maxon motor EPOS4 Module 50/8, EPOS4 Compact 50/8 CAN, EPOS4 Compact 50/8 EtherCAN Reference Manual

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Page 1

maxon motor control

EPOS4 Positioning Controller

Hardware Reference

Edition November 2018

P/N 504384

P/N 520885

P/N 605298

Hardware Reference

Document ID: rel8399

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 Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

2 Specifications 11

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

2.2 Thermal Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.3 Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.4 Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.5 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3Setup 21

3.1 Generally applicable Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.2 Pin Assignment for Module Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.3 Pin Assignment for Connector Boards & Compact Versions . . . . . . . . . . . . . 25

3.3.1 EPOS4 CB Power CAN (520884) / EPOS4 Compact 50/8 CAN (520885) . . . . . . . . . . 25

3.3.2 EPOS4 CB Power EtherCAT (604594) / EPOS4 Compact 50/8 EtherCAT (605298) . . 25

3.3.3 Cabling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.3.4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.3.5 Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.3.5.1 Power Supply (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.3.5.2 Logic Supply (X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.3.5.3 Motor (X3a) (X3b) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

3.3.5.4 Hall Sensor (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

3.3.5.5 Encoder (X5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.3.5.6 Sensor (X6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.3.5.7 Digital I/O (X7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.3.5.8 Analog I/O (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

3.3.5.9 STO (X9). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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 50/8 and EPOS4 Compact 50/8 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 other machinery fully complies with the EU directive’s requirements!

• unless the other machinery fulfills all relevant health and safety aspects!

• unless all respective interfaces have been established and fulfill the herein stated requirements!

maxon motor control

A-2 Document ID: rel8399 EPOS4 Positioning Controller

Edition: November 2018 EPOS4 Module/Compact 50/8 Hardware Reference

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3.3.5.10 RS232 (X10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

3.3.5.11 CAN 1 (X11) CAN 2 (X12). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

3.3.5.12 EtherCAT IN (X14) & EtherCAT OUT (X15) . . . . . . . . . . . . . . . . . . . . . . . . . . .42

3.3.6 DIP Switch Configuration (SW1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.3.6.1 CAN ID (Node-ID) / DEV ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

3.3.6.2 CAN automatic Bit Rate Detection (Compact CAN) . . . . . . . . . . . . . . . . . . . . .46

3.3.6.3 CAN Bus Termination (Compact CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

3.3.6.4 Digital Input Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

3.3.7 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3.4 Connection Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3.4.1 Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3.4.2 Logic Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3.4.3 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.4.4 Hall Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.4.5 Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.4.6 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.4.6.1 Incremental Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

3.4.6.2 SSI Absolute Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

3.4.6.3 High-speed Digital I/Os . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

3.4.7 Digital I/Os . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

3.4.7.1 Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

3.4.7.2 Compact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

3.4.8 Safe Torque Off I/Os . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3.4.9 Analog I/Os . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

3.4.10 Serial Communication Interface (SCI) / RS232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

3.4.10.1 Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

3.4.10.2 Compact CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

3.4.11 CAN Interface / ID Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

3.4.11.1 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

3.4.11.2 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

3.4.12 Serial Peripheral Interface (SPI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

3.4.13 USB (X13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

3.5 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

4 Motherboard Design Guide 81

4.1 Requirements for Components of Third-party Suppliers . . . . . . . . . . . . . . . . 82

4.1.1 Socket Headers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

4.1.2 Supply Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

4.1.3 Logic Supply Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

4.1.4 Motor Cables and Motor Chokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

4.1.5 RS232 Transceiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

4.1.6 Recommended Components and Manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

4.2 Design Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

4.2.1 Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

4.2.2 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

4.3 THT Footprint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

maxon motor control EPOS4 Positioning Controller Document ID: rel8399 EPOS4 Module/Compact 50/8 Hardware Reference Edition: November 2018

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5Wiring 91

5.1 Possible Combinations to connect a Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 92

5.2 Main Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

5.3 Excerpts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

maxon motor control

A-4 Document ID: rel8399 EPOS4 Positioning Controller

Edition: November 2018 EPOS4 Module/Compact 50/8 Hardware Reference

Page 5

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 50/8 and EPOS4 Compact 50/8 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: rel8399 EPOS4 Module/Compact 50/8 Hardware Reference Edition: November 2018

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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 signs 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

(typical)

Mandatory action

(typical)

Information

Table 1-2 Symbols and signs

Indicates a dangerous action. Hence, you must not!

Indicates a mandatory action. Hence, you must!

Requirement / Note / Remark

Best practice

Material Damage

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.

maxon motor control

1-6 Document ID: rel8399 EPOS4 Positioning Controller

Edition: November 2018 EPOS4 Module/Compact 50/8 Hardware Reference

Page 7

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®

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: rel8399 EPOS4 Module/Compact 50/8 Hardware Reference Edition: November 2018

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Page 8

About About the Devices

1.2 About the Devices

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

maxon motor control’s EPOS4 Module 50/8 and EPOS4 Compact 50/8 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 400 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 or EtherCAT network. In addition, the units can be operated via any USB or RS232 communication port of a Windows or Linux workstation (the Module thereby requires an external transceiver). Moreover, the integrated extension interface of the Module allows pooling with optionally available communication interfaces or other additional functionalities.

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

Thanks to its smart design, the EPOS4 Module 50/8 can either be used in combination with EPOS4 CB Power 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 50/8 (504384) Plug-in module for use with maxon motor control EPOS4 connector boards or customer-specific motherboards

• EPOS4 CB Power CAN (520884) Connector board for initial commissioning or combination to a compact solution providing all connectors, including CANopen and RS232 interface

• EPOS4 CB Power EtherCAT (604594) Connector board for initial commissioning or combination to a compact solution providing all connectors, including EtherCAT interface

• EPOS4 Compact 50/8 CAN (520885) Fully integrated, compact, ready-to-use assembly of plug-in module and CANopen connector board

• EPOS4 Compact 50/8 EtherCAT (605298) Fully integrated, compact, ready-to-use assembly of plug-in module and EtherCAT connector board

Figure 1-2 Configuration overview

maxon motor control

1-8 Document ID: rel8399 EPOS4 Positioning Controller

Edition: November 2018 EPOS4 Module/Compact 50/8 Hardware Reference

Page 9

About

About the Devices

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

Short form Meaning

CB a connector board (EPOS4 CB Power CAN, EPOS4 CB Power EtherCAT)

Compact any type of Compact 50/8 version

Compact CAN EPOS4 Compact 50/8 CAN

Compact EtherCAT EPOS4 Compact 50/8 EtherCAT

EPOS4

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

Module EPOS4 Module 50/8

Table 1-4 Abbreviations

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: rel8399 EPOS4 Module/Compact 50/8 Hardware Reference Edition: November 2018

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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 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.

maxon motor control

1-10 Document ID: rel8399 EPOS4 Positioning Controller

Edition: November 2018 EPOS4 Module/Compact 50/8 Hardware Reference

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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

Sampling rate PI current controller 25 kHz (40 μs)

Electrical

Rating

Inputs

Outputs

Continued on next page.

Sampling rate PID speed controller 2.5 kHz (400 μs)

Sampling rate PID positioning controller

Max. efficiency 98% (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

EPOS4 Module 50/8 (504384)

EPOS4 Compact 50/8 CAN (520885)

EPOS4 Compact 50/8 EtherCAT (605298)

10…50 VDC

Module 10…50 VDC

Compact 10…50 VDC, optional

/ I

max

min

(<5 s)

/ +V

8 VDC / 56 VDC

max

0.9 x +V

8 A / 30 A

2.5 kHz (400 μs)

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

Module —

Compact 3 x 2.2 μH; 15 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 shortcircuit 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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Specifications Technical Data

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

Inputs

Outputs

(continued)

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

Voltage

Outputs

Motor

Connections

Sensor supply voltage V

Auxiliary output voltage V

DC motor + Motor, − Motor

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

USB 2.0 / USB 3.0 Full Speed Full Speed Full Speed

RS232

CAN max. 1 Mbit/s max. 1 Mbit/s —

Interfaces

EtherCAT

Device status

Status

Indicators

(LEDs)

NET status — —

NET port — — Link activity (green)

Weight approx. 23 g approx. 86 g approx. 100 g

Dimensions (L x W x H) [mm] 59.5 x 46.0 x 14.1 59.5 x 58.5 x 33.0 59.5 x 79.5 x 35.7

Physical

Mounting

Continued on next page.

