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About
About the Devices

maxon motor control

1-8

Document ID: rel8003

EPOS4 Positioning Controller

Edition: May 2018

EPOS4 Module/Compact 50/5 Hardware Reference

© 2018 maxon motor. Subject to change without prior notice.

1.2

About the Devices

Capabilities of the
device, included fea-
tures, and supported
motors.

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

The devices are specially designed to be commanded and controlled as a slave node in a CANopen net-
work. In addition, the units can be operated via any USB or RS232 (the Module requires an external
transceiver) communication port of a Windows or Linux workstation. Moreover, the integrated extension
interface allows pooling with optionally available communication interfaces, such as EtherCAT or other
additional functionalities.

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

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

•

EPOS4 Module 50/5 (534130)

Plug-in module for use with maxon motor control EPOS4 connector boards or customer-spe-
cific motherboards

•

EPOS4 CB 50/5 CAN (534133)

Connector board for initial commissioning or combination to a compact solution providing all
connectors, including CANopen interface

•

EPOS4 Compact 50/5 CAN (541718)

Fully integrated, compact, ready-to-use assembly of plug-in module and CANopen connector
board

Figure 1-2

Configuration overview

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

Table 1-4

Abbreviations

Short form

Meaning

CB

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

Compact

any type of Compact 50/5 version

Compact CAN

EPOS4 Compact 50/5 CAN

Compact EtherCAT

EPOS4 Compact 50/5 EtherCAT (available shortly)

EPOS4

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

Module

EPOS4 Module 50/5

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Summary of Contents for 534130

Page 1: ...hseln Phone 41 41 666 15 00 Fax 41 41 666 16 50 www maxonmotor com Edition May 2018 EPOS4 Positioning Controller Hardware Reference maxon motor control Positioning Controller P N 534130 Positioning Controller P N 541718 Hardware Reference Document ID rel8003 ...

Page 2: ...ly 38 3 4 2 Logic Supply 39 3 4 3 Motor 40 3 4 4 Hall Sensor 41 3 4 5 Encoder 42 3 4 6 Sensor 44 3 4 7 Digital I Os 55 TABLE OF CONTENTS READ THIS FIRST These instructions are intended for qualified technical personnel Prior commencing with any activities you must carefully read and understand this manual and you must follow the instructions given therein EPOS4 Module 50 5 and EPOS4 Compact 50 5 p...

Page 3: ... Serial Peripheral Interface SPI 67 3 4 13 USB X13 68 3 5 Status Indicators 69 4 Motherboard Design Guide 71 4 1 Requirements for Components of Third party Suppliers 72 4 1 1 Socket Headers 72 4 1 2 Supply Voltage 72 4 1 3 Logic Supply Voltage 73 4 1 4 Motor Cables and Motor Chokes 74 4 1 5 RS232 Transceiver 75 4 1 6 Recommended Components and Manufacturers 76 4 2 Design Guidelines 77 4 2 1 Ground...

Page 4: ...A 4 Document ID rel8003 EPOS4 Positioning Controller Edition May 2018 EPOS4 Module Compact 50 5 Hardware Reference 2018 maxon motor Subject to change without prior notice p a g e i n t e n ti o n a l l y l e f t b l a n k ...

Page 5: ... 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 assign...

Page 6: ...es see see also take note of or go to Type Symbol Meaning Safety alert typical DANGER Indicates an imminent hazardous situation If not avoided it will result in death or serious injury WARNING Indicates a potential hazardous situation If not avoided it can result in death or serious injury CAUTION Indicates a probable hazardous situation or calls the attention to unsafe practices If not avoided it...

Page 7: ...opyright Any use including repro duction 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 sub ject to prosecution under the applicable law Brand Name Trademark Owner Adobe Reader Adobe Systems Incorporated USA San Jose CA BiSS iC Haus GmbH DE Bodenheim CANopen...

Page 8: ... velocity feed forward in combi nation with highest control cycle rates allow sophisticated ease of use motion control Thanks to its smart design the EPOS4 Module 50 5 can either be used in combination with EPOS4 CB 50 5 connector boards as a compact integrated solution or be incorporated into customer specific moth erboards for single axis or multi axes motion control systems The controller is av...

Page 9: ...4 Compact 50 5 CAN will be named as Compact CAN EPOS4 will be used to describe both versions Module and Compact and or other EPOS4 positioning controllers as a whole Find the latest edition of the present document as well as additional documentation and software for EPOS4 positioning controllers also on the Internet http epos maxonmotor com In addition you may wish to browse the EPOS video library...

Page 10: ...ctronic 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 machine apparatus should break down if it is operated incorrectly if the control unit breaks down or if the cables break or get disconnected etc the complete drive system must return and be kept in a safe operating mode Be...

