maxon motor EPOS4 Module 50/5, EPOS4 Compact 50/5 CAN Reference Manual

maxon motor control

EPOS4 Positioning Controller

Hardware Reference

Edition May 2018

Positioning Controller

P/N 534130

Positioning Controller

P/N 541718

Hardware Reference

Document ID: rel8003

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

1 About 5

1.1 About this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2 About the Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.3 About the Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2 Specifications 11

2.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.2 Thermal Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.3 Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.4 Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.5 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3Setup 17

3.1 Generally applicable Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.2 Pin Assignment for Module Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.3 Pin Assignment for Connector Boards & Compact Versions . . . . . . . . . . . . . 21

3.3.1 EPOS4 CB 50/5 CAN (534133) / EPOS4 Compact 50/5 CAN (541718) . . . . . . . . . . . 21

3.3.2 Cabling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.3.3 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.3.4 Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.3.5 DIP Switch Configuration (SW1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.3.6 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.4 Connection Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.4.1 Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.4.2 Logic Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.4.3 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.4.4 Hall Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.4.5 Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.4.6 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.4.7 Digital I/Os . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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. EPOS4 Module 50/5 and EPOS4 Compact 50/5 positioning controllers are considered as partly completed machinery

according to EU Directive 2006/42/EC, Article 2, Clause (g) and are intended to be incorporated into or assembled with

other machinery or other partly completed machinery or equipment. Therefore, you must not put the device into service,…

• unless you have made completely sure that th e 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!

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3.4.8 Safe Torque Off I/Os . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

3.4.9 Analog I/Os . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3.4.10 Serial Communication Interface (SCI) / RS232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.4.11 CAN Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

3.4.12 Serial Peripheral Interface (SPI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

3.4.13 USB (X13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3.5 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

4 Motherboard Design Guide 71

4.1 Requirements for Components of Third-party Suppliers . . . . . . . . . . . . . . . . 72

4.1.1 Socket Headers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

4.1.2 Supply Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

4.1.3 Logic Supply Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4.1.4 Motor Cables and Motor Chokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

4.1.5 RS232 Transceiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

4.1.6 Recommended Components and Manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4.2 Design Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

4.2.1 Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

4.2.2 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

4.3 SMT Footprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

5Wiring 79

5.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

5.2 DC Motors (brushed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

5.3 EC Motors (BLDC, brushless) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

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A-4 Document ID: rel8003 EPOS4 Positioning Controller

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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 Module 50/5 and EPOS4 Compact 50/5 positioning controllers. 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 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.

maxon motor control EPOS4 Positioning Controller Document ID: rel8003 EPOS4 Module/Compact 50/5 Hardware Reference Edition: May 2018

1-5

About About this Document

1.1.3 How to use

If not stated otherwise, the described details are valid for both the plug-in module and the stand-alone compact version (chapter “1.2 About the Devices” on page 1-8).

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.

Typ e Symbol Meaning

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

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 this Document

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®

har-flexicon® © HARTING AG & Co. KG, DE-Espelkamp

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

Littelfuse® SMD NANO2®

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.

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: rel8003 EPOS4 Module/Compact 50/5 Hardware Reference Edition: May 2018

1-7

About About the Devices

1.2 About the Devices

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

maxon motor control’s EPOS4 Module 50/5 and EPOS4 Compact 50/5 are small-sized, full digital, smart positioning control units. Their high power density allow 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 devices are specially designed to be commanded and controlled as a slave node in a CANopen network. In addition, the units can be operated via any USB or RS232 (the Module requires an external transceiver) 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.

Thanks to its smart design, the EPOS4 Module 50/5 can either be used in combination with EPOS4 CB 50/5 connector boards as a compact, integrated solution or be incorporated into customer-specific motherboards for single axis or multi axes motion control systems. The controller is available in the following configurations:

• EPOS4 Module 50/5 (534130) Plug-in module for use with maxon motor control EPOS4 connector boards or customer-specific motherboards

• EPOS4 CB 50/5 CAN (534133) Connector board for initial commissioning or combination to a compact solution providing all connectors, including CANopen interface

• EPOS4 Compact 50/5 CAN (541718) Fully integrated, compact, ready-to-use assembly of plug-in module and CANopen connector board

Figure 1-2 Configuration overview

For easier legibility, in the later course of this document naming of components will be as follows:

Short form Meaning

a connector board (EPOS4 CB 50/5 CAN, EPOS4 CB 50/5 EtherCAT, available shortly)

Compact any type of Compact 50/5 version

Compact CAN EPOS4 Compact 50/5 CAN

Compact EtherCAT EPOS4 Compact 50/5 EtherCAT (available shortly)

EPOS4

all controller versions (Module and Compact) as well as other EPOS4 positioning controllers as a whole

Module EPOS4 Module 50/5

Table 1-4 Abbreviations

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1-8 Document ID: rel8003 EPOS4 Positioning Controller

Edition: May 2018 EPOS4 Module/Compact 50/5 Hardware Reference

About

About the Devices

For easier legibility, in the later course of this document naming of components will be as follows:

• EPOS4 Module 50/5 will be named as «Module»

• EPOS4 Compact 50/5 will be named as «Compact» covering all Compact versions

• EPOS4 Compact 50/5 CAN will be named as «Compact CAN»

•«EPOS4» will be used to describe both versions, Module and Compact and/or other EPOS4

positioning controllers as a whole

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

maxon motor control EPOS4 Positioning Controller Document ID: rel8003 EPOS4 Module/Compact 50/5 Hardware Reference Edition: May 2018

1-9

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 can not be considered fail-safe. Therefore, you must make sure that any machine/apparatus has been fitted with independent monitoring and safety equipment. If the machin e/appa ratus shou ld brea k 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 97% (Figure 2-4)

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

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

cont

/ I

EPOS4 Module 50/5 (534130)

EPOS4 Compact 50/5 CAN (541718)

10…50 VDC

Module 10…50 VDC

max

min

(<3 s)

/ +V

max

Compact 10…50 VDC, optional

8 VDC / 56 VDC

0.9 x +V

5 A / 15 A

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

Module –

Compact 3 x 9.4 μH; 5 A

Module +2.1…+36 VDC

Compact

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)

Specifications

Technical Data

DIP switch-selectable levels:

• Logic: +2.0…+30 VDC

• PLC: +9.0…+30 VDC

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2-11

Specifications Technical Data

EPOS4 Module 50/5 (534130)

EPOS4 Compact 50/5 CAN (541718)

Inputs

Outputs

(continued)

Voltage

Outputs

Motor

Connections

Interfaces

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

Sensor signals (choice between multiple functions)

• Digital incremental encoder

• Analog incremental encoder

• SSI absolute encoder

• High-speed digital input 1…4 and High-speed digital output 1

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

EIA RS422, max. 6.25 MHz

3-channel, EIA RS422, max. 6.25 MHz 3-channel, resolution 12-bit, ±1.8 V, differential configurable, EIA RS422, 5 MHz EIA RS422, max. 6.25 MHz EIA RS422, max. 6.25 MHz

Module

max. 115’200 bit/s; external transceiver necessary

Compact max. 115’200 bit/s

USB 2.0 / USB 3.0 Full Speed

CAN max. 1 Mbit/s

Status

Indicators

Operation green LED

Error red LED

Module approx. 17 g

Weight

Compact CAN approx. 58 g

Module 53.8 x 38.8 x 11.1 mm

Physical

Dimensions (L x W x H)

Mounting

Compact CAN 55.0 x 40.0 x 31.1 mm

Module

pluggable female box headers 1.27 mm or mounting holes for M2.5 screws

Compact mounting holes for M2.5 screws 3)

Operation

Module: −30…+45 °C Compact: −30…+25 °C

Module: +45…+75 °C

Derating −0.167 A/°C

Environ-

mental

Temperature

Extended range 1)

Compact: +25…+70 °C

(Figure 2-3)

Derating −0.111 A/°C (Figure 2-3)

Conditions

Storage −40…+85 °C

Operation 0…6’000 m MSL

Altitude 2)

Extended range 1)

6’000…10’000 m MSL Derating Figure 2-3

Humidity 5…90% (condensation not permitted)

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

) as to the stated values will apply.

cont

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

3) Max. tightening torque 0.16 Nm.