EPOS4 Module 50/8 (504384)

EPOS4 Compact 50/8 CAN (520885)

EPOS4 Compact 50/8 EtherCAT (605298)

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, 0.4…2 MHz EIA RS422, max. 6.25 MHz EIA RS422, max. 6.25 MHz

+5 VDC / IL ≤100 mA

Sensor

+5 VDC / IL ≤150 mA

Aux

Module Compact CAN Compact EtherCAT

max. 115’200 bit/s;

external transceiver

max. 115’200 bit/s —

necessary

Full duplex

(100 Mbit/s) as to IEE

802.3 100 Base Tx; optional «EPOS4

EtherCAT Card»

required

Module Compact CAN Compact EtherCAT

Operation (green)

Error (red)

Module Compact CAN Compact EtherCAT

pluggable female

headers 2.54 mm

mounting holes for

M2.5 screws

—

Error (red)

M2.5 screws

Full duplex

(100 Mbit/s) as to IEE

802.3 100 Base Tx

Operation (green)

Error (red)

RUN state (green)

Error (red)

mounting holes for

M2.5 screws

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Specifications

Technical Data

EPOS4 Module 50/8 (504384)

EPOS4 Compact 50/8 CAN (520885)

EPOS4 Compact 50/8 EtherCAT (605298)

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

+45…+77 °C Derating −0.250 A/°C (Figure 2-3)

Temperature

Operation

Extended range 1)

Environ-

mental

Conditions

Altitude 2)

Storage −40…+85 °C

Operation 0…6’000 m MSL

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.

Table 2-5 Technical data

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Specifications Thermal Data

2.2 Thermal Data

2.2.1 Derating of Output Current

Figure 2-3 Derating of output current

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2.2.2 Power Dissipation and Efficiency

Figure 2-4 Power dissipation and efficiency – EPOS4 Module/Compact 50/8 CAN

Specifications

Limitations

Figure 2-5 Power dissipation and efficiency – EPOS4 Compact 50/8 EtherCAT

2.3 Limitations

Protection functionality Switch-off threshold Recovery threshold

Undervoltage 8.0 V 8.5 V

Overvoltage 58 V 56 V

Overcurrent 40 A —

Thermal overload 100 °C 90 °C

Table 2-6 Limitations

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Specifications Dimensional Drawings

2.4 Dimensional Drawings

Figure 2-6 EPOS4 Module 50/8 – Dimensional drawing [mm]

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Figure 2-7 EPOS4 CB Power CAN – Dimensional drawing [mm]

Specifications

Dimensional Drawings

Figure 2-8 EPOS4 Compact 50/8 CAN – Dimensional drawing [mm]

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Specifications Dimensional Drawings

Figure 2-9 EPOS4 CB Power EtherCAT – Dimensional drawing [mm]

Figure 2-10 EPOS4 Compact 50/8 EtherCAT – Dimensional drawing [mm]

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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

Specifications

Standards

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: E76251; E207844; E337862

• Compact CAN: E76251; E116354; E207844; E337862

• Compact EtherCAT: E76251; E207844; E337862; E133472

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: 245’451 hours

• Compact CAN: 210’109 hours

• Compact EtherCAT: 197’129 hours

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Specifications Standards

••page intentionally left blank••

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3Setup

IMPORTANT NOTICE: PREREQUISITES FOR PERMISSION TO COMMENCE INSTALLATION

EPOS4 Module 50/8 and EPOS4 Compact 50/8 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. 8 A – short-time (acceleration) max. 30 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 3-47.

Figure 3-11 Pin assignment

Header

A1…A4**

A5…A8**

Signal Description

Motor (+M) Motor winding 1

Motor (−M) Motor winding 2

DC motor: Motor + EC motor: Winding 1

DC motor: Motor − EC motor: Winding 2

A9…A12** Motor winding 3 EC motor: Winding 3

A13…A16**

A17

+VC

Power supply voltage (+10…+50 VDC)

Logic supply voltage (+10…+50 VDC)

A18…A22** GND Ground

A23 Hall sensor 1 Hall sensor 1 input

A24 Hall sensor 2 Hall sensor 2 input

A25 Hall sensor 3 Hall sensor 3 input

A26

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

Sensor

A27 Channel A Digital incremental encoder channel A

A28 Channel A\ Digital incremental encoder channel A complement

A29 Channel B Digital incremental encoder channel B

A30 Channel B\ Digital incremental encoder channel B complement

A31 Channel I Digital incremental encoder channel I

A32 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…A32 (X1…X5)

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Setup

Pin Assignment for Module Version

Header

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

Continued on next page.

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Setup Pin Assignment for Module Version

Header

Signal Description

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

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

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

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

B33 ID 5 CAN ID / DEV 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

DSP_RxD Serial communication interface receive (UART)

B40 DSP_TxD Serial communication interface transmit (UART)

SPI_CLK Serial Peripheral Interface clock

B41

SPI_IRQ Serial Peripheral Interface interrupt request

B42

SPI_SOMI Serial Peripheral Interface Slave output, Master input

B43

SPI_SIMO Serial Peripheral Interface Slave input, Master output

B44

SPI_CS2 Serial Peripheral Interface chip select 2

B45

SPI_CS1 Serial Peripheral Interface chip select 1

B46

3) connect to sensor supply voltage V

(A26) when RS232 is not in use

Sensor

4) only used for maxon extension modules

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

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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 3-47.

3.3.1 EPOS4 CB Power CAN (520884) / EPOS4 Compact 50/8 CAN (520885)

Setup

Figure 3-12 EPOS4 CB Power CAN (left) / EPOS4 Compact 50/8 CAN (right)

3.3.2 EPOS4 CB Power EtherCAT (604594) / EPOS4 Compact 50/8 EtherCAT (605298)

Figure 3-13 EPOS4 CB Power EtherCAT (left) / EPOS4 Compact 50/8 EtherCAT (right)

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Setup Pin Assignment for Connector Boards & Compact Versions

3.3.3 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.

Connector Prefab Cable Assembly

Compact

CAN

Compact

EtherCAT

Designation

Power Cable High Current Mandatory for supply of power stage!

Power Cable Optional for separate logic supply!

X3a Motor Cable 275851 3-32

X3b Motor Cable High Current 520851 3-32

X4 Hall Sensor Cable 275878 3-33

X5 Encoder Cable 275934 3-34

X6 Sensor Cable 5x2core 520852 3-36

X7 Signal Cable 8core 520853 3-37

X8 Signal Cable 7core 520854 3-38

X9 Signal Cable 8core 520853 3-37

X10 — RS232-COM Cable 520856 3-40

X11 —

X12 —

X13

CAN-COM Cable CAN-CAN Cable

USB Type A - micro B Cable (located at the Module)

— X14 Ethernet Cable 422827 3-43

— X15 Ethernet Cable 422827 3-43

Part

Number

Page

520850 3-29

275829 3-30

520857 520858

3-41 3-41

403968 3-77

Table 3-10 Prefab maxon cables

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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

Connectors

X1 Molex Mega-Fit, 2 poles (171692-0102) 1

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

X3a Molex Mini-Fit Jr., 4 poles (39-01-2040) 1

X3b 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

Crimp Terminals

X1 / X3b Molex Mega-Fit, female crimp terminal (172063-0311) 7

X2 / X3a 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

Accessories

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

Table 3-11 EPOS4 Connector Set – Content

3.3.4 Tools

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 Mega-Fit crimp terminals Molex 63825-7100

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

Table 3-12 Recommended tools

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Setup Pin Assignment for Connector Boards & Compact Versions

3.3.5 Connections

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

EPOS4 CB Power CAN

Power Supply page 3-29

Logic Supply page 3-30

X3a

Motor page 3-31

X3b

Motor page 3-31

Hall Sensor page 3-33

Encoder page 3-34

Sensor page 3-35

EPOS4 CB Power EtherCAT

Digital I/O page 3-37

Analog I/O page 3-38

STO page 3-39

X10

RS232 page 3-40

X11

CAN 1 page 3-41

X12

CAN 2 page 3-41

X14

EtherCAT IN page 3-42

X15

EtherCAT OUT page 3-42

Figure 3-14 Connector Boards – 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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Pin Assignment for Connector Boards & Compact Versions

3.3.5.1 Power Supply (X1)

Best practice

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

Figure 3-15 Power supply connector X1

Setup

Head A

Prefab

Cable

Head B

Signal Description

Pin Color Pin

1 black − GND Ground

2 black +

Power supply voltage (+10…+50 VDC)

Table 3-13 Power supply connector X1 – Pin assignment

Power Cable High Current (520850)

Cross-section

2 x 2.5 mm2, grey

Length 3 m

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

Head A

Contacts Molex Mega-Fit, female crimp terminals (172063)

Head B

Wire end sleeves 2.5 mm

Table 3-14 Power Cable High Current

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Setup Pin Assignment for Connector Boards & Compact Versions

3.3.5.2 Logic Supply (X2)

Figure 3-16 Logic supply connector X2

Head A

Prefab

Cable

Head B

Signal Description

Pin Color Pin

1 black − GND Ground

2 black +

Logic supply voltage (+10…+50 VDC)

Table 3-15 Logic supply connector X2 – Pin assignment

Power Cable (275829)

Cross-section

2 x 0.75 mm

, 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 3-16 Power Cable

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Setup

Pin Assignment for Connector Boards & Compact Versions

3.3.5.3 Motor (X3a) (X3b)

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.