Page 11: ...ax speed DC motor limited by max permissible speed motor and max output voltage controller 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 Module Compact 3 x 9 4 μH 5 A Inputs Outputs Digital Input 1 general purpose Digital Input 2 general purpose Digital Input 3 general purpose Digital Input 4 general purpose Module 2 1 36...

Page 12: ...2 Module max 115 200 bit s external transceiver necessary Compact max 115 200 bit s USB 2 0 USB 3 0 Full Speed CAN max 1 Mbit s Status Indicators Operation green LED Error red LED Physical Weight Module approx 17 g Compact CAN approx 58 g Dimensions L x W x H Module 53 8 x 38 8 x 11 1 mm Compact CAN 55 0 x 40 0 x 31 1 mm Mounting Module pluggable female box headers 1 27 mm or mounting holes for M2...

Page 13: ...oning Controller Document ID rel8003 2 13 EPOS4 Module Compact 50 5 Hardware Reference Edition May 2018 2018 maxon motor Subject to change without prior notice 2 2 Thermal Data 2 2 1 Derating of Output Current Figure 2 3 Derating of output current Module Compact ...

Page 14: ...t to change without prior notice 2 2 2 Power Dissipation and Efficiency Figure 2 4 Power dissipation and efficiency 2 3 Limitations Table 2 6 Limitations 2 4 Dimensional Drawings Figure 2 5 EPOS4 Module 50 5 Dimensional drawing mm Protection functionality Switch off threshold Recovery threshold Undervoltage 8 0 V 8 5 V Overvoltage 58 V 56 V Overcurrent 20 A Thermal overload 105 C 90 C ...

Page 15: ...ioning Controller Document ID rel8003 2 15 EPOS4 Module Compact 50 5 Hardware Reference Edition May 2018 2018 maxon motor Subject to change without prior notice Figure 2 6 EPOS4 CB 50 5 CAN Dimensional drawing mm Figure 2 7 EPOS4 Compact 50 5 CAN Dimensional drawing mm ...

Page 16: ...dards Electromagnetic Compatibility Generic IEC EN 61000 6 2 Immunity for industrial environments IEC EN 61000 6 3 Emission standard for residential commercial and light industrial environments Applied IEC EN 55022 CISPR22 Radio disturbance characteristics radio interference IEC EN 61000 4 3 Radiated radio frequency electromagnetic field immunity test 10 V m IEC EN 61000 4 4 Electrical fast transi...

Page 17: ...rent limits are as follows continuous max 5 A short time acceleration max 15 A Hot plugging the USB interface may cause hardware damage If the USB interface is being hot plugged connecting while the power supply is on the possibly high potential differences of the two power supplies of controller and PC Notebook can lead to damaged hardware Avoid potential differences between the power supply of c...

Page 18: ...tor Motor EC motor Winding 2 A15 A21 Motor winding 3 EC motor Winding 3 A22 VC Logic supply voltage 10 50 VDC A23 A29 VCC Power supply voltage 10 50 VDC A30 A36 GND Ground A37 Hall sensor 1 Hall sensor 1 input A38 Hall sensor 2 Hall sensor 2 input A39 Hall sensor 3 Hall sensor 3 input A40 VSensor Sensor supply voltage 5 VDC IL 100 mA A41 Channel A Digital incremental encoder channel A A42 Channel ...

Page 19: ...remental encoder channel I High speed digital input 3 Clock SSI High speed digital output 1 B12 Channel I HsDigIN3 Clock HsDigOUT1 Digital analog incremental encoder channel I complement High speed digital input 3 complement Clock SSI complement High speed digital output 1 complement B13 Data HsDigIN4 Data SSI High speed digital input 4 B14 Data HsDigIN4 Data SSI complement High speed digital inpu...

Page 20: ...e B36 CAN low CAN low bus line B37 B38 GND Ground B39 4 DSP_RxD Serial communication interface receive UART B40 DSP_TxD Serial communication interface transmit UART B41 5 SPI_CLK Serial Peripheral Interface clock B42 5 SPI_IRQ Serial Peripheral Interface interrupt request B43 5 SPI_SOMI Serial Peripheral Interface Slave output Master input B44 5 SPI_SIMO Serial Peripheral Interface Slave input Mas...

Page 21: ...0 5 CAN right 3 3 2 Cabling PLUG PLAY Take advantage of maxon s prefab cable assemblies They come as ready to use parts and will help to reduce commissioning time to a minimum a Check the following table and find the part number of the cable assembly that matches the setup you will be using b Follow the cross reference to get the cable s pin assignment Table 3 10 Prefab maxon cables Connector Pref...

