ms

Figure 3-36 STO-IN1 circuit (analogously valid for STO-IN2)

Setup

Connections

Safe Torque Off output

Circuit type

Optically isolated output with self-resetting shortcircuit protection

Max. input voltage ±30 VDC

Max. load current 15 mA

Leakage current <10 μA @ +30 VDC

Max. voltage drop

1.3 V @ 2 mA

2.5 V @ 15 mA

Figure 3-37 STO-OUT circuit

STO Logic State

STO-IN1 STO-IN2 STO-OUT Power Stage

0 0 open inactive

1 0 closed inactive

0 1 closed inactive

1 1 closed active

Table 3-29 STO logic state

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Setup Connections

3.3.10 RS232 (X10)

Figure 3-38 RS232 connector X10

X10

Head A

Prefab

Cable

Head B

Signal Description

Pin Color Pin

1 white 3 EPOS_RxD EPOS RS232 receive

2 brown 5 GND Ground

3 green 2 EPOS_TxD EPOS RS232 transmit

4 yellow 5 GND Ground

5 Shield Housing Shield Cable shield

Table 3-30 RS232 connector X10 – Pin assignment

RS232-COM Cable (520856)

Cross-section

2 x 2 x 0.14 mm

, twisted pair, shielded

Length 3 m

Plug Molex CLIK-Mate, single row, 5 poles (502578-0500)

Head A

Contacts Molex CLIK-Mate crimp terminals (502579)

Head B Female D-Sub connector DIN 41652, 9 poles, with mounting screws

Table 3-31 RS232-COM Cable

RS232 Interface

Max. input voltage ±30 VDC

Output voltage typically ±9 V @ 3 kΩ to GND

Max. bit rate 115’200 bit/s

RS232 transceiver EIA RS232 standard

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Setup

Connections

3.3.11 CAN 1 (X11) & CAN 2 (X12)

The EPOS4 is specially designed being commanded and controlled via a Controller Area Network (CAN), a highly efficient data bus very common in all fields of automation and motion control. It is preferably used as a slave node in the CANopen network.

For the CAN configuration “DIP Switch Configuration (SW1)” on page 3-54.

Figure 3-39 CAN 1 connector X11 and CAN 2 connector X12

X11

X12

Head A

Prefab

Cable

Head B

Signal Description

Pin Color Pin

1 white 7 CAN high CAN high bus line

2 brown 2 CAN low CAN low bus line

3 green 3 GND Ground

4 Shield 5 Shield Cable shield

Table 3-32 CAN 1 connector X11/CAN 2 connector X12 – Pin assignment

CAN-COM Cable (520857)

Cross-section

2 x 2 x 0.14 mm

, twisted pair, shielded

Length 3 m

Plug Molex CLIK-Mate, single row, 4 poles (502578-0400)

Head A

Contacts Molex CLIK-Mate crimp terminals (502579)

Head B Female D-Sub connector DIN 41652, 9 poles, with mounting screws

Table 3-33 CAN-COM Cable

Continued on next page.

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Setup Connections

CAN-CAN Cable (520858)

Cross-section

2 x 2 x 0.14 mm2, twisted pair, shielded

Length 3 m

Plug Molex CLIK-Mate, single row, 4 poles (502578-0400)

Head A

Contacts Molex CLIK-Mate crimp terminals (502579)

Plug Molex CLIK-Mate, single row, 4 poles (502578-0400)

Head B

Contacts Molex CLIK-Mate crimp terminals (502579)

Table 3-34 CAN-CAN Cable

CAN interface

Standard ISO 11898-2:2003

Max. bit rate 1 Mbit/s

Max. number of CAN nodes 127/31 (via software/hardware setting)

Protocol CiA 301 version 4.2.0

Identifier setting By DIP switch or software

Note

• Consider the CAN master’s maximal bit rate.

• The standard bit rate setting (factory setting) is 1 Mbit/s, automatic bit rate detection is set.

• Use 120

termination resistor at both ends of the CAN bus.