Maximum permitted current

The connectors are designed for the following output currents:

•X3a: I

•X3b: I

cont

≤11 A ≤15 A

Figure 3-17 Motor connectors X3a (left) and X3b (right)

X3a X3b

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 3-17 Motor connector X3a / X3b – Pin assignment for maxon DC motor

X3a X3b

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 3-18 Motor connector X3a / X3b – Pin assignment for maxon EC motor

Continued on next page.

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Setup Pin Assignment for Connector Boards & Compact Versions

Motor Cable for X3a (275851)

Cross-section

3 x 0.75 mm

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 3-19 Motor Cable

Cross-section

3 x 2.5 mm2, shielded, grey

Length 3 m

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

Head A

Contacts Molex Mega-Fit, female crimp terminals (172063)

Head B

Wire end sleeves 2.5 mm

, shielded, grey

Motor Cable High Current for X3b (520851)

Table 3-20 Motor Cable High Current

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3.3.5.4 Hall Sensor (X4)

Figure 3-18 Hall sensor connector X4

Setup

Pin Assignment for Connector Boards & Compact Versions

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 3-21 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 3-22 Hall Sensor Cable

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Setup Pin Assignment for Connector Boards & Compact Versions

3.3.5.5 Encoder (X5)

Figure 3-19 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 3-23 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 3-24 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 3-25 Encoder Cable

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Pin Assignment for Connector Boards & Compact Versions

3.3.5.6 Sensor (X6)

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

Figure 3-20 Sensor connector X6

Setup

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\

4yellow4

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 3-26 Sensor connector X6 – Pin assignment

Continued on next page.

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Setup Pin Assignment for Connector Boards & Compact Versions

Sensor Cable 5x2core (520852)

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 3-27 Sensor Cable 5x2core

, twisted pair, grey

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3.3.5.7 Digital I/O (X7)

Figure 3-21 Digital I/O connector X7

Setup

Pin Assignment for Connector Boards & Compact Versions

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 3-28 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 3-29 Signal Cable 8core

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Setup Pin Assignment for Connector Boards & Compact Versions

3.3.5.8 Analog I/O (X8)

Figure 3-22 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 3-30 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 3-31 Signal Cable 7core

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Setup

Pin Assignment for Connector Boards & Compact Versions

3.3.5.9 STO (X9)

Figure 3-23 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 3-33; included with every Compact version delivery) 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

6 pink 6 STO-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 3-32 STO connector X9 – Pin assignment

For the matching prefab cable assembly Table 3-29 on page 3-37.

STO Idle Connector (520860)

—included with every Compact version delivery—

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

Table 3-33 STO Idle Connector

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Setup Pin Assignment for Connector Boards & Compact Versions

3.3.5.10 RS232 (X10)

Figure 3-24 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 3-34 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 3-35 RS232-COM Cable

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Pin Assignment for Connector Boards & Compact Versions

3.3.5.11 CAN 1 (X11) CAN 2 (X12)

Figure 3-25 CAN 1 connector X11 and CAN 2 connector X12

Setup

X11/12

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 3-36 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 3-37 CAN-COM Cable

CAN-CAN Cable (520858)

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)

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

Head B

Contacts Molex CLIK-Mate crimp terminals (502579)

Table 3-38 CAN-CAN Cable

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Setup Pin Assignment for Connector Boards & Compact Versions

3.3.5.12 EtherCAT IN (X14) & EtherCAT OUT (X15)

Wrong plugging may cause hardware damage

Even though both EtherCAT 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 EtherCAT IN (X14) as «Input».

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

Figure 3-26 EtherCAT IN & EtherCAT OUT connectors X14 & X15

X14 X15

Head A

Prefab

Cable

Head B

Signal Description

Pin Color Pin

white/

orange

1 TX+ Transmission Data+

2 orange 2 TX− 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 3-39 EtherCAT IN & EtherCAT OUT connectors X14 & X15 – Pin assignment

Continued on next page.

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Pin Assignment for Connector Boards & Compact Versions

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 3-40 Ethernet Cable

Setup

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Setup Pin Assignment for Connector Boards & Compact Versions

3.3.6 DIP Switch Configuration (SW1)

EPOS4 CB Power CAN

EPOS4 CB Power EtherCAT

Figure 3-27 DIP switch SW1

3.3.6.1 CAN ID (Node-ID) / DEV ID

Setting the ID by means of DIP switches is currently available for CAN only!

The device’s identification (subsequently called “ID”) is set by means of DIP switches 1…5. The ID (1…31) may be coded using binary code.

Setting the ID by DIP switch SW1

• By setting the DIP switch (1…5) address 0 (“OFF”), the ID may be set by software (object 0x2000 «Node-ID», range 1…127).

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

• With EPOS4 CB Power CAN, DIP switches 6…8 do not have any impact on the ID.

• With EPOS4 CB Power EtherCAT, DIP switch 6 does not have any impact on the ID.

Controller

Compact

CAN

Compact

EtherCAT

(factory setting) (factory setting)

Switch Binary Code Valenc e

Table 3-41 DIP switch SW1 – Binary code values

Continued on next page.

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Setup

Pin Assignment for Connector Boards & Compact Versions

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

Controller Switch

Compact

CAN

Compact

EtherCAT

1 2 3 4 5

00000 –

1 0000 1

0 1 000 2

001 00 4

0 = Switch “OFF” 1 = Switch “ON”

Table 3-42 DIP switch SW1 – Examples

1 0 1 00 5

0001 08

00001 16

11111 31

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Setup Pin Assignment for Connector Boards & Compact Versions

3.3.6.2 CAN automatic Bit Rate Detection (Compact CAN)

Controller Switch OFF ON

Compact

CAN

Automatic bit rate detection

deactivated

Automatic bit rate detection activated

(factory setting)

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

3.3.6.3 CAN Bus Termination (Compact CAN)

Controller Switch OFF ON

Compact

CAN

Without bus termination

Bus termination with 120 Ω

(factory setting)

Table 3-44 DIP switch SW1 – CAN bus termination

3.3.6.4 Digital Input Level

For details chapter “3.4.7 Digital I/Os” on page 3-64.

Controller Switch OFF ON

Compact

CAN

Logic level

(factory setting)

Compact

EtherCAT

Logic level

(factory setting)

Table 3-45 DIP switch SW1 – Digital input level

3.3.7 Spare Parts

Order

number

Description

520860 STO Idle Connector X9

Table 3-46 Spare parts list

PLC level

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3.4 Connection Specifications

The actual connection will depend on the overall configuration of your drive system and the type of motor you will be using. Follow the description in given order and choose the wiring diagram (as of page 5-91) that best suits the components you are using.

How to read the following data

The following tables feature, where applicable, connection details for both versions the Module and the Compact. Thereby,…

• the column «Module Header Pin» refers to the Module’s header pin number. Example: A13…A16 means header A, pins 13 thru 16

• the column «Compact/CB Connector Pin» refers to the Compact’s or CB’s connector pin number. Example: X1 | 2 means connector X1, pin 2

For easier legibility, the subsequently used circuit diagrams refer to the Module. For the corresponding Compact’s circuitry take the second column «Connector Pin» into account.