Table 2-5 Technical data

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2.2 Thermal Data

2.2.1 Derating of Output Current

Specifications

Thermal Data

Module Compact

Figure 2-3 Derating of output current

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2-13

Specifications Limitations

2.2.2 Power Dissipation and Efficiency

Figure 2-4 Power dissipation and efficiency

2.3 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 105 °C 90 °C

Table 2-6 Limitations

2.4 Dimensional Drawings

Figure 2-5 EPOS4 Module 50/5 – Dimensional drawing [mm]

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Figure 2-6 EPOS4 CB 50/5 CAN – Dimensional drawing [mm]

Specifications

Dimensional Drawings

Figure 2-7 EPOS4 Compact 50/5 CAN – Dimensional drawing [mm]

maxon motor control EPOS4 Positioning Controller Document ID: rel8003 EPOS4 Module/Compact 50/5 Hardware Reference Edition: May 2018

2-15

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

Environment

IEC/EN 60068-2-6

MIL-STD-810F

Safety UL File Number

Reliability MIL-HDBK-217F

Table 2-7 Standards

Others

Environmental testing – Test Fc: Vibration (sinusoidal,

10…500 Hz, 20 m/s

Random transport (10…500 Hz up to 2.53 g

)

rms

Unassembled printed circuit board

• Module: E207844

• Compact CAN: E207844

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)

• Module: 314'822 hours

• Compact CAN: 253'865 hours

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3Setup

IMPORTANT NOTICE: PREREQUISITES FOR PERMISSION TO COMMENCE INSTALLATION

EPOS4 Module 50/5 and EPOS4 Compact 50/5 positioning controllers are considered as partly com- pleted machinery according to EU Directive 2006/42/EC, Article 2, Clause (g) and are intended to be incorporated into or assembled with other machinery or other partly completed machinery or equipment.

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.

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Setup Pin Assignment for Module Version

3.2 Pin Assignment for Module Version

For in-depth details on connections chapter “3.4 Connection Specifications” on page 3-38.

Figure 3-8 Pin assignment

Pin Signal Description

A1…A7**

A8…A14**

A15…A21** Motor winding 3 EC motor: Winding 3

A22

A23…A29**

Motor (+M) Motor winding 1

Motor (−M) Motor winding 2

+VCC

DC motor: Motor + EC motor: Winding 1

DC motor: Motor − EC motor: Winding 2

Logic supply voltage (+10…+50 VDC)

Power supply voltage (+10…+50 VDC)

A30…A36** GND Ground

A37 Hall sensor 1 Hall sensor 1 input

A38 Hall sensor 2 Hall sensor 2 input

A39 Hall sensor 3 Hall sensor 3 input

A40

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

Sensor

A41 Channel A Digital incremental encoder channel A

A42 Channel A\ Digital incremental encoder channel A complement

A43 Channel B Digital incremental encoder channel B

A44 Channel B\ Digital incremental encoder channel B complement

A45 Channel I Digital incremental encoder channel I

A46 Channel I\ Digital incremental encoder channel I complement

** Connect all pins in respect to the individual pin current rating.

Table 3-8 Pin assignment A1…A46 (X1…X5)

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3-18 Document ID: rel8003 EPOS4 Positioning Controller

Edition: May 2018 EPOS4 Module/Compact 50/5 Hardware Reference

Pin Assignment for Module Version

Pin Signal Description

B1 DigIN1 Digital input 1

B2 DigIN2 Digital input 2

B3 DigIN3 Digital input 3

B4 DigIN4 Digital input 4

B5 DigOUT1 Digital output 1

B6 DigOUT2 Digital output 2

B10

B11

B12

B13

B14

B15

Channel A HsDigIN1

Channel A\ HsDigIN1\

Channel B HsDigIN2

Channel B\ HsDigIN2\

Channel I HsDigIN3 Clock HsDigOUT1

Channel I\ HsDigIN3\ Clock\ HsDigOUT1\

Data HsDigIN4

Data\ HsDigIN4\

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

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

B16 GND Ground

B17 STO-IN1+ Safe Torque Off input 1, positive signal

B18 STO-IN1− Safe Torque Off input 1, negative signal

B19 STO-IN2+ Safe Torque Off input 2, positive signal

B20 STO-IN2− Safe Torque Off input 2, negative signal

B21 STO-OUT+ Safe Torque Off output, positive signal

B22 STO-OUT− Safe Torque Off output, negative signal

B23 AnIN1+ Analog input 1, positive signal

B24 AnIN1− Analog input 1, negative signal

B25 AnIN2+ Analog input 2, positive signal

B26 AnIN2− Analog input 2, negative signal

B27 AnOUT1 Analog output 1

B28 AnOUT2 Analog output 2

B29 CAN ID 1 CAN ID 1 (valence = 1)

B30 CAN ID 2 CAN ID 2 (valence = 2)

Continued on next page.