• For detailed CAN information separate document «EPOS4 Communication Guide».

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Setup

Connections

3.3.12 USB (X13)

Hot plugging the USB interface may cause hardware damage

• Avoid potential differences between the power supply of controller and PC/Notebook or, if possible, balance them.

• Insert the USB connector first, then switch on the power supply of the controller.

Figure 3-40 USB connector X13

X13

Head A

PC’s USB

T erminal

Head B

Signal Description

Pin Pin

BUS

USB bus supply voltage input +5 VDC

2 2 USB_D− USB Data− (twisted pair with Data+)

3 3 USB_D+ USB Data+ (twisted pair with Data−)

4 – ID not connected

5 4 GND USB ground

Table 3-35 USB connector X13 – Pin assignment

USB Type A - micro B Cable (403968)

Cross-section According to USB 2.0 / USB 3.0 specification

Length 1.5 m

Head A USB Type “micro B”, male

Head B USB Type “A”, male

Table 3-36 USB Type A - micro B Cable

USB Standard USB 2.0 / USB 3.0 (full speed)

Max. bus supply voltage +5.25 VDC

Max. DC data input voltage −0.5…+3.8 VDC

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USB

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Setup Connections

3.3.13 Extension NET IN (X14) & Extension NET OUT (X15)

The EPOS4 50/5 features two NET connectors for extension communication interfaces, such as EtherCAT. One serves for NET input, the other for NET output. Both sockets are identical in respect to their external wiring.

Wrong plugging may cause hardware damage

Even though both NET sockets are prepared for identical external wiring, make sure to always connect them as follows.

• Use only standard Cat5 cables with RJ45 plug, such as maxon’s «Ethernet Cable» (422827).

• Use NET IN (X14) as «Input».

• Use NET OUT (X15) as «Output». For detailed information separate document «EPOS4 Communication Guide».

Figure 3-41 Extension NET IN & NET OUT connectors X14 & X15

X14 X15

Head A

Prefab

Cable

Head B

Signal Description

Pin Color Pin

white/

orange

1 TX+ Transmission Data+

2orange2TX− Transmission Data−

white/

green

3 RX+ Receive Data+

4 blue 4 – not applicable

white/

blue

5 – not applicable

6 green 6 RX− Receive Data−

white/ brown

7 – not applicable

8 brown 8 – not applicable

Table 3-37 Extension NET IN & NET OUT connectors X14 & X15 – Pin assignment

Continued on next page.

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Ethernet Cable (422827)

Cross-section Cat. 5e SF/UTP (ISO/IEC 11801), 1:1 patch cable, green

Length 2 m

Head A RJ45 (8P8CS) EIA/TIA-568B

Head B RJ45 (8P8CS) EIA/TIA-568B

Table 3-38 Ethernet Cable

Setup

Connections

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Setup Connections

3.3.14 Extension Signal (X16)

The connector provides direct access to the signal extension slot EXT2 (chapter “3.3.15 Extension Slots (EXT1 & EXT2)” on page 3-53) thus allowing the use of signal extension cards (such as for additional absolute sensors or customized signal extensions). The pin assignment is directly related to the corresponding extension card.

Figure 3-42 Extension Signal connector X16

X16

Head A

Prefab

Cable

Head B

Signal Description

Pin Color Pin

1white1EXT-1

2 brown 2 EXT-2

3 green 3 EXT-3

4 yellow 4 EXT-4

5grey5EXT-5

6pink6EXT-6

Depending on signal extension card inserted in extension slot EXT2 (Ta bl e 3 -4 0)

7blue7EXT-7

8red8EXT-8

9black9EXT-9

10 violet 10 EXT-10

Table 3-39 Extension Signal connector X16 – Pin assignment

For the matching prefab cable assembly Table 3-22 on page 3-29.

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Setup

Connections

3.3.15 Extension Slots (EXT1 & EXT2)

The controller provides two extension slots (Figure 3-43) located underneath the plastic lid at the controller housing’s top face. They host optionally available extension cards (Table 3-40) and thereby expand the controller’s comprehensive motion control functionality even further.