3.4.1 Power Supply

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

Setup

Connection Specifications

Module Header

A13…A16** X1 | 2

Compact/CB

Connector

Signal Description

+VCC

Power supply voltage (+10…+50 VDC)

A18…A22** X1 | 1 GND Ground

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

Table 3-47 Power supply – Pin assignment

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. 8 A

• short-time (acceleration, <5 s) max. 30 A

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.

Continued on next page.

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Setup

-------

Δn

ΔM

---------

M⋅+





0.9

-------

⋅⋅1 V[]+≥

Connection Specifications

The formula already takes the following into account:

• Maximum PWM duty cycle of 90%

• Controller’s max. voltage drop of 1 V @ 8 A

NOWN VAL UES:

• 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 VAL UE:

• Supply voltage +V

OLUTION:

[Volt]

; nO [rpm]

3.4.2 Logic Supply

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 requirements.

For the voltage supply observe the following:

• Module: You will need to provide both, logic supply and power supply.

• Compact: Either use two cables, the «Power Cable» (275829) to provide the logic suppl y and the «Power Cable High Current» (520850) to provide the power supply. Or use just one cable, the «Power Cable High Current» (520850) to provide the power supply. In this case, the logic supply is internally connected to the power supply voltage.

Module

Header

A17 X2 | 2

A18…A22** X2 | 1 GND Ground

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

Table 3-48 Logic supply – Pin assignment

Compact/CB

Connector

Signal Description

Logic supply voltage (+10…+50 VDC)

Power supply requirements

Output voltage

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

Min. output power

+VC 10…50 VDC

PC min. 3.5 W

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Connection Specifications

3.4.3 Motor

The EPOS4 is set to drive either maxon DC motors (brushed) or maxon EC motors (brushless).

Setup

Module Header

A1…A4**

A5…A8**

–

Compact/CB

Connector

X3a | 1 X3b | 1

X3a | 2 X3b | 2

X3a | 3 X3b | 3

X3a | 4 X3b | 4

Signal Description

Motor (+M) Motor +

Motor (−M) Motor −

– not connected

Motor shield Cable shield

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

Table 3-49 DC motor – Pin assignment

Module Header

A1…A4**

A5…A8**

A9…A12**

–

Compact/CB

Connector

X3a | 1 X3b | 1

X3a | 2 X3b | 2

X3a | 3 X3b | 3

X3a | 4 X3b | 4

Signal Description

Motor winding 1 Winding 1

Motor winding 2 Winding 2

Motor winding 3 Winding 3

Motor shield Cable shield

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

Table 3-50 EC motor – Pin assignment

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Setup Connection Specifications

3.4.4 Hall Sensor

Module

Header

Compact/CB

Connector

Signal Description

A18…A22 X4 | 4 GND Ground

A23 X4 | 1 Hall sensor 1 Hall sensor 1 input

A24 X4 | 2 Hall sensor 2 Hall sensor 2 input

A25 X4 | 3 Hall sensor 3 Hall sensor 3 input

A26 X4 | 5

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

Sensor

– X4 | 6 Hall shield Cable shield

Table 3-51 Hall sensor – Pin assignment

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 3-28 Hall sensor 1 input circuit (analogously valid for Hall sensors 2 & 3)

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Setup

Connection Specifications

3.4.5 Encoder

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.

Module Header

Compact/CB

Connector

Signal Description

A18…A22 X5 | 3 GND Ground

A26 X5 | 2

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

Sensor

A27 X5 | 6 Channel A Digital incremental encoder channel A

A28 X5 | 5 Channel A\

Digital incremental encoder channel A complement

A29 X5 | 8 Channel B Digital incremental encoder channel B

A30 X5 | 7 Channel B\

Digital incremental encoder channel B complement

A31 X5 | 10 Channel I Digital incremental encoder channel I

A32 X5 | 9 Channel I\

Digital incremental encoder channel I complement

Table 3-52 Encoder – Pin assignment

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

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Setup Connection Specifications

Figure 3-29 Encoder input circuit Ch A “differential” (analogously valid for Ch B & Ch I)

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 +250 μA @ 5 V

IIL = typically −330 μA @ 0 V

Push-pull Open collector

Max. input frequency

6.25 MHz

40 kHz (internal pull-up only)

150 kHz (additional external 3k3 pull-up)

Figure 3-30 Encoder input circuit Ch A “single-ended” (analogously valid for Ch B & Ch I)

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Setup

Connection Specifications

3.4.6 Sensor

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

3.4.6.1 Incremental Encoder

Module Header

Compact/CB

Connector

Signal Description

B7 X6 | 1 Channel A Digital/analog incremental encoder channel A

B8 X6 | 2 Channel A\

Digital/analog incremental encoder channel A complement

B9 X6 | 3 Channel B Digital/analog incremental encoder channel B

B10 X6 | 4 Channel B\

Digital/analog incremental encoder channel B complement

B11 X6 | 5 Channel I Digital/analog incremental encoder channel I

B12 X6 | 6 Channel I\

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

B15 X6 | 10

Aux

Digital/analog incremental encoder channel I complement

B16 X6 | 9 GND Ground

Table 3-53 Incremental encoder – Pin assignment

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

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Setup Connection Specifications

Figure 3-31 Digital incremental encoder input circuit Ch A “differential” (analogously valid for Ch B)

Figure 3-32 Digital incremental encoder input circuit Ch I

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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

Connection Specifications

100 kHz (additional external 3k3 pull-up)

Figure 3-33 Digital incremental encoder input circuit Ch A “single-ended” (analogously valid for Ch B)

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Setup Connection Specifications

Figure 3-34 Digital incremental encoder input circuit Ch I

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Connection Specifications

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

Figure 3-35 Analog incremental encoder input circuit Ch A “differential” (analogously valid for Ch B)

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Setup Connection Specifications

Figure 3-36 Analog incremental encoder input circuit Ch I (digital evaluation)

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3.4.6.2 SSI Absolute Encoder

Setup

Connection Specifications

Module Header

Compact/CB

Connector

Signal Description

B11 X6 | 5 Clock Clock (SSI)

B12 X6 | 6 Clock\ Clock (SSI) complement

B13 X6 | 7 Data Data (SSI)

B14 X6 | 8 Data\ Data (SSI) complement

B15 X6 | 10

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

Aux

B16 X6 | 9 GND Ground

Table 3-54 SSI absolute encoder – Pin assignment

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

Encoder input/output frequency 0.4… 2 MHz

Figure 3-37 SSI absolute encoder data input

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Setup Connection Specifications

Figure 3-38 SSI absolute encoder clock output

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Connection Specifications

3.4.6.3 High-speed Digital I/Os

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

Setup

Module Header

Compact/CB

Connector

Signal Description

B7 X6 | 1 HsDigIN1 High-speed digital input 1

B8 X6 | 2 HsDigIN1\ High-speed digital input 1 complement

B9 X6 | 3 HsDigIN2 High-speed digital input 2

B10 X6 | 4 HsDigIN2\ High-speed digital input 2 complement

B11 X6 | 5

B12 X6 | 6

HsDigIN3 HsDigOUT1

HsDigIN3\ HsDigOUT1\

High-speed digital input 3 High-speed digital output 1

High-speed digital input 3 complement High-speed digital output 1 complement

B13 X6 | 7 HsDigIN4 High-speed digital input 4

B14 X6 | 8 HsDigIN4\ High-speed digital input 4 complement

B15 X6 | 10

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

Aux

B16 X6 | 9 GND Ground

Table 3-55 High-speed digital I/Os – Pin assignment

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 3-39 HsDigIN1 circuit “differential” (analogously valid for HsDigIN2…4)

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Setup Connection Specifications

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

Max. input frequency 6.25 MHz

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

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)

Figure 3-40 HsDigIN1 circuit “single-ended” (analogously valid for HsDigIN2…4)

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Connection Specifications

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

Figure 3-41 HsDigOUT1 output circuit

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3.4.7 Digital I/Os

3.4.7.1 Module

Module

Header

Table 3-56 Digital I/Os – Pin assignment – Module

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

B15

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

Aux

B16 GND Ground

Digital inputs 1…4 (Module)

Input voltage 0…36 VDC

Max. input voltage ±36 VDC

Logic 0 <0.8 V

Logic 1 >2.1 V

typically 47 kΩ (<3.3 V)

Input resistance

typically 37.5 kΩ (@ 5 V) typically 25.5 kΩ (@ 24 V)

Input current at logic 1 typically 135 µA @ +5 VDC

Switching delay <300 μs

Figure 3-42 DigIN1 circuit (analogously valid for DigIN2…4) – Module

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3.4.7.2 Compact

Compact/CB

Connector

Signal Description

X7 | 1 DigIN1 Digital input 1

X7 | 2 DigIN2 Digital input 2

X7 | 3 DigIN3 Digital input 3

X7 | 4 DigIN4 Digital input 4

X7 | 5 DigOUT1 Digital output 1

X7 | 6 DigOUT2 Digital output 2

X7 | 7 GND Ground

X7 | 8

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

Aux

Table 3-57 Digital I/Os – Pin assignment – Compact

Digital inputs 1…4 (Compact / 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

Setup

Connection Specifications

Figure 3-43 DigIN1 circuit (analogously valid for DigIN2…4) – Compact / Logic level setting

Continued on next page.

