maxon motor EPOS4 EtherCAT Card Reference Manual

maxon motor ag Brünigstrasse 220 P.O.Box 263 CH-6072 Sachseln Phone [phone] Fax [phone] www.maxonmotor.com

Edition December 2017

EPOS4 Positioning Controller

Hardware Reference

maxon motor control

Extension Card

P/N 581245

Hardware Reference

Document ID: rel7777

maxon motor control

A-2 Document ID: rel7777 EPOS4 Positioning Controller

Edition: December 2017 EPOS4 EtherCAT Card Hardware Reference

© 2017 maxon motor. Subject to change without prior notice.

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 Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.3 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3Setup 11

3.1 Generally applicable Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.3.1 EPOS4 Controllers with encased Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.3.2 EPOS4 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4 Motherboard Design Guide 17

4.1 Schematic Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.2 Requirements for Components of Third-party Suppliers . . . . . . . . . . . . . . . . 18

4.2.1 Card Edge Connector & Socket Headers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.2.2 Supply Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.2.3 EtherCAT Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.2.4 EtherCAT Port LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.2.5 EtherCAT Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.2.6 Recommended Components and Manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.3 THT Footprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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.

About

About this Document

maxon motor control
EPOS4 Positioning Controller Document ID: rel7777

1-3

EPOS4 EtherCAT Card Hardware Reference Edition: December 2017

© 2017 maxon motor. Subject to change without prior notice.

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 EtherCAT Card. 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:

Figure 1-1 Documentation structure

1.1.2 Target Audience

The present document is intended for trained and skilled personnel. It conveys information on how to
understand and fulfill the respective work and duties.

About
About this Document

maxon motor control

1-4 Document ID: rel7777 EPOS4 Positioning Controller

Edition: December 2017 EPOS4 EtherCAT Card Hardware Reference

© 2017 maxon motor. Subject to change without prior notice.

1.1.3 How to use

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

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.

Table 1-2 Symbols and signs

Notation Meaning

Module

refers to an EPOS4 Module (such as «EPOS4 Module 24/1.5», «EPOS4
Module 50/15»,and others)

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

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

Typ e 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.

About

About the Device

maxon motor control
EPOS4 Positioning Controller Document ID: rel7777

1-5

EPOS4 EtherCAT Card Hardware Reference Edition: December 2017

© 2017 maxon motor. Subject to change without prior notice.

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.

Table 1-3 Brand names and trademark owners

1.1.6 Copyright

© 2017 maxon motor. All rights reserved.

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
controllers.

maxon motor control's «EPOS4 EtherCAT Card» is a plug-in extension card to provide complete Ether­CAT communication capability for an EPOS4 positioning controller. It is optionally available to equip
either an EPOS4 encased housing variant or an EPOS4 Module with full EtherCAT functionality. For the
latter, development of an own motherboard as to particular guidelines is needed (for details chapter “4
Motherboard Design Guide” on page 4-17).

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

In addition, you may wish to browse the EPOS video library. It features video tutorials that provide easy
to follow instructions on how to get started with «EPOS Studio» and shows you tips and tricks on how to
setup communication interfaces, and so on. Explore on Vimeo: https://vimeo.com/album/4646388

Brand Name Trademark Owner

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

EtherCAT®

© EtherCAT Technology Group, DE-Nuremberg, licensed by Beckhoff
Automation GmbH, DE-Verl

PCI Express®
PCIe®

© PCI-SIG, USA-Beaverton, OR

Windows® © Microsoft Corporation, USA-Redmond, WA

maxon motor ag

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

Phone

Fax

Web

[phone]
[phone]
www.maxonmotor.com

About
About the Safety Precautions

maxon motor control

1-6 Document ID: rel7777 EPOS4 Positioning Controller

Edition: December 2017 EPOS4 EtherCAT Card Hardware Reference

© 2017 maxon motor. Subject to change without prior notice.

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 1-3)!

• Refer to chapter “1.1.4 Symbols & Signs” on page 1-4 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!

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. There fo re, you
must make sure that any machine/apparatus has been fitted with independent monitoring and safety
equipment. If the machine/ apparat us shoul d 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.

Hot plugging/hot swapping the card may cause hardware damage

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

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

maxon motor control
EPOS4 Positioning Controller Document ID: rel7777

2-7

EPOS4 EtherCAT Card Hardware Reference Edition: December 2017

© 2017 maxon motor. Subject to change without prior notice.

2 Specifications

2.1 Technical Data

Table 2-4 Technical data

EPOS4 EtherCAT Card (581245)

Electrical

Rating

Nominal power supply voltage +V

CC

10…70 VDC

Absolute supply voltage +V

min

/ +V

max

8 VDC / 76 VDC

Interface

EtherCAT input
EtherCAT output

As to IEEE 802.3 100 Base T

Max. bit rate 100 Mbit/s (full duplex)

Physical

Weight approx. 7 g

Dimensions (L x W x H) 41 x 25 x 9.2 mm

Mounting Card edge connector, PCIe; 2x18 position

Environ-

mental

Conditions

Temperature

Operation −30…+60 °C

Extended range 1)

For details consult Hardware Reference of
respective EPOS4 controller

Storage −40…+85 °C

Altitude 2) Operation 0…10’000 m MSL

Humidity 5…90% (condensation not permitted)

Legend

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.

Specifications
Dimensional Drawings

maxon motor control

2-8 Document ID: rel7777 EPOS4 Positioning Controller

Edition: December 2017 EPOS4 EtherCAT Card Hardware Reference

© 2017 maxon motor. Subject to change without prior notice.

2.2 Dimensional Drawings

Figure 2-2 EPOS4 EtherCAT Card with card edge connector & retainer – Dimensional drawing [mm]

Specifications

Standards

maxon motor control
EPOS4 Positioning Controller Document ID: rel7777

2-9

EPOS4 EtherCAT Card Hardware Reference Edition: December 2017

© 2017 maxon motor. Subject to change without prior notice.

2.3 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.

Table 2-5 Standards

Electromagnetic Compatibility

Generic

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

IEC/EN 61000-6-3

Emission standard for residential, commercial and light­industrial environments

Applied

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 radio­frequency fields 10 Vrms

Others

Environment

IEC/EN 60068-2-6

Environmental testing – Test Fc: Vibration (sinusoidal,
10…500 Hz, 20 m/s

2

)

MIL-STD-810F

Random transport (10…500 Hz up to 2.53 g

rms

)

Safety UL File Number Unassembled printed circuit board: E207844

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) 544’021 hours