Page 22: ...4 poles 39 01 2040 1 Molex Mega Fit 4 poles 171692 0104 1 X4 Molex Micro Fit 3 0 6 poles 430 25 0600 1 X6 Molex CLIK Mate dual row 10 poles 503149 1000 1 X7 X9 Molex CLIK Mate single row 8 poles 502578 0800 2 X8 Molex CLIK Mate single row 7 poles 502578 0700 1 X10 Molex CLIK Mate single row 5 poles 502578 0500 1 X11 X12 Molex CLIK Mate single row 4 poles 502578 0400 2 Crimp Terminals Molex Mega Fi...

Page 23: ...nectors 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 X1 X2 X3 X4 X5 X6 X7 X8 X9 X10 X11 X12 Power Logic Supply page 3 24 Motor page 3 25 Hall Senso...

Page 24: ...nment Table 3 14 Power logic supply connector X1 X2 Specification and accessories X1 X2 Head A Prefab Cable Head B Signal Description Pin Color Pin 1 GND Ground 2 VCC Power supply voltage 10 50 VDC 3 VC Logic supply voltage 10 50 VDC Power Logic Supply Connector X1 X2 590736 Type Spring loaded contacts 3 poles pitch 2 54 mm Suitable plug Harting har flexicon 2 54 FPV 3 BK 14 31 031 3101 000 includ...

Page 25: ...r Table 3 16 Motor connector X3 Pin assignment for maxon EC motor Table 3 17 Motor Cable X3 Head A Prefab Cable Head B Signal Description Pin Color Pin 1 white Motor M DC motor Motor 2 brown Motor M DC motor Motor 3 green not connected 4 black Motor shield Cable shield X3 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 ...

Page 26: ...gnment Table 3 19 Hall Sensor Cable X4 Head A Prefab Cable Head B Signal Description Pin Color Pin 1 green Hall sensor 1 Hall sensor 1 input 2 brown Hall sensor 2 Hall sensor 2 input 3 white Hall sensor 3 Hall sensor 3 input 4 yellow GND Ground 5 grey VSensor Sensor supply voltage 5 VDC IL 100 mA 6 black Hall shield Cable shield Hall Sensor Cable 275878 Cross section 5 x 0 14 mm2 shielded grey Len...

Page 27: ...mA 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 Accessories Suitable strain relief Retainer For sockets with strain relief 1 retainer clip height 13 5 mm 3M 3505 8110 For sockets withou...

Page 28: ... encoder channel A complement High speed digital input 1 complement 3 green 3 Channel B HsDigIN2 Digital analog incremental encoder channel B High speed digital input 2 4 yellow 4 Channel B HsDigIN2 Digital analog incremental encoder channel B complement High speed digital input 2 complement 5 grey 5 Channel I HsDigIN3 Clock HsDigOUT1 Digital analog incremental encoder channel I High speed digital...

Page 29: ...50 5 Hardware Reference Edition May 2018 2018 maxon motor Subject to change without prior notice Table 3 24 Sensor Cable 5x2core Sensor Cable 5x2core 520852 Cross section 5 x 2 x 0 14 mm2 twisted pair grey Length 3 m Head A Plug Molex CLIK Mate dual row 10 poles 503149 1000 Contacts Molex CLIK Mate crimp terminals 502579 Head B Wire end sleeves 0 14 mm2 ...

Page 30: ...3 26 Signal Cable 8core X7 Head A Prefab Cable Head B Signal Description Pin Color Pin 1 white 1 DigIN1 Digital input 1 2 brown 2 DigIN2 Digital input 2 3 green 3 DigIN3 Digital input 3 4 yellow 4 DigIN4 Digital input 4 5 grey 5 DigOUT1 Digital output 1 6 pink 6 DigOUT2 Digital output 2 7 blue 7 GND Ground 8 red 8 VAux Auxiliary output voltage 5 VDC IL 150 mA Signal Cable 8core 520853 Cross sectio...

Page 31: ... 28 Signal Cable 7core 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 Signal Cable 7core 520854 Cross section 7...

Page 32: ...ing prefab cable assembly Table 3 26 on page 3 30 Table 3 30 STO Idle Connector X9 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 To...

Page 33: ...X10 Pin assignment Table 3 32 RS232 COM Cable 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 RS232 COM Cable 520856 Cross section 2 x 2 x 0 14 mm2 twisted pair shielded Length 3 m Head A Plug Molex CLIK Mate single row 5 poles...

Page 34: ...tion 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 CAN COM Cable 520857 Cross section 2 x 2 x 0 14 mm2 twisted pair shielded Length 3 m Head A Plug Molex CLIK Mate single row 4 poles 502578 0400 Contacts Molex CLIK Mate crimp terminals 502579 Head B Female D Sub connector DIN 41652 9 poles with mounting scr...