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Input voltage 0…30 VDC

Max. input voltage ±30 VDC

Logic 0 <5.5 V

Logic 1 >9 V

Input current at logic 1

Switching delay <300 μs @ 24 VDC

Figure 3-44 DigIN1 circuit (analogously valid for DigIN2…4) – Compact / PLC level setting

Digital inputs 1…4 (Compact / PLC level setting)

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

For pin assignment of digital outputs Table 3-56 and Table 3-57.

Digital outputs 1…2

Circuit

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

Figure 3-45 DigOUT1 circuit (analogously valid for DigOUT2 and Compact)

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

Figure 3-46 DigOUT1 “sinks” (analogously valid for DigOUT2 and Compact)

DigOUT “source”

Output voltage

Max. load current

= 5.45 V − 0.75 V − (I

Out

≤2 mA

Load

Figure 3-47 DigOUT1 “source” (analogously valid for DigOUT2 and Compact)

x 2200 Ω)

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3.4.8 Safe Torque Off I/Os

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».

Activation of power stage In order to activate the power stage, both STO inputs must be powered.

Module

Header

Compact/CB

Connector

Signal Description

Activation voltage for STO inputs (+5 VDC)

–X9 | 8

STO

Note: Do not use this voltage for any other purpose

B15 –

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

Aux

B16 X9 | 7 GND Ground

B17 X9 | 1 STO-IN1+ Safe Torque Off input 1, positive signal

B18 X9 | 2 STO-IN1− Safe Torque Off input 1, negative signal

B19 X9 | 3 STO-IN2+ Safe Torque Off input 2, positive signal

B20 X9 | 4 STO-IN2− Safe Torque Off input 2, negative signal

B21 X9 | 5 STO-OUT+ Safe Torque Off output, positive signal

B22 X9 | 6 STO-OUT− Safe Torque Off output, negative signal

Table 3-58 STO I/Os – Pin assignment

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 3-48 STO-IN1 circuit (analogously valid for STO-IN2)

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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 3-49 STO-OUT circuit

Setup

Connection Specifications

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 3-59 STO logic state

STO Logic State

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3.4.9 Analog I/Os

Module

Header

Compact/CB

Connector

Signal Description

B16 X8 | 7 GND Ground

B23 X8 | 1 AnIN1+ Analog input 1, positive signal

B24 X8 | 2 AnIN1− Analog input 1, negative signal

B25 X8 | 3 AnIN2+ Analog input 2, positive signal

B26 X8 | 4 AnIN2− Analog input 2, negative signal

B27 X8 | 5 AnOUT1 Analog output 1

B28 X8 | 6 AnOUT2 Analog output 2

Table 3-60 Analog I/Os – Pin assignment

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

Figure 3-50 AnIN1 circuit (analogously valid for AnIN2)

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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

Setup

Connection Specifications

Figure 3-51 AnOUT1 circuit (analogously valid for AnOUT2)

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3.4.10 Serial Communication Interface (SCI) / RS232

The SCI is a two-wire asynchronous serial port, commonly known as a UART. The SCI modules support digital communication between the CPU and other asynchronous peripherals that use the standard nonreturn-to-zero (NRZ) format.

A common use of the Module’s SCI is to build an RS232 interface by wiring it to an RS232 transceiver. Alternatively, using any of the Compact versions does not require an external transceiver.

Bit rate settings

• Consider the master’s maximal bite rate.

• The standard bit rate setting (factory setting) is 115’200 bit/s.

3.4.10.1 Module

Module

Header

B39

5) connect to sensor supply voltage V

Signal Description

B38 GND Ground

*5)

DSP_RxD Serial communication interface receive (UART)

B40 DSP_TxD Serial communication interface transmit (UART)

(A26) when RS232 is not in use

Sensor

Table 3-61 SCI – Pin assignment

Serial Communication Interface (SCI)

Input voltage 0…3.3 VDC

Max. input voltage 5 VDC

High-level input voltage >2.0 VDC

Low-level input voltage <0.8 VDC

High-level output voltage >2.4 VDC

Low-level output voltage <0.4 VDC

Max. bit rate 115’200 bit/s

Data format NRZ (non-return-to-zero)

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3.4.10.2 Compact CAN

Compact/CB

Connector

Signal Description

X10 | 1 EPOS_RxD EPOS RS232 receive

X10 | 2 GND Ground

X10 | 3 EPOS_TxD EPOS RS232 transmit

X10 | 4 GND Ground

X10 | 5 Shield Cable shield

Table 3-62 RS232 – Pin assignment

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

Setup

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3.4.11 CAN Interface / ID Setting

3.4.11.1 Connection

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.

Module

Header

B35

B36

B37

–

Compact/CB

Connector

X11 | 1 X12 | 1

X11 | 2 X12 | 2

X11 | 3 X12 | 3

X11 | 4 X12 | 4

Signal Description

CAN high CAN high bus line

CAN low CAN low bus line

GND Ground

Shield Cable shield

Table 3-63 CAN bus line / CAN 1 / CAN 2 – Pin assignment

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

Node-ID setting

Module By external wiring or software

Compact CAN 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. For connector boards and Compact CAN versions, 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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3.4.11.2 Configuration

Setting the ID is currently available for CAN only!

The device’s identification (subsequently called “ID”) can be set by different means:

• For configuration on Compact versions “DIP Switch Configuration (SW1)” on page 3-44.

• For configuration on Module versions, the ID is set using the input lines ID1…ID5. The ID (1…31) may be coded using binary code.

Module Header

Signal Description Binary Code Valence

B29 ID 1 CAN ID / DEV ID 1

B30 ID 2 CAN ID / DEV ID 2

B31 ID 3 CAN ID / DEV ID 3

B32 ID 4 CAN ID / DEV ID 4

B33 ID 5 CAN ID / DEV ID 5

B37 GND Ground

Setup

Table 3-64 ID – Pin assignment

CAN ID / DEV ID

Max. input voltage 3.3 VDC

Logic 1 connected to GND

Logic 0 not connected

The set ID can be observed by adding the valences of all inputs connected externally to GND. Use the following table as a (non-concluding) guide:

CAN ID / DEV ID

1 2 3 4 5

0*0000–

1** 00001

0 1 0002

001 004

1 0 1 005

0001 08

00001 16

1111131

0* = ID input line not connected 1** = ID input line externally connected to GND

Table 3-65 ID – Examples

Setting the ID by means of «EPOS Studio»

• The ID may be set by software (changing object 0x2000 «Node-ID», range 1…127).

• The ID set by software is valid if the ID is set to “0” (none of the ID input lines connected).

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CAN AUTOMATIC BIT RATE DETECTION

With this function, the CANopen interface can be put in a “listen only” mode. For further details separate document EPOS4 Firmware Specification. Automatic bit rate detection is activated when the input line is externally connected to GND.

Auto Bit Rate GND

Max. input voltage 3.3 VDC

Logic 1 connected to GND

Logic 0 not connected

3.4.12 Serial Peripheral Interface (SPI)

The SPI is a high-speed synchronous serial input/output port allowing the use of optional maxon extension modules.

Note

Do not connect any other signals to the SPI apart from those for the maxon extension modules!