• EXT1 provides connectivity for a communication extension card, such as for EtherCAT.

With the optionally available «EPOS4 EtherCAT Card», the controller serves as slave in an EtherCAT network, provides access for EtherCAT master control (such as Beckhoff TwinCAT), and offers real-time operation in an Ethernet master/slave network. For further details sepa- rate document «EPOS4 Communication Guide».

• EXT2 provides connectivity for advanced signal extension cards, such as for additional abso-

lute sensors or customized signal extensions. Using the respective optionally available EPOS4 cards, additional functions can be directly accessed via the connector “Extension Signal (X16)” on page 3-52.

Figure 3-43 Extension slots

An inserted extension card mechanically interlocks in both horizontal and vertical direction. To insert or remove an extension card, proceed as follows:

Hot plugging/hot swapping the extension slots may cause hardware damage

Switch off the controller’s power supply before removing or inserting an extension card.

NSERT

1) Make sure to switch off the controller’s power supply.

2) Make sure that the extension slots are clean and free of any foreign objects.

3) Carefully insert the extension card in the respective extension slot (either EXT1 or EXT2), keep right-angled, and press down firmly.

4) Mount the plastic lid, press it down firmly, and let the two latches snap into place.

EMOVE

1) Make sure to switch off the controller’s power supply.

2) Unlock the latches and remove the plastic lid, turn it over, and look for the molded catch in one of its corners.

3) Engage the catch into the extension card’s bore.

4) Pull both – the plastic lid together with the extension card – straight upward.

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Setup Connections

Extension Cards

Slot Description Part number

EXT1 EPOS4 EtherCAT Card available soon

EXT2 — —

Table 3-40 Extension cards (optional)

3.3.16 DIP Switch Configuration (SW1)

Figure 3-44 DIP switch SW1

3.3.16.1 CAN ID (Node Address)

The CAN ID is set with DIP switches 1…5. The node address (1…31) may be coded using binary code.

Setting the CAN ID by DIP switch SW1

• By setting the DIP switch (1…5) address 0 (“OFF”), the CAN ID may be set by software (changing object “Node ID”, range 1…127).

• The CAN ID results in the summed values of DIP switch addresses 1 (“ON”).

• DIP switches 6…8 do not have any impact on the CAN ID.

Switch Binary Code Valence Setting

(factory setting)

Table 3-41 DIP switch SW1 – Binary code values

Continued on next page.

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Setup

Connections

The set CAN ID (node address) can be observed by adding the valence of all activated switches. Use the following table as a (non-concluding) guide:

Setting

1 2 3 4 5

00000–

1 00001

0 1 0002

001 004

1 0 1 005

0001 08

00001 16

1111131

0 = Switch “OFF” 1 = Switch “ON”

Switch

Node

Address

Table 3-42 DIP switch SW1 – Examples

3.3.16.2 CAN automatic Bit Rate Detection

Switch OFF ON

Automatic bit rate detection deactivated Automatic bit rate detection activated

Table 3-43 DIP switch SW1 – CAN automatic bit rate detection

3.3.16.3 CAN Bus Termination

Switch OFF ON

Without bus termination

Bus termination with 120 Ω

(factory setting)

Table 3-44 DIP switch SW1 – CAN bus termination

(factory setting)

Continued on next page.

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Setup Connections

3.3.16.4 Digital Input Level

For details chapter “3.3.7 Digital I/O (X7)” on page 3-38.

Switch OFF ON

Logic level

(factory setting)

Table 3-45 DIP switch SW1 – Digital input level

3.3.17 Spare Parts

Order

number

Description

520860 STO Idle Connector X9

Table 3-46 Spare parts list

PLC level

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3.4 Status Indicators

The EPOS4 features three sets of LED indicators to display the device condition.

A NET Status; the LEDs display communication RUN states and errors conditions B Device Status; the LEDs display the device’s operation status and error conditions C NET Port; the LED displays the NET link activity

For detailed information separate document «EPOS4 Firmware Specification».