Page 35: ...CAN ID Node Address The CAN ID is set with DIP switches 1 5 The node address 1 31 may be coded using binary code Setting the CAN ID by DIP switch SW1 By setting the DIP switch 1 5 address 0 OFF the CAN ID may be set by software changing object Node ID range 1 127 The CAN ID results in the summed values of DIP switch addresses 1 ON DIP switches 6 8 do not have any impact on the CAN ID Table 3 36 DI...

Page 36: ...adding the valence of all activated switches Use the following table as a non concluding guide Table 3 37 DIP switch SW1 Examples 3 3 5 2 CAN automatic Bit Rate Detection Table 3 38 DIP switch SW1 CAN automatic bit rate detection Setting Switch Node Address 1 2 3 4 5 0 0 0 0 0 1 0 0 0 0 1 0 1 0 0 0 2 0 0 1 0 0 4 1 0 1 0 0 5 0 0 0 1 0 8 0 0 0 0 1 16 1 1 1 1 1 31 0 Switch OFF 1 Switch ON Switch OFF ...

Page 37: ...us Termination Table 3 39 DIP switch SW1 CAN bus termination 3 3 5 4 Digital Input Level For details chapter 3 4 7 Digital I Os on page 3 55 Table 3 40 DIP switch SW1 Digital input level 3 3 6 Spare Parts Table 3 41 Spare parts list Switch OFF ON 7 Without bus termination factory setting Bus termination with 120 Ω Switch OFF ON 8 Logic level factory setting PLC level Order number Description 52086...

Page 38: ...ms refer to the Module For the corresponding Compact s circuitry take the second column Compact CB Connector Pin into account 3 4 1 Power Supply Basically any power supply may be used provided that it meets the below stated minimum require ments Table 3 42 Power supply Pin assignment 1 Use the formula below to calculate the required voltage under load 2 Choose a power supply according to the calcu...

Page 39: ...e VCC Volt SOLUTION 3 4 2 Logic Supply Separate power supply The logic part of the controller may be supplied by separate supply voltage provided that it meets the below stated minimum requirements Module The logic supply must be connected separately Compact If not supplied separately the logic supply is internally connected to the power supply Table 3 43 Logic supply Pin assignment Module Header ...

Page 40: ... assignment Table 3 45 EC motor Pin assignment Module Header Pin Compact CB Connector Pin Signal Description A1 A7 X3 1 Motor M Motor A8 A14 X3 2 Motor M Motor X3 3 not connected X3 4 Motor shield Cable shield Connect all pins in respect to the individual pin current rating Module Header Pin Compact CB Connector Pin Signal Description A1 A7 X3 1 Motor winding 1 Winding 1 A8 A14 X3 2 Motor winding ...

Page 41: ...l sensors 2 3 Module Header Pin Compact CB Connector Pin Signal Description A30 A36 X4 4 GND Ground A37 X4 1 Hall sensor 1 Hall sensor 1 input A38 X4 2 Hall sensor 2 Hall sensor 2 input A39 X4 3 Hall sensor 3 Hall sensor 3 input A40 X4 5 VSensor Sensor supply voltage 5 VDC IL 100 mA X4 6 Hall shield Cable shield Hall sensor Sensor supply voltage VSensor 5 VDC Max Hall sensor supply current 30 mA I...

Page 42: ...trongly recommend to use only 3 channel versions Table 3 47 Encoder Pin assignment Continued on next page Module Header Pin Compact CB Connector Pin Signal Description A30 A36 X5 3 GND Ground A40 X5 2 VSensor Sensor supply voltage 5 VDC IL 100 mA A41 X5 6 Channel A Digital incremental encoder channel A A42 X5 5 Channel A Digital incremental encoder channel A complement A43 X5 8 Channel B Digital i...

Page 43: ...ously valid for Ch B Ch I Figure 3 24 Encoder input circuit Ch A single ended analogously valid for Ch B Ch I Encoder single ended Sensor supply voltage VSensor 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 IIH typically 250 μA 5 V Input low current IIL typically 330 μA 0 V Max input frequency Push pull Open col...

Page 44: ...er Pin Compact CB Connector Pin 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 C...

Page 45: ...ID rel8003 3 45 EPOS4 Module Compact 50 5 Hardware Reference Edition May 2018 2018 maxon motor Subject to change without prior notice Figure 3 25 Digital incremental encoder input circuit Ch A differential analogously valid for Ch B Figure 3 26 Digital incremental encoder input circuit Ch I ...