Bit rate detection

Pin B34 Pin B38

Module

Header

Signal Description

B38 GND Ground

B41 SPI_CLK Serial Peripheral Interface clock

B42 SPI_IRQ Serial Peripheral Interface interrupt request

B43 SPI_SOMI Serial Peripheral Interface Slave output, Master input

B44 SPI_SIMO Serial Peripheral Interface Slave input, Master output

B45 SPI_CS2 Serial Peripheral Interface chip select 2

B46 SPI_CS1 Serial Peripheral Interface chip select 1

Table 3-66 SPI – Pin assignment

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Setup

Connection Specifications

3.4.13 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 3-52 USB connector X13

Compact

Connector

X13 | 1 1

PC’s USB

Terminal

Signal Description

BUS

USB bus supply voltage input +5 VDC

X13 | 2 2 USB_D− USB Data− (twisted pair with Data+)

X13 | 3 3 USB_D+ USB Data+ (twisted pair with Data−)

X13 | 4 – ID not connected

X13 | 5 4 GND USB ground

Table 3-67 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 3-68 USB Type A - micro B Cable

USB

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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3.5 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 EtherCAT Port; the LED displays the NET link activity

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

Figure 3-53 LEDs – Location

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Status Indicators

3.5.1 NET Status

The LEDs (Figure 3-53; 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

Flicker — EPOS4 is in state BOOTSTRAP

— 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 Flicker = continuous flickering (≈10Hz)

Table 3-69 NET Status LEDs

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3.5.2 Device Status

The LEDs (Figure 3-53; 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 3-70 Device Status LEDs

3.5.3 EtherCAT Port

The LED (Figure 3-53; C) displays the link activity of the EtherCAT 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 3-71 EtherCAT Port LED

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4 Motherboard Design Guide

The «Motherboard Design Guide» provides helpful information on integrating the Module on a printed circuit board. It contains recommendations for the motherboard layout and specifies external components that may be required, pin assignments, and connection examples.

CAUTION

Dangerous Action Errors in implementing the design can result in serious Injury!

• Only proceed if you are skilled in electronics design!

• Designing a printed circuit board requires special skills and knowledge and may only be performed by experienced electronic developers!

• This quick guide is only intended as an aid, does not make any claim to completeness, and will not automatically result in a functional component!

Get help

If you are not trained in the design and development of printed circuit boards, you will need additional support for this point. maxon motor will be happy to provide you with a quote for designing and manufacturing a motherboard for your specific application.

Motherboard Design Guide

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Motherboard Design Guide Requirements for Components of Third-party Suppliers

4.1 Requirements for Components of Third-party Suppliers

Best practice

For references and recommended components consult Table 4-72.

4.1.1 Socket Headers

The Module’s implementation with pin headers permits mounting in two different ways. It can either be plugged onto a socket header or be directly soldered to a printed circuit board.

4.1.2 Supply Voltage

To protect the Module, we recommend using an external circuit breaker, a TVS diode, and a capacitor in the voltage supply cable. In this regard, please note the following recommendations:

Figure 4-54 Wiring of power supply

NPUT FUSE (FU1)

An input fuse (FU1) is necessary in order to provide reverse polarity protection. Together with an unipolar TVS diode (D1), this prevents current from flowing in the wrong direction.

IODE (D1)

TVS D

To protect against overvoltage resulting from voltage transients or brake energy feedback, we recommend connecting a TVS (transient voltage suppressor) diode (D1) to the voltage supply line.

APACITOR (C1)

The function of the Module does not necessarily require the use of an external capacitor. Nevertheless, to further reduce voltage ripple and feedback currents, an electrolytic capacitor (C1) can be connected to the voltage supply line. Use of an electrolytic capacitor is also recommended to avoid oscillations caused by supply cable inductance or the Module’s built-in capacitors that could lead to a voltage overshoot at power plug-in.

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Requirements for Components of Third-party Suppliers

4.1.3 Logic Supply Voltage

The Module features a logic supply voltage input. Its voltage range is 10…50 V and must be either sourced separately or by the power supply voltage.

Figure 4-55 Wiring of logic supply

TVS D

IODE (D2)

If the logic supply voltage is sourced separately, a transient voltage suppressor diode (D2) at the logic supply voltage input can be connected to protect the module against overvoltage.

CAPACITOR (C2)

Use an electrolytic capacitor (C2) if the logic supply is sourced separately. This will avoid oscillations caused by supply cable inductance or the Module’s built-in capacitors that could lead to a voltage overshoot at power plug-in.

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Motherboard Design Guide

Phase

1 2

---

6 f

PWMIN

⋅⋅

----------------------------- 0 . 3 L

Motor

⋅()–





⋅≥

Phase

H[]

VCCV[]

PWM

Hz[]

INA[]

Motor

H[]

Requirements for Components of Third-party Suppliers

4.1.4 Motor Cables and Motor Chokes

The Module is not equipped with internal motor chokes. The majority of motors and applications do not require additional chokes. However, in case of high supply voltage with very low terminal inductance, the ripple of the motor current can reach an unacceptably high value. This causes the motor to heat up unnecessarily and causes instable control behavior. The minimum terminal inductance required per phase can be calculated using the following formula:

Additional external inductance per phase

Operating voltage +V

Switching frequency of the power stage = 50’000 Hz

Nominal current of the motor (line 6 in the maxon catalog)

Terminal inductance of the motor (line 11 in the maxon catalog)

If the result of the calculation is negative, no additional chokes are necessary. Nevertheless, the use of chokes in combination with additional filter components can be useful to reduce the emission of electromagnetic interference.

An additional choke must feature electromagnetic shielding, an adequate saturation current, minimal losses, and a nominal current greater than the continuous current of the motor. The below wiring example refers to an additional inductance of 2.2 μH or 22 μH. If a different additional inductance is required, also the filter components must be adapted accordingly. Should you need further help with the filter design, contact maxon Support at http://support.maxonmotor.com.

Example 1

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Example 2

Figure 4-56 Wiring of motor winding 1 (analogously valid also for motor windings 2 & 3)

4.1.5 RS232 Transceiver

If you intend to use an RS232 interface, an external transceiver is necessary.

Figure 4-57 Wiring of RS232 transceiver

IMPORTANT

If you do not intend to use the RS232 interface, you must connect pin [B39] (DSP_RxD) with pin [A26] (sensor supply voltage V

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4.1.6 Recommended Components and Manufacturers

Recommended components

Straight socket header, pluggable with 0.64 x 0.64 mm pin headers, 2.54 mm pitch, contact length 6 mm, current rating per pin = I

/ 4, contact material: gold

cont

16 poles, 2 rows:

• Samtec (SSM-116-x-DV) SMT, 5.2 A per pin, 7.37 mm

• E-Tec (BS2-032-H750-55) SMT, 3 A per pin, 7.50 mm

• FCI (91618-316LF) SMT, 3 A per pin, 7.20 mm

• Samtec (SSW-116-0x-x-D) THT, 5.7 A per pin, 8.51 mm

Socket header

• E-Tec (BL2-032-S842-55) THT, 3 A per pin, 8.50 mm

• FCI (87606-316LF) THT, 3 A per pin, 8.50 mm

23 poles, 2 rows:

• Samtec (SSM-123-x-DV) SMT, 5.2 A per pin, 7.37 mm

• E-Tec (BS2-046-H750-55) SMT, 3 A per pin, 7.50 mm

• FCI (91618-323LF) SMT, 3 A per pin, 7.20 mm

• Samtec (SSW-123-0x-x-D) THT, 5.7 A per pin, 8.51 mm

• E-Tec (BL2-046-S842-55) THT, 3 A per pin, 8.50 mm

• FCI (87606-323LF) THT, 3 A per pin, 8.50 mm

Fuse (FU1)

TVS Diode (D1; D2)

• Littelfuse 456 series, SMD NANO2 Fuse 20 A, 18 A2sec (0456 020)

• Vishay (SMBJ54A) UR = 54 V, UBR = 60.0…66.3 V @ 1 mA, UC = 87.1 V @ 6.9 A

• Fairchild (SMBJ54A) U

• Littelfuse (SMBJ54A) U

The ripple current load for C1 depends on the motor’s operating point and the power supply output capacity. Under worst case conditions however, the ripple current may reach I

Capacitor

voltage ≥ 63 V and adequate ripple current to avoid overheat or life time reduction.