Setup

Status Indicators

Figure 3-45 LEDs – Location

3.4.1 NET Status

The LEDs (Figure 3-45; A) display the actual status and possible errors of the EPOS4 in respect to

the NET network:

• Green LED shows the RUN state

• Red LED indicates errors

LED

Description

Green Red

OFF — EPOS4 is in state INIT

Blink — EPOS4 is in state PRE-OPERATIONAL

Single flash — EPOS4 is in state SAFE-OPERATIONAL

ON — EPOS4 is in state OPERATIONAL

— OFF EPOS4 is in operating condition

— Double flash

— Single flash

An application watchdog timeout has occurred

Example: Timeout of Sync Manager Watchdog

EPOS4 has changed the COM state due to an internal error

Example: Change of state “Op” to “SafeOpError” due to Sync Error

General Configuration Error

—Blink

Example: State change commanded by master is not possible due to actual settings (register, object, hardware configuration)

Blink = continuous blinking (≈2.5 Hz) Flash = Flashing (≈0.2 s), followed by pause of 1 s

Table 3-47 NET Status LEDs

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Setup Status Indicators

3.4.2 Device Status

The LEDs (Figure 3-45; B) display the actual status and possible errors of the EPOS4:

• Green LED shows the status

• Red LED indicates errors

LED

Description

Green Red

Power stage is disabled. The EPOS4 is in status…

Slow OFF

• “Switch ON Disabled”

• “Ready to Switch ON”

• “Switched ON”

Power stage is enabled. The EPOS4 is in status…

ON OFF

• “Operation Enable”

• “Quick Stop Active”

OFF ON

ON ON

FAULT state. The EPOS4 is in status…

• “Fault”

Power stage is enabled. The EPOS4 is in temporary status…

• “Fault Reaction Active”

Flash ON No valid firmware or firmware download in progress

Flash = Flashing (≈0.9 s OFF/≈0.1 s ON) Slow = Slow blinking (≈1 Hz)

Table 3-48 Device Status LEDs

3.4.3 NET Port

The LED (Figure 3-45; C) displays the link activity of the NET port (applies for both ports, X14 “IN”

and X15 “OUT”):

• Green LED indicates link activity

LED

Description

Green

OFF Port is closed

Flicker Port is open / activity is present

ON Port is open

— Data rate is 100 MBit/s

Flicker = Continuous flickering (≈10 Hz)

Table 3-49 NET Port LED

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4 Wiring

Wiring

In this section you will find the wiring information for the setup you are using. You can either use the consolidated wiring diagram (Figure 4-47) featuring the full scope of interconnectivity and pin assignment. Or you may wish to use the connection overviews for either DC motor or EC (BLDC) motor that will assist you in determining the wiring for your particular motor type and the appropriate feedback signals.

Figure 4-46 Interfaces – Designations and location

Signs and abbreviations used

The subsequent diagrams feature this signs and abbreviations:

• Items marked with an asterisk (*) will be available with an upcoming firmware release.

• «EC Motor» stands for brushless EC motor (BLDC).

• Ground safety earth connection (optional).

ONTENTS

Possible Combinations to connect a Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60

DC Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60

EC (BLDC) Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61

Main Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62

Excerpts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63

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Wiring Possible Combinations to connect a Motor

4.1 Possible Combinations to connect a Motor

The following tables show feasible ways on how to connect the motor with its respective feedback signals or possible combinations thereof. To find the wiring that best suits your setup, proceed as follows:

1) Decide on the type of motor you are using; either DC or EC (BLDC) motor.

2) Connect the power supply and the logic supply by following the links to the stated figure.

3) Check-out the listing for the combination that best suits your setup. Pick the wiring method #

and go to the respective table; for DC motor Table 4-50, for EC (BLDC) motor Table 4-51.

4) Pick the row with the corresponding wiring method # and follow the link (or links) to the stated figure(s) to find the relevant wiring information.