Page 46: ...nalogously valid for Ch B Continued on next page Digital incremental encoder single ended Auxiliary output voltage VAux 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 typically 210 μA 5 VDC channel A B typically 60 μA 5 VDC channel I Input low current typically 80 μA 0 VDC channel A B typically 7 μA 0 VDC chan...

Page 47: ...tor control EPOS4 Positioning Controller Document ID rel8003 3 47 EPOS4 Module Compact 50 5 Hardware Reference Edition May 2018 2018 maxon motor Subject to change without prior notice Figure 3 28 Digital incremental encoder input circuit Ch I ...

Page 48: ...Figure 3 29 Analog incremental encoder input circuit Ch A differential analogously valid for Ch B Continued on next page Analog incremental encoder differential Auxiliary output voltage VAux 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 Resolutio...

Page 49: ...ol EPOS4 Positioning Controller Document ID rel8003 3 49 EPOS4 Module Compact 50 5 Hardware Reference Edition May 2018 2018 maxon motor Subject to change without prior notice Figure 3 30 Analog incremental encoder input circuit Ch I digital evaluation ...

Page 50: ...xt page Module Header Pin Compact CB Connector Pin 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 VAux Auxiliary output voltage 5 VDC IL 150 mA B16 X6 9 GND Ground SSI absolute encoder Auxiliary output voltage VAux 5 VDC Max auxiliary supply current 150 mA Min differential input voltage 200 mV Min d...

Page 51: ...xon motor control EPOS4 Positioning Controller Document ID rel8003 3 51 EPOS4 Module Compact 50 5 Hardware Reference Edition May 2018 2018 maxon motor Subject to change without prior notice Figure 3 32 SSI absolute encoder clock output ...

Page 52: ... 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 HsDigIN3 HsDigOUT1 High speed digital input 3 High speed digital output 1 B12 X6 6 HsDigIN3 HsDigOUT1 High speed digital input 3 complement High speed digital output 1 complement B13 X6 7 HsDigIN4 ...

Page 53: ...hout prior notice Figure 3 34 HsDigIN1 circuit single ended analogously valid for HsDigIN2 4 High speed digital input 1 4 single ended Input voltage 0 5 VDC Max input voltage 12 VDC Logic 0 1 0 V Logic 1 2 4 V Input high current typically 210 μA 5 VDC HsDigIN1 2 typically 60 μA 5 VDC HsDigIN3 4 Input low current typically 80 μA 0 VDC HsDigIN1 2 typically 7 μA 0 VDC HsDigIN3 4 Max input frequency 6...

Page 54: ...EPOS4 Module Compact 50 5 Hardware Reference 2018 maxon motor Subject to change without prior notice Figure 3 35 HsDigOUT1 output circuit 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 ...

Page 55: ...valid for DigIN2 4 Module Module Header Pin Signal Description B1 DigIN1 Digital input 1 B2 DigIN2 Digital input 2 B3 DigIN3 Digital input 3 B4 DigIN4 Digital input 4 B5 DigOUT1 Digital output 1 B6 DigOUT2 Digital output 2 B15 VAux Auxiliary output voltage 5 VDC IL 150 mA 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 Input resi...

Page 56: ...or DigIN2 4 Compact Logic level setting Continued on next page Compact CB Connector Pin 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 VAux Auxiliary output voltage 5 VDC IL 150 mA Digital inputs 1 4 Compact Logic level setting Input v...

Page 57: ... Compact PLC level setting For pin assignment of digital outputs Table 3 51 and Table 3 52 Figure 3 39 DigOUT1 circuit analogously valid for DigOUT2 and Compact Continued on next page Digital inputs 1 4 Compact PLC level setting Input voltage 0 30 VDC Max input voltage 30 VDC Logic 0 5 5 V Logic 1 9 V Input current at logic 1 2 mA 9 VDC typically 3 5 mA 24 VDC Switching delay 300 μs 24 VDC Digital...

Page 58: ...nge without prior notice WIRING EXAMPLES Figure 3 40 DigOUT1 sinks analogously valid for DigOUT2 and Compact Figure 3 41 DigOUT1 source analogously valid for DigOUT2 and Compact 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 DigOUT source Output voltage UOut 5 45 V 0 75 V ILoad x 2200 Ω Max load current ILoad 2 m...

Page 59: ...Pin assignment Figure 3 42 STO IN1 circuit analogously valid for STO IN2 Module Header Pin Compact CB Connector Pin Signal Description X9 8 VSTO Activation voltage for STO inputs 5 VDC Note Do not use this voltage for any other purpose B15 VAux Auxiliary output voltage 5 VDC IL 150 mA 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 inpu...