Setup

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Setup Pin Assignment for Module Version

Pin Signal Description

B31 CAN ID 3 CAN ID 3 (valence = 4)

B32 CAN ID 4 CAN ID 4 (valence = 8)

B33 CAN ID 5 CAN ID 5 (valence = 16)

B34 Auto bit rate Automatic bit rate detection of CAN bus

B35 CAN high CAN high bus line

B36 CAN low CAN low bus line

B37…B38 GND Ground

B39

B40 DSP_TxD Serial communication interface transmit (UART)

B41

B42

B43

B44

B45

B46

4) connect to sensor supply voltage V

5) only used for maxon extension modules

DSP_RxD Serial communication interface receive (UART)

SPI_CLK Serial Peripheral Interface clock

SPI_IRQ Serial Peripheral Interface interrupt request

SPI_SOMI Serial Peripheral Interface Slave output, Master input

SPI_SIMO Serial Peripheral Interface Slave input, Master output

SPI_CS2 Serial Peripheral Interface chip select 2

SPI_CS1 Serial Peripheral Interface chip select 1

(A40) when RS232 is not in use

Sensor

Table 3-9 Pin assignment B1…B46 (X6…X12)

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Edition: May 2018 EPOS4 Module/Compact 50/5 Hardware Reference

Pin Assignment for Connector Boards & Compact Versions

3.3 Pin Assignment for Connector Boards & Compact Versions

As an alternative to developing an own motherboard, ready-made connector boards are available to combine the Module to Compact versions. They comprise all required connections. For in-depth details on connections chapter “3.4 Connection Specifications” on page 3-38.

3.3.1 EPOS4 CB 50/5 CAN (534133) / EPOS4 Compact 50/5 CAN (541718)

Setup

Figure 3-9 EPOS4 CB 50/5 CAN (left) / EPOS4 Compact 50/5 CAN (right)

3.3.2 Cabling

LUG&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

Designation

Part

Number

Page

X3 Motor Cable 275851 3-25

X4 Hall Sensor Cable 275878 3-26

X5 Encoder Cable 275934 3-27

X6 Sensor Cable 5x2core 520852 3-29

X7 Signal Cable 8core 520853 3-30

X8 Signal Cable 7core 520854 3-31

X9 Signal Cable 8core 520853 3-30

X10 RS232-COM Cable 520856 3-33

X11

X12

CAN-COM Cable CAN-CAN Cable

520857 520858

3-34 3-34

X13 USB Type A - micro B Cable (located at the Module) 403968 3-68

Table 3-10 Prefab maxon cables

maxon motor control EPOS4 Positioning Controller Document ID: rel8003 EPOS4 Module/Compact 50/5 Hardware Reference Edition: May 2018

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Setup Pin Assignment for Connector Boards & Compact Versions

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

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

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 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

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

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

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

Connectors

Crimp Terminals

Accessories

Table 3-11 EPOS4 Connector Set – Content

3.3.3 Tools

Too l 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 3-12 Recommended tools

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3-22 Document ID: rel8003 EPOS4 Positioning Controller

Edition: May 2018 EPOS4 Module/Compact 50/5 Hardware Reference

Pin Assignment for Connector Boards & Compact Versions

3.3.4 Connections

The USB interface (X13) is located at the Module.

Setup

X1/X2

X10

X11

X12

Power & Logic Supply page 3-24

Motor page 3-25

Hall Sensor page 3-26

Encoder page 3-27

Sensor page 3-28

Digital I/O page 3-30

Analog I/O page 3-31

STO page 3-32

RS232 page 3-33

CAN 1 page 3-34

CAN 2 page 3-34

Figure 3-10 EPOS4 CB 50/5 CAN – Connectors

How to read pin assignment tables

• 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.