4.1.1 DC Motor

Power supply & optional logic supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 4-48

Motor & feedback signals

Without sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # DC1

Digital incremental encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # DC2

Digital incremental encoder & Digital incremental encoder . . . . . . . . . . . . . . . . . . . . . . . . Method # DC3

Digital incremental encoder & Analog incremental encoder. . . . . . . . . . . . . . . . . . . . . . . . Method # DC4

Digital incremental encoder & SSI absolute encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # DC5

Analog incremental encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # DC6

SSI absolute encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # DC7

Encoders

Method

DC1 4-49

DC2  4-49 / 4-52

DC3

DC4

DC5

DC6 * 4-49 / 4-56

DC7

Table 4-50 Possible combinations of feedback signals for DC motor

Digital

Incremental 1

X5 X6 X6 X6

 * 4-49 / 4-53

 * 4-49 / 4-54

  4-49 / 4-55

Digital

Incremental 2

Analog

Incremental

SSI

Absolute

 4-49 / 4-57



Figure(s)

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Wiring

Possible Combinations to connect a Motor

4.1.2 EC (BLDC) Motor

Power supply & optional logic supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-48

Motor & feedback signals

Hall sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # EC1

Hall sensors & Digital incremental encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # EC2

Hall sensors & Analog incremental encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # EC3

Hall sensors & SSI absolute encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # EC4

Hall sensors & Digital incremental encoder & Digital incremental encoder . . . . . . . . . . . . Method # EC5

Hall sensors & Digital incremental encoder & Analog incremental encoder . . . . . . . . . . . . Method # EC6

Hall sensors & Digital encoder & SSI absolute encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . Method # EC7

Digital incremental encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # EC8

Digital incremental encoder & Digital incremental encoder . . . . . . . . . . . . . . . . . . . . . . . . Method # EC9

Digital incremental encoder & Analog incremental encoder . . . . . . . . . . . . . . . . . . . . . . . Method # EC10

Digital incremental encoder & SSI absolute encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # EC11

Analog incremental encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # EC12

SSI absolute encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # EC13

Method

Hall

sensors

Digital

Incremental 1

Incremental 2

Digital

Encoders

Incremental

Analog

SSI

Absolute



Figure(s)

X4 X5 X6 X6 X6

EC1

EC2

EC3

EC4

EC5

EC6

EC7

EC8

EC9

EC10

EC11

 4-50 / 4-51

  4-50 / 4-51 / 4-52

 * 4-50 / 4-51 / 4-56

  4-50 / 4-51 / 4-57

  * 4-50 / 4-51 / 4-53

  * 4-50 / 4-51 / 4-54

   4-50 / 4-51 / 4-55

 4-50 / 4-52

 * 4-50 / 4-53

 * 4-50 / 4-54

  4-50 / 4-55

EC12 * 4-50 / 4-56

EC13

 4-50 / 4-57

Table 4-51 Possible combinations of feedback signals for EC (BLDC) motor

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Wiring Main Wiring Diagram

4.2 Main Wiring Diagram

Figure 4-47 Main wiring diagram

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4.3 Excerpts

Wiring

Excerpts

4.3.1 Power & Logic Supply

Figure 4-48 Power & logic supply

4.3.2 DC Motor

Figure 4-49 DC motor

4.3.3 EC (BLDC) Motor

Figure 4-50 EC (BLDC) motor

4.3.4 Hall Sensors

Figure 4-51 Hall sensors

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Wiring Excerpts

4.3.5 Digital Incremental Encoder

Figure 4-52 Digital incremental encoder

4.3.6 Digital & Digital Incremental Encoder

Figure 4-53 Digital & Digital incremental encoder

4.3.7 Digital & Analog Incremental Encoder

Figure 4-54 Digital & Analog incremental encoder

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4.3.8 Digital Incremental & SSI Encoder