Page 60: ...or notice Figure 3 43 STO OUT circuit Table 3 54 STO logic state Safe Torque Off output Circuit type Optically isolated output with self resetting short circuit 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 STO Logic State STO IN1 STO IN2 STO OUT Power Stage 0 0 open inactive 1 0 closed inactive 0 1 closed inactive 1...

Page 61: ... Compact CB Connector Pin 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 Analog inputs 1 2 Input voltage 10 VDC differential Max input voltage 24 VDC Common mod...

Page 62: ... Subject to change without prior notice Figure 3 45 AnOUT1 circuit analogously valid for AnOUT2 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 Max capacitive load 300 nF 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 ...

Page 63: ...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 Table 3 56 SCI Pin assignment Module Header Pin Signal Description B38 GND Ground B39 6 DSP_RxD Serial communication interface receive UART B40 DSP_TxD Serial com...

Page 64: ... change without prior notice 3 4 10 2 Compact Table 3 57 RS232 Pin assignment Compact CB Connector Pin 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 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 ...

Page 65: ...ote Consider the CAN master s maximal bit rate The standard bit rate setting factory setting is 1 Mbit s For connector boards and Compact ver sions automatic bit rate detection is set Use 120 Ω termination resistor at both ends of the CAN bus For detailed CAN information separate document EPOS4 Communication Guide Module Header Pin Compact CB Connector Pin Signal Description B35 X11 1 X12 1 CAN hi...

Page 66: ...o GND Use the following table as a non concluding guide Table 3 60 CAN ID Examples Setting the CAN ID by EPOS Studio The CAN ID may be set by software changing object Node ID range 1 127 The CAN ID set by the software is valid if the Node Address is set to 0 all CAN ID input lines not connected Module Header Pin Signal Description Binary Code Valence B29 CAN ID 1 CAN ID 1 20 1 B30 CAN ID 2 CAN ID ...

Page 67: ... speed synchronous serial input output port allowing the use of optional maxon exten sion modules Note Do not connect any other signals to the SPI apart from those for the maxon extension modules Table 3 61 SPI Pin assignment Bit rate detection Auto Bit Rate GND Pin B34 Pin B38 Max input voltage 3 3 VDC Logic 1 connected to GND Logic 0 not connected Module Header Pin Signal Description B38 GND Gro...

Page 68: ...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 46 USB connector X13 Table 3 62 USB connector X13 Pin assignment Table 3 63 USB Type A micro B Cable Compact CB Connector Pin PC s USB Terminal Signal Description X13 1 1 VBUS USB bus supply voltage input 5 VDC X13 2 2 USB_D USB Data twisted pair with Dat...

Page 69: ...Ds display the actual status and possible errors of the EPOS4 Green LED shows the status Red LED indicates errors Table 3 64 Status LED LED Status Error Green Red Slow OFF Power stage is disabled The EPOS4 is in status Switch ON Disabled Ready to Switch ON Switched ON ON OFF Power stage is enabled The EPOS4 is in status Operation Enable Quick Stop Active OFF ON FAULT state The EPOS4 is in status F...

Page 70: ...tor control 3 70 Document ID rel8003 EPOS4 Positioning Controller Edition May 2018 EPOS4 Module Compact 50 5 Hardware Reference 2018 maxon motor Subject to change without prior notice p a g e i n t e n ti o n a l l y l e f t b l a n k ...

Page 71: ...n examples 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 CAUTION Dangerous Action Errors in implementing the design can result in serious Injury Only proceed if you are skilled in ...

Page 72: ...mmendations Figure 4 48 Wiring of power supply INPUT FUSE FU1 An input fuse FU1 is necessary in order to provide reverse polarity protection Together with an unipo lar TVS diode D1 this prevents current from flowing in the wrong direction TVS DIODE D1 To protect against overvoltage resulting from voltage transients or brake energy feedback we recom mend connecting a TVS transient voltage suppresso...

Page 73: ...range is 10 50 V and must be either sourced separately or by the power supply voltage Figure 4 49 Wiring of logic supply TVS DIODE 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 separa...

Page 74: ...ulation 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 electro magnetic 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 ex...

Page 75: ...axon motor Subject to change without prior notice Example 2 Figure 4 50 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 51 Wiring of RS232 transceiver IMPORTANT If you do not intend to use the RS232 interface you are recommended to connect pin B39 to pin A40 sensor ...

Page 76: ...h rated voltage 63 V and adequate ripple current to avoid overheat or life time reduction Example for C1 worst case dimensioning Icont 5 A Rubycon 63YXJ470M12 5X25 470 μF 63 V 1990 mA r m s Capacitor C2 To avoid voltage overshoot at power plug in with a separately sourced logic supply use an electrolytic capacitor covering the following requirements 33 μF or 47 μF 63 V at least 265 mA r m s Rubico...