(C1)

Example for C1 worst-case dimensioning:

= 12 A  3x Panasonic (EEU-FR1J391); 390 μF, 63 V, 2000 mA r.m.s., ØxL 12.5 x 25 mm

cont

To avoid voltage overshoot at power plug-in with a separately sourced logic supply, use an electrolytic

Capacitor (C2)

capacitor covering the following requirements: 33 μF or 47 μF, 63 V, at least 265 mA r.m.s.

• Rubicon (63ZLH47MEFCTA6.3X11) or (63YXJ47M6.3X11)

• Panasonic (EEU-FR1J470B)

• Nippon Chemicon (EKYB630ELL330MF11D) or (EKY-630 ELL330MF11D)

Inductance: “Motor Cables and Motor Chokes” on page 4-84 Rated current: I

rms

≥ I

cont

; I

≥ I

sat

peak

Construction: shielded

= 54 V, UBR = 60.0…66.6 V @ 1 mA, UC = 87.1 V @ 6.9 A

/ 2. Use capacitors with rated

cont

Motor Choke (L)

2.2 μH:

• Bourns (SRP1265A-2R2M) I

• Vishay (IHLP5050FDER2R2M01) I

• Laird (MGV12072R2M-10) I

22 A, I

rms

22 A, I

rms

22 A, I

rms

37 A, 12.5 x 13.5 x 6.4 mm

sat

40 A, 12.9 x 13.2 x 6.5 mm

sat

40 A, 12.6 x 13.5 x 6.5 mm

sat

22 μH:

• Würth (WE-PD-XXL / 7447709220) I

5.3 A, I

rms

6.5 A, 12.5 x 12.5 x 10 mm

sat

Continued on next page.

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Motor Filter

RS232 (IC1) (C3…C7)

Motherboard Design Guide

Requirements for Components of Third-party Suppliers

Recommended components

Example 1

• Motor Choke L 22 μH

• Filter Capacitor Cf 150 pF, 100 V

• Snubber Capacitor Cs 330 pF, 100 V

• Snubber Resistor Rs 390 Ω, 0.125 W

Example 2

• Motor Choke L 2.2 μH

• Filter Capacitor Cf 220 pF, 100 V

• Snubber Capacitor Cs 470 pF, 100 V

• Snubber Resistor Rs 100 Ω, 0.25 W

RS232 transceiver (IC1)

• Texas Instruments (MAX202IPW)

• ST Microelectronics (ST202EBTR)

Capacitors (C3…C7)

• 100 nF, X7R, 16 V

Table 4-72 Motherboard Design Guide – Recommended components

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Motherboard Design Guide Design Guidelines

4.2 Design Guidelines

The following instructions are intended to serve as an aid when designing an application-specific motherboard and ensures the correct and reliable integration of the Module.

While designing a motherboard, consider the following characteristics of the Module:

• Pin assignment (page 3-22)

• Technical data (page 2-11) and dimensional drawing (page 2-16)

4.2.1 Ground

All ground connections (GND) should be internally connected to the Module (equal potential). It is customary to equip the motherboard with a ground plane. All ground connections should be connected to the voltage supply ground via wide conductive tracks.

Pin Signal Description

A18…A22 GND Ground

B16 GND Ground

B37…B38 GND Ground

Table 4-73 Motherboard Design Guide – Grounding

If an earth potential is in place or required, the ground plane should be connected to the earth potential via one or more capacitors. The use of ceramic capacitors with 100 nF and 100 V is recommended.

4.2.2 Layout

Guidelines for the layout of the motherboard:

• Connector pins [A13], [A14], [A15], and [A16] for +V

(nominal power supply voltage) should

be connected to the fuse via wide conductive tracks.

• Connector pins [A18], [A19], [A20], [A21], [A22], [B16], [B37], and [B38] for GND (ground)

should be connected with the operating voltage ground via wide conductive tracks.

• Connector pin [B39] (DSP_RxD) must be connected to [A26] (sensor supply voltage; V

Sensor

)

when RS232 is not in use.

• The width of the conductive tracks and the copper coating thickness of the conductors for sup-

ply voltage and motor depend on the current required in your application. A minimum track width of 75 mil and a minimum copper coating thickness of 35 μm are recommended.

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4.3 THT Footprint

Figure 4-58 THT footprint [mm] – Top View

Motherboard Design Guide

THT Footprint

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Motherboard Design Guide THT Footprint

••page intentionally left blank••

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5 Wiring

Wiring

In this section you will find the wiring information for the setup you are using. You can either use the consolidated wiring diagrams (Figure 5-60 and Figure 5-61) 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 5-59 Interfaces – Designations and location

Signs and abbreviations used

The subsequent diagrams feature these signs and abbreviations:

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

• Ground safety earth connection (optional).

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Wiring Possible Combinations to connect a Motor

5.1 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 link 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 5-74, for EC (BLDC) motor Table 5-75.

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.

5.1.1 DC Motor

Power supply & optional logic supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 5-62

Motor & feedback signals

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

Digital incremental encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # DC2 or DC3

Analog incremental encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # DC4

SSI absolute encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # DC5

Digital incremental encoder & Digital incremental encoder . . . . . . . . . . . . . . . . . . . . . . . . Method # DC6

Digital incremental encoder & Analog incremental encoder. . . . . . . . . . . . . . . . . . . . . . . . Method # DC7

Digital incremental encoder & SSI absolute encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # DC8

Digital

Method

DC1 5-63

DC2

DC3

DC4

DC5

DC6

DC7  

DC8

Table 5-74 Possible combinations of feedback signals for DC motor

Incremental

Encoder 1

(Sensor 1)

X5 X6 X6 X6



 

Digital

Incremental

Encoder 2 (Sensor 2)



Analog

Incremental

Encoder

(Sensor 2)



SSI

Absolute

Encoder

(Sensor 2)





Figure(s)

5-63 5-66

5-63 5-67

5-63 5-68

5-63 5-69

5-63

5-66 / 5-67

5-63

5-66 / 5-68

5-63

5-66 / 5-69

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Wiring

Possible Combinations to connect a Motor

5.1.2 EC (BLDC) Motor

Power supply & optional logic supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-62

Motor & feedback signals

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

Hall sensors & Digital incremental encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # EC2 or EC3

Hall sensors & Analog incremental encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # EC4

Hall sensors & SSI absolute encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # EC5

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

Hall sensors & Digital incremental encoder & Analog incremental encoder . . . . . . . . . . . . Method # EC7

Hall sensors & Digital encoder & SSI absolute encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . Method # EC8

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

SSI absolute encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # EC10

Method

Hall

sensors

(Sensor 3)

Digital

Incremental

Encoder 1

(Sensor 1)

Digital

Incremental

Encoder 2 (Sensor 2)

Analog

Incremental

Encoder

(Sensor 2)

X4 X5 X6 X6 X6

EC1 

EC2

EC3

 

EC4  

EC5

EC6

EC7

EC8

 

  

EC9  

EC10

Table 5-75 Possible combinations of feedback signals for EC (BLDC) motor

SSI

Absolute

Encoder





Figure(s)

5-64 5-65

5-64

5-65 / 5-66

5-64

5-65 / 5-67

5-64

5-65 / 5-68

5-64

5-65 / 5-69

5-64

5-65 / 5-66 /5-67

5-64

5-65 / 5-66 / 5-68

5-64

5-65 / 5-66 / 5-69

5-64

5-66 / 5-69

5-64 5-69

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Wiring

Figure 5-67 Figure 5-68 Figure 5-69

Main Wiring Diagrams

5.2 Main Wiring Diagrams

5.2.1 Module & Compact CAN

Figure 5-60 Main wiring diagram – Module & Compact CAN

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5.2.2 Module & Compact EtherCAT

Figure 5-67 Figure 5-68 Figure 5-69

Wiring

Main Wiring Diagrams

Figure 5-61 Main wiring diagram – Module & Compact EtherCAT

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Wiring Excerpts

5.3 Excerpts

5.3.1 Power & Logic Supply

Figure 5-62 Power & logic supply

5.3.2 DC Motor

Figure 5-63 DC motor

5.3.3 EC (BLDC) Motor

Figure 5-64 EC (BLDC) motor

5.3.4 Hall Sensors (Sensor 3)

Figure 5-65 Hall sensors (Sensor 3)

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5.3.5 Digital Incremental Encoder 1 (Sensor 1)

Figure 5-66 Digital incremental encoder 1 (Sensor 1)