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Setup Pin Assignment for Connector Boards & Compact Versions

3.3.4.1 Power & Logic Supply (X1/X2)

Best practice

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

Figure 3-11 Power & logic supply connector X1/X2

X1/X2

Head A

Prefab

Cable

Head B

Signal Description

Pin Color Pin

1 − GND Ground

Power supply voltage (+10…+50 VDC)

Logic supply voltage (+10…+50 VDC)

Table 3-13 Power & logic supply connector X1/X2 – Pin assignment

Power & Logic Supply Connector X1/X2 (590736)

Type Spring-loaded contacts, 3 poles, pitch 2.54 mm

Suitable plug

Suitable cables

Harting har-flexicon 2.54 FPV-3 BK (14 31 031 3101 000) —included with every Compact version delivery—

Rigid

Flexible

0.14…0.5 mm

0.2…0.5 mm

0.25…0.34 mm

, AWG 26-20 / wire stripping length 6 mm

, AWG 24-20 / wire stripping length 6 mm

, AWG 24-22 / wire stripping length 6 mm, wire

end sleeves

Suitable tools Miniature screwdriver, size “00”

Table 3-14 Power & logic supply connector X1/X2 – Specification and accessories

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3-24 Document ID: rel8003 EPOS4 Positioning Controller

Edition: May 2018 EPOS4 Module/Compact 50/5 Hardware Reference

Setup

Pin Assignment for Connector Boards & Compact Versions

3.3.4.2 Motor (X3)

The controller is set to drive either maxon EC motor (BLDC, brushless DC motor) or maxon DC motor (brushed DC motor) with separated motor/encoder cable.

Figure 3-12 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 3-15 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 3-16 Motor connector X3– Pin assignment for maxon EC motor

Motor Cable for X3 (275851)

Cross-section

3 x 0.75 mm

, 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 3-17 Motor Cable

maxon motor control EPOS4 Positioning Controller Document ID: rel8003 EPOS4 Module/Compact 50/5 Hardware Reference Edition: May 2018

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Setup Pin Assignment for Connector Boards & Compact Versions

3.3.4.3 Hall Sensor (X4)

Figure 3-13 Hall sensor connector X4

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 3-18 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 3-19 Hall Sensor Cable

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3-26 Document ID: rel8003 EPOS4 Positioning Controller

Edition: May 2018 EPOS4 Module/Compact 50/5 Hardware Reference

3.3.4.4 Encoder (X5)

Figure 3-14 Encoder connector X5

Setup

Pin Assignment for Connector Boards & Compact Versions

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 3-20 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 3-21 Encoder connector X5 – Accessories

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 3-22 Encoder Cable

maxon motor control EPOS4 Positioning Controller Document ID: rel8003 EPOS4 Module/Compact 50/5 Hardware Reference Edition: May 2018

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Setup Pin Assignment for Connector Boards & Compact Versions

3.3.4.5 Sensor (X6)

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

Figure 3-15 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 3-23 Sensor connector X6 – Pin assignment

Continued on next page.

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Edition: May 2018 EPOS4 Module/Compact 50/5 Hardware Reference

Pin Assignment for Connector Boards & Compact Versions

Sensor Cable 5x2core (520852)

Setup

Cross-section

5 x 2 x 0.14 mm

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 3-24 Sensor Cable 5x2core

, twisted pair, grey

maxon motor control EPOS4 Positioning Controller Document ID: rel8003 EPOS4 Module/Compact 50/5 Hardware Reference Edition: May 2018

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Setup Pin Assignment for Connector Boards & Compact Versions

3.3.4.6 Digital I/O (X7)

Figure 3-16 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 3-25 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 3-26 Signal Cable 8core

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3-30 Document ID: rel8003 EPOS4 Positioning Controller

Edition: May 2018 EPOS4 Module/Compact 50/5 Hardware Reference

+ 74 hidden pages

maxon motor EPOS4 Module 50/5, EPOS4 Compact 50/5 CAN 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 Target 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 Devices

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 Drawings

2.5 Standards

3Setup

3.1 Generally applicable Rules

3.2 Pin Assignment for Module Version

3.3 Pin Assignment for Connector Boards & Compact Versions

3.3.1 EPOS4 CB 50/5 CAN (534133) / EPOS4 Compact 50/5 CAN (541718)

3.3.2 Cabling

3.3.3 Tools

3.3.4 Connections

3.3.4.1 Power & Logic Supply (X1/X2)

3.3.4.2 Motor (X3)

3.3.4.3 Hall Sensor (X4)

3.3.4.4 Encoder (X5)

3.3.4.5 Sensor (X6)

3.3.4.6 Digital I/O (X7)