Page 77: ...tracks Table 4 66 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 A23 A24 A25 A26 A27 A28 and A29 for VCC nominal power sup ply voltage shou...

Page 78: ...on motor control 4 78 Document ID rel8003 EPOS4 Positioning Controller Edition May 2018 EPOS4 Module Compact 50 5 Hardware Reference 2018 maxon motor Subject to change without prior notice 4 3 SMT Footprint Figure 4 52 SMT footprint mm Top View ...

Page 79: ... Motor Digital Incremental Encoder 5 81 DC Motor Digital Digital Incremental Encoder 5 82 DC Motor Digital Analog Incremental Encoder 5 83 DC Motor Digital Incremental SSI Encoder 5 84 DC Motor Analog Incremental Encoder 5 85 DC Motor SSI Encoder 5 86 EC BLDC Motors EC Motor Hall Sensors 5 87 EC Motor Hall Sensors Digital Incremental Encoder 5 88 EC Motor Hall Sensors Analog Incremental Encoder 5 ...

Page 80: ... Document ID rel8003 EPOS4 Positioning Controller Edition May 2018 EPOS4 Module Compact 50 5 Hardware Reference 2018 maxon motor Subject to change without prior notice 5 2 DC Motors brushed 5 2 1 DC Motor without Sensor Figure 5 54 DC motor no sensor ...

Page 81: ...sitioning Controller Document ID rel8003 5 81 EPOS4 Module Compact 50 5 Hardware Reference Edition May 2018 2018 maxon motor Subject to change without prior notice 5 2 2 DC Motor Digital Incremental Encoder Figure 5 55 DC motor digital incremental encoder ...

Page 82: ... rel8003 EPOS4 Positioning Controller Edition May 2018 EPOS4 Module Compact 50 5 Hardware Reference 2018 maxon motor Subject to change without prior notice 5 2 3 DC Motor Digital Digital Incremental Encoder Figure 5 56 DC motor digital digital incremental encoder ...

Page 83: ...ng Controller Document ID rel8003 5 83 EPOS4 Module Compact 50 5 Hardware Reference Edition May 2018 2018 maxon motor Subject to change without prior notice 5 2 4 DC Motor Digital Analog Incremental Encoder Figure 5 57 DC motor digital analog incremental encoder ...

Page 84: ...t ID rel8003 EPOS4 Positioning Controller Edition May 2018 EPOS4 Module Compact 50 5 Hardware Reference 2018 maxon motor Subject to change without prior notice 5 2 5 DC Motor Digital Incremental SSI Encoder Figure 5 58 DC motor digital incremental SSI encoder ...

Page 85: ...ositioning Controller Document ID rel8003 5 85 EPOS4 Module Compact 50 5 Hardware Reference Edition May 2018 2018 maxon motor Subject to change without prior notice 5 2 6 DC Motor Analog Incremental Encoder Figure 5 59 DC motor analog incremental encoder ...

Page 86: ...control 5 86 Document ID rel8003 EPOS4 Positioning Controller Edition May 2018 EPOS4 Module Compact 50 5 Hardware Reference 2018 maxon motor Subject to change without prior notice 5 2 7 DC Motor SSI Encoder Figure 5 60 DC motor SSI encoder ...

Page 87: ...4 Positioning Controller Document ID rel8003 5 87 EPOS4 Module Compact 50 5 Hardware Reference Edition May 2018 2018 maxon motor Subject to change without prior notice 5 3 EC Motors BLDC brushless 5 3 1 EC Motor Hall Sensors Figure 5 61 EC motor Hall sensors ...

Page 88: ...el8003 EPOS4 Positioning Controller Edition May 2018 EPOS4 Module Compact 50 5 Hardware Reference 2018 maxon motor Subject to change without prior notice 5 3 2 EC Motor Hall Sensors Digital Incremental Encoder Figure 5 62 EC motor Hall sensors digital incremental encoder ...

Page 89: ... Controller Document ID rel8003 5 89 EPOS4 Module Compact 50 5 Hardware Reference Edition May 2018 2018 maxon motor Subject to change without prior notice 5 3 3 EC Motor Hall Sensors Analog Incremental Encoder Figure 5 63 EC motor Hall sensors analog incremental encoder ...

Page 90: ...90 Document ID rel8003 EPOS4 Positioning Controller Edition May 2018 EPOS4 Module Compact 50 5 Hardware Reference 2018 maxon motor Subject to change without prior notice 5 3 4 EC Motor Hall Sensors SSI Encoder Figure 5 64 EC motor Hall sensors SSI encoder ...