Figure 4-55 Digital incremental & SSI encoder

4.3.9 Analog Incremental Encoder

Wiring

Excerpts

Figure 4-56 Analog incremental encoder

4.3.10 SSI Encoder

Figure 4-57 SSI encoder

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Wiring Excerpts

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LIST OF FIGURES

Figure 1-1 Documentation structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Figure 2-2 Derating of output current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Figure 2-3 Power dissipation and efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Figure 2-4 Dimensional drawing [mm] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Figure 3-5 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Figure 3-6 Power supply connector X1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Figure 3-7 Logic supply connector X2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Figure 3-8 Motor connectors X3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Figure 3-9 Hall sensor connector X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Figure 3-10 Hall sensor 1 input circuit (analogously valid for Hall sensors 2 & 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Figure 3-11 Encoder connector X5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Figure 3-12 Encoder input circuit Ch A “differential” (analogously valid for Ch B & Ch I) . . . . . . . . . . . . . . . . . . . . . . . . .26

Figure 3-13 Encoder input circuit Ch A “single-ended” (analogously valid for Ch B & Ch I) . . . . . . . . . . . . . . . . . . . . . . .27

Figure 3-14 Sensor connector X6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Figure 3-15 Digital incremental encoder input circuit Ch A “differential” (analogously valid for Ch B). . . . . . . . . . . . . . . .29

Figure 3-16 Digital incremental encoder input circuit Ch I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Figure 3-17 Digital incremental encoder input circuit Ch A “single-ended” (analogously valid for Ch B). . . . . . . . . . . . . .31

Figure 3-18 Digital incremental encoder input circuit Ch I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Figure 3-19 Analog incremental encoder input circuit Ch A “differential” (analogously valid for Ch B) . . . . . . . . . . . . . . .33

Figure 3-20 Analog incremental encoder input circuit Ch I (digital evaluation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Figure 3-21 SSI absolute encoder data input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Figure 3-22 SSI absolute encoder clock output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Figure 3-23 HsDigIN1 circuit “differential” (analogously valid for HsDigIN2…4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Figure 3-24 HsDigIN1 circuit “single-ended” (analogously valid for HsDigIN2…4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Figure 3-25 HsDigOUT1 output circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Figure 3-26 Digital I/O connector X7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Figure 3-27 DigIN1 circuit (analogously valid for DigIN2…4) – Logic level setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Figure 3-28 DigIN1 circuit (analogously valid for DigIN2…4) – PLC level setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Figure 3-29 DigOUT1 circuit (analogously valid for DigOUT2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Figure 3-30 DigOUT1 “sinks” (analogously valid for DigOUT2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Figure 3-31 DigOUT1 “source” (analogously valid for DigOUT2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Figure 3-32 Analog I/O connector X8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Figure 3-33 AnIN1 circuit (analogously valid for AnIN2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Figure 3-34 AnOUT1 circuit (analogously valid for AnOUT2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Figure 3-35 STO connector X9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Figure 3-36 STO-IN1 circuit (analogously valid for STO-IN2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Figure 3-37 STO-OUT circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Figure 3-38 RS232 connector X10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Figure 3-39 CAN 1 connector X11 and CAN 2 connector X12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Figure 3-40 USB connector X13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3-41 Extension NET IN & NET OUT connectors X14 & X15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Figure 3-42 Extension Signal connector X16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

. . . . . . . . . . . . . . . . . . .49

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Figure 3-43 Extension slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Figure 3-44 DIP switch SW1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Figure 3-45 LEDs – Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Figure 4-46 Interfaces – Designations and location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Figure 4-47 Main wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Figure 4-48 Power & logic supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Figure 4-49 DC motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Figure 4-50 EC (BLDC) motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Figure 4-51 Hall sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Figure 4-52 Digital incremental encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Figure 4-53 Digital & Digital incremental encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Figure 4-54 Digital & Analog incremental encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Figure 4-55 Digital incremental & SSI encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Figure 4-56 Analog incremental encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Figure 4-57 SSI encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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LIST OF TABLES