5.3.6 Digital Incremental Encoder 2 (Sensor 2)

Wiring

Excerpts

Figure 5-67 Digital incremental encoder 2 (Sensor 2)

5.3.7 Analog Incremental Encoder (Sensor 2)

Figure 5-68 Analog incremental encoder (Sensor 2)

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Wiring Excerpts

5.3.8 SSI Encoder (Sensor 2)

Figure 5-69 SSI encoder (Sensor 2)

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LIST OF FIGURES

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

Figure 1-2 Configuration overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Figure 2-3 Derating of output current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Figure 2-4 Power dissipation and efficiency – EPOS4 Module/Compact 50/8 CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Figure 2-5 Power dissipation and efficiency – EPOS4 Compact 50/8 EtherCAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Figure 2-6 EPOS4 Module 50/8 – Dimensional drawing [mm]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Figure 2-7 EPOS4 CB Power CAN – Dimensional drawing [mm] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Figure 2-8 EPOS4 Compact 50/8 CAN – Dimensional drawing [mm] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Figure 2-9 EPOS4 CB Power EtherCAT – Dimensional drawing [mm] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Figure 2-10 EPOS4 Compact 50/8 EtherCAT – Dimensional drawing [mm] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Figure 3-11 Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Figure 3-12 EPOS4 CB Power CAN (left) / EPOS4 Compact 50/8 CAN (right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Figure 3-13 EPOS4 CB Power EtherCAT (left) / EPOS4 Compact 50/8 EtherCAT (right) . . . . . . . . . . . . . . . . . . . . . . . .25

Figure 3-14 Connector Boards – Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Figure 3-15 Power supply connector X1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Figure 3-16 Logic supply connector X2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Figure 3-17 Motor connectors X3a (left) and X3b (right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Figure 3-18 Hall sensor connector X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Figure 3-19 Encoder connector X5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Figure 3-20 Sensor connector X6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Figure 3-21 Digital I/O connector X7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Figure 3-22 Analog I/O connector X8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Figure 3-23 STO connector X9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Figure 3-24 RS232 connector X10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Figure 3-25 CAN 1 connector X11 and CAN 2 connector X12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Figure 3-26 EtherCAT IN & EtherCAT OUT connectors X14 & X15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Figure 3-27 DIP switch SW1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Figure 3-28 Hall sensor 1 input circuit (analogously valid for Hall sensors 2 & 3) . . . . . . . . . . . . . . . . . . . . . . .

Figure 3-29 Encoder input circuit Ch A “differential” (analogously valid for Ch B & Ch I) . . . . . . . . . . . . . . . . . . . . . . . . .52

Figure 3-30 Encoder input circuit Ch A “single-ended” (analogously valid for Ch B & Ch I) . . . . . . . . . . . . . . . . . . . . . . .52

Figure 3-31 Digital incremental encoder input circuit Ch A “differential” (analogously valid for Ch B). . . . . . . . . . . . . . . .54

Figure 3-32 Digital incremental encoder input circuit Ch I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Figure 3-33 Digital incremental encoder input circuit Ch A “single-ended” (analogously valid for Ch B) . . . . . . . . . . . . . .55

Figure 3-34 Digital incremental encoder input circuit Ch I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Figure 3-35 Analog incremental encoder input circuit Ch A “differential” (analogously valid for Ch B) . . . . . . . . . . . . . . .57

Figure 3-36 Analog incremental encoder input circuit Ch I (digital evaluation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Figure 3-37 SSI absolute encoder data input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Figure 3-38 SSI absolute encoder clock output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Figure 3-39 HsDigIN1 circuit “differential” (analogously valid for HsDigIN2…4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Figure 3-40 HsDigIN1 circuit “single-ended” (analogously valid for HsDigIN2…4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Figure 3-41 HsDigOUT1 output circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Figure 3-42 DigIN1 circuit (analogously valid for DigIN2…4) – Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

. . . . . . . .50

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Figure 3-43 DigIN1 circuit (analogously valid for DigIN2…4) – Compact / Logic level setting . . . . . . . . . . . . . . . . . . . . .65

Figure 3-44 DigIN1 circuit (analogously valid for DigIN2…4) – Compact / PLC level setting . . . . . . . . . . . . . . . . . . . . . .66

Figure 3-45 DigOUT1 circuit (analogously valid for DigOUT2 and Compact) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Figure 3-46 DigOUT1 “sinks” (analogously valid for DigOUT2 and Compact) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Figure 3-47 DigOUT1 “source” (analogously valid for DigOUT2 and Compact) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Figure 3-48 STO-IN1 circuit (analogously valid for STO-IN2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Figure 3-49 STO-OUT circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Figure 3-50 AnIN1 circuit (analogously valid for AnIN2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Figure 3-51 AnOUT1 circuit (analogously valid for AnOUT2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Figure 3-52 USB connector X13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Figure 3-53 LEDs – Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Figure 4-54 Wiring of power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

Figure 4-55 Wiring of logic supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

Figure 4-56 Wiring of motor winding 1 (analogously valid also for motor windings 2 & 3) . . . . . . . . . . . . . . . . . . . . . . . .85

Figure 4-57 Wiring of RS232 transceiver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Figure 4-58 THT footprint [mm] – Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Figure 5-59 Interfaces – Designations and location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Figure 5-60 Main wiring diagram – Module & Compact CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Figure 5-61 Main wiring diagram – Module & Compact EtherCAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Figure 5-62 Power & logic supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

Figure 5-63 DC motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

Figure 5-64 EC (BLDC) motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Figure 5-65 Hall sensors (Sensor 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Figure 5-66 Digital incremental encoder 1 (Sensor 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Figure 5-67 Digital incremental encoder 2 (Sensor 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Figure 5-68 Analog incremental encoder (Sensor 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Figure 5-69 SSI encoder (Sensor 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

maxon motor control

Z-100 Document ID: rel8399 EPOS4 Positioning Controller

Edition: November 2018 EPOS4 Module/Compact 50/8 Hardware Reference

maxon motor EPOS4 Module 50/8, EPOS4 Compact 50/8 CAN, EPOS4 Compact 50/8 EtherCAN 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 Power CAN (520884) / EPOS4 Compact 50/8 CAN (520885)

3.3.2 EPOS4 CB Power EtherCAT (604594) / EPOS4 Compact 50/8 EtherCAT (605298)

3.3.3 Cabling

3.3.4 Tools

3.3.5 Connections

3.3.5.1 Power Supply (X1)

3.3.5.2 Logic Supply (X2)

3.3.5.3 Motor (X3a) (X3b)

3.3.5.4 Hall Sensor (X4)

3.3.5.5 Encoder (X5)

3.3.5.6 Sensor (X6)

3.3.5.7 Digital I/O (X7)

3.3.5.8 Analog I/O (X8)

3.3.5.9 STO (X9)

3.3.5.10 RS232 (X10)

3.3.5.11 CAN 1 (X11) CAN 2 (X12)

3.3.5.12 EtherCAT IN (X14) & EtherCAT OUT (X15)

3.3.6 DIP Switch Configuration (SW1)

3.3.6.1 CAN ID (Node-ID) / DEV ID

3.3.6.2 CAN automatic Bit Rate Detection (Compact CAN)

3.3.6.3 CAN Bus Termination (Compact CAN)

3.3.6.4 Digital Input Level

3.3.7 Spare Parts

3.4 Connection Specifications

3.4.1 Power Supply

3.4.2 Logic Supply

3.4.3 Motor

3.4.4 Hall Sensor

3.4.5 Encoder

3.4.6 Sensor

3.4.6.1 Incremental Encoder

3.4.6.2 SSI Absolute Encoder

3.4.6.3 High-speed Digital I/Os

3.4.7 Digital I/Os

3.4.7.1 Module

3.4.7.2 Compact

3.4.8 Safe Torque Off I/Os

3.4.9 Analog I/Os

3.4.10 Serial Communication Interface (SCI) / RS232

3.4.10.1 Module

3.4.10.2 Compact CAN

3.4.11 CAN Interface / ID Setting

3.4.11.1 Connection

3.4.11.2 Configuration

3.4.12 Serial Peripheral Interface (SPI)

3.4.13 USB (X13)

3.5 Status Indicators

3.5.1 NET Status

3.5.2 Device Status

3.5.3 EtherCAT Port

4 Motherboard Design Guide

4.1 Requirements for Components of Third-party Suppliers