Table 1-1 Notation used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Table 1-2 Symbols and signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Table 1-3 Brand names and trademark owners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Table 2-4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Table 2-5 Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Table 2-6 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Table 3-7 Prefab maxon cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Table 3-8 EPOS4 Connector Set – Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Table 3-9 Recommended tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Table 3-10 Power supply connector X1 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Table 3-11 Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Table 3-12 Logic supply connector X2 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Table 3-13 Motor connector X3 – Pin assignment for maxon DC motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Table 3-14 Motor connector X3– Pin assignment for maxon EC motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Table 3-15 Motor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Table 3-16 Hall sensor connector X4 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Table 3-17 Hall Sensor Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Table 3-18 Encoder connector X5 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Table 3-19 Encoder connector X5 – Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Table 3-20 Encoder Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Table 3-21 Sensor connector X6 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Table 3-22 Sensor Cable 5x2core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Table 3-23 Digital I/O connector X7 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Table 3-24 Signal Cable 8core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Table 3-25 Analog I/O connector X8 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Table 3-26 Signal Cable 7core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Table 3-27 STO connector X9 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Table 3-28 STO Idle Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Table 3-29 STO logic state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Table 3-30 RS232 connector X10 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Table 3-31 RS232-COM Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Table 3-32 CAN 1 connector X11/CAN 2 connector X12 – Pin assignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Table 3-33 CAN-COM Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Table 3-34 CAN-CAN Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Table 3-35 USB connector X13 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Table 3-36 USB Type A - micro B Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Table 3-37 Extension NET IN & NET OUT connectors X14 & X15 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Table 3-38 Ethernet Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Table 3-39 Extension Signal connector X16 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Table 3-40 Extension cards (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Table 3-41 DIP switch SW1 – Binary code values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Table 3-42 DIP switch SW1 – Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

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Table 3-43 DIP switch SW1 – CAN automatic bit rate detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Table 3-44 DIP switch SW1 – CAN bus termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Table 3-45 DIP switch SW1 – Digital input level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Table 3-46 Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Table 3-47 NET Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Table 3-48 Device Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Table 3-49 NET Port LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Table 4-50 Possible combinations of feedback signals for DC motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Table 4-51 Possible combinations of feedback signals for EC (BLDC) motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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INDEX

alerts 6

analog incremental encoder (differential) analog inputs analog outputs applicable EU directive applicable regulations

Beckhoff TwinCAT 53

BiSS encoder

wiring

bit rate detection bit rate, default

cables (prefab)

CAN-CAN Cable

CAN-COM Cable 47 Encoder Cable 26

Ethernet Cable

Hall Sensor Cable 23 Motor Cable 22

Power Cable

RS232-COM Cable 46 Sensor Cable 5x2core 29

Signal Cable 7core

Signal Cable 8core 38 STO Idle Connector 44

USB Type A - micro B Cable CAN bus termination CAN ID CAN interface connectors

country-specific regulations

EXT1

EXT2

X3 22

X6 28

X9 44

X10

X11 47

X12 47

X13

X14

X15 50

X16

53 53

48, 55

device condition, display of 57

digital high-speed inputs (differential) digital high-speed inputs (single-ended) digital high-speed output digital incremental encoder (differential) digital incremental encoder (single-ended) digital outputs DIP switch SW1

36 29

encoders

absolute 35

differential

incremental 29 serial 35

single-ended

EnDat encoder

wiring EPOS4 Connector Set EPOS4 EtherCAT Card ESD

EtherCAT

network

option card EU directive, applicable

Hall sensor 24

how to

calculate the required supply voltage

connect extension signals

interpret icons (and signs) used in this document

unplug an extension card

incorporation into surrounding system 15

informatory signs inputs

analog

high-speed digital

STO

interfaces

CAN

location and designation

RS232 46

USB 49

LEDs, interpretation of 57

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mandatory action signs 6

motor types, supported

regulations, applicable 8

Requirements of power supply

Node Address 54

notations used

operating license 15

outputs

analog

digital 40

high-speed digital

STO 45

part numbers

275829

275851 22 275878 23

275934

403968 49 422827 51

520852

520853 38 520854 42

520856

520857 47 520858 48

520859

520860 44 546047 9

performance data power supply requirements precautions prerequisites prior installation prohibitive signs protective measures (ESD) purpose

of the device 7

of the document

safety alerts 6

safety first! signs used SSI encoder

specification

wiring 65

standards, fulfilled status LEDs supply voltage, required

SW1 54

symbols used

technical data 9

termination (CAN bus) TwinCAT

48, 55

USB port 49

wiring examples

analog incremental encoder 65 DC motor 63

digital & analog incremental encoder

digital & digital incremental encoder 64 digital incremental & SSI encoder 65

digital incremental encoder

DigOUT 41

EC (BLDC) motor Hall sensors power & logic supply SSI encoder

63 65

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EtherCAT® is a registered trademark and patented technology, licensed by Beckhoff Automation GmbH, Germany

maxon motor ag

Brünigstrasse 220 P.O.Box 263 CH-6072 Sachseln Switzerland

Phone +41 41 666 15 00 Fax +41 41 666 16 50

www.maxonmotor.com

maxon motor control

Z-74 Document ID: rel6852 EPOS4 Positioning Controller

Edition: May 2017 EPOS4 50/5 Hardware Reference

maxon motor EPOS4 50/5 Reference Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

READ THIS FIRST

1 About

1.1 About this Document

1.1.1 Intended Purpose

1.1.2 T arget Audience

1.1.3 How to use

1.1.4 Symbols & Signs

1.1.5 Trademarks and Brand Names

1.1.6 Copyright

1.2 About the Device

1.3 About the Safety Precautions

2 Specifications

2.1 Technical Data

2.2 Thermal Data

2.2.1 Derating of Output Current

2.2.2 Power Dissipation and Efficiency

2.3 Limitations

2.4 Dimensional Drawing

2.5 Standards

3Setup

3.1 Generally applicable Rules

3.2 Cabling

3.3 Connections

3.3.1 Power Supply (X1)

3.3.2 Logic Supply (X2)

3.3.3 Motor (X3)

3.3.4 Hall Sensor (X4)

3.3.5 Encoder (X5)

3.3.6 Sensor (X6)

3.3.6.1 Incremental Encoder

3.3.6.2 SSI Absolute Encoder

3.3.6.3 High-speed Digital I/Os

3.3.7 Digital I/O (X7)

3.3.8 Analog I/O (X8)

3.3.9 STO (X9)

3.3.10 RS232 (X10)

3.3.11 CAN 1 (X11) & CAN 2 (X12)

3.3.12 USB (X13)

3.3.13 Extension NET IN (X14) & Extension NET OUT (X15)

3.3.14 Extension Signal (X16)

3.3.15 Extension Slots (EXT1 & EXT2)

3.3.16 DIP Switch Configuration (SW1)

3.3.16.1 CAN ID (Node Address)

3.3.16.2 CAN automatic Bit Rate Detection

3.3.16.3 CAN Bus Termination

3.3.16.4 Digital Input Level

3.3.17 Spare Parts

3.4 Status Indicators

3.4.1 NET Status

3.4.2 Device Status

3.4.3 NET Port

4 Wiring

4.1 Possible Combinations to connect a Motor

4.1.1 DC Motor

4.1.2 EC (BLDC) Motor

4.2 Main Wiring Diagram

4.3 Excerpts

4.3.1 Power & Logic Supply

4.3.2 DC Motor

4.3.3 EC (BLDC) Motor

4.3.4 Hall Sensors

4.3.5 Digital Incremental Encoder

4.3.6 Digital & Digital Incremental Encoder

4.3.7 Digital & Analog Incremental Encoder

4.3.8 Digital Incremental & SSI Encoder

4.3.9 Analog Incremental Encoder

4.3.10 SSI Encoder

LIST OF FIGURES

LIST OF TABLES

INDEX