Page 91: ...er Document ID rel8003 5 91 EPOS4 Module Compact 50 5 Hardware Reference Edition May 2018 2018 maxon motor Subject to change without prior notice 5 3 5 EC Motor Hall Sensors Digital Digital Incremental Encoder Figure 5 65 EC motor Hall sensors digital digital incremental encoder ...

Page 92: ...EPOS4 Positioning Controller Edition May 2018 EPOS4 Module Compact 50 5 Hardware Reference 2018 maxon motor Subject to change without prior notice 5 3 6 EC Motor Hall Sensors Digital Analog Incremental Encoder Figure 5 66 EC motor Hall sensors digital analog incremental encoder ...

Page 93: ...roller Document ID rel8003 5 93 EPOS4 Module Compact 50 5 Hardware Reference Edition May 2018 2018 maxon motor Subject to change without prior notice 5 3 7 EC Motor Hall Sensors Digital Incremental SSI Encoder Figure 5 67 EC motor Hall sensors digital incremental SSI encoder ...

Page 94: ...4 Document ID rel8003 EPOS4 Positioning Controller Edition May 2018 EPOS4 Module Compact 50 5 Hardware Reference 2018 maxon motor Subject to change without prior notice 5 3 8 EC Motor Digital Incremental SSI Encoder Figure 5 68 EC motor digital SSI encoder ...

Page 95: ...or control EPOS4 Positioning Controller Document ID rel8003 5 95 EPOS4 Module Compact 50 5 Hardware Reference Edition May 2018 2018 maxon motor Subject to change without prior notice 5 3 9 EC Motor SSI Encoder Figure 5 69 EC motor SSI encoder ...

Page 96: ...n motor control 5 96 Document ID rel8003 EPOS4 Positioning Controller Edition May 2018 EPOS4 Module Compact 50 5 Hardware Reference 2018 maxon motor Subject to change without prior notice p a g e i n t e n ti o n a l l y l e f t b l a n k ...

Page 97: ...ously valid for Ch B Ch I 43 Figure 3 24 Encoder input circuit Ch A single ended analogously valid for Ch B Ch I 43 Figure 3 25 Digital incremental encoder input circuit Ch A differential analogously valid for Ch B 45 Figure 3 26 Digital incremental encoder input circuit Ch I 45 Figure 3 27 Digital incremental encoder input circuit Ch A single ended analogously valid for Ch B 46 Figure 3 28 Digita...

Page 98: ...ions and location 79 Figure 5 54 DC motor no sensor 80 Figure 5 55 DC motor digital incremental encoder 81 Figure 5 56 DC motor digital digital incremental encoder 82 Figure 5 57 DC motor digital analog incremental encoder 83 Figure 5 58 DC motor digital incremental SSI encoder 84 Figure 5 59 DC motor analog incremental encoder 85 Figure 5 60 DC motor SSI encoder 86 Figure 5 61 EC motor Hall senso...

Page 99: ...25 Table 3 18 Hall sensor connector X4 Pin assignment 26 Table 3 19 Hall Sensor Cable 26 Table 3 20 Encoder connector X5 Pin assignment 27 Table 3 21 Encoder connector X5 Accessories 27 Table 3 22 Encoder Cable 27 Table 3 23 Sensor connector X6 Pin assignment 28 Table 3 24 Sensor Cable 5x2core 29 Table 3 25 Digital I O connector X7 Pin assignment 30 Table 3 26 Signal Cable 8core 30 Table 3 27 Anal...

Page 100: ... 50 High speed digital I Os Pin assignment 52 Table 3 51 Digital I Os Pin assignment Module 55 Table 3 52 Digital I Os Pin assignment Compact 56 Table 3 53 STO I Os Pin assignment 59 Table 3 54 STO logic state 60 Table 3 55 Analog I Os Pin assignment 61 Table 3 56 SCI Pin assignment 63 Table 3 57 RS232 Pin assignment 64 Table 3 58 CAN bus line CAN 1 CAN 2 Pin assignment 65 Table 3 59 CAN ID Pin as...

Page 101: ...8 CAN bus termination 37 65 CAN ID 35 66 CAN interface 65 choke motor 74 connectors X1 X2 24 X3 25 X4 26 X5 27 X6 28 X7 30 X8 31 X9 32 X10 33 X11 34 X12 34 X13 68 country specific regulations 10 D D1 DVS diode 72 D2 DVS diode 73 DC motor connection 18 40 wiring diagram 80 device condition display of 69 digital high speed inputs differential 52 digital high speed inputs single ended 53 digital high...

Page 102: ...icense 17 outputs analog 62 digital 57 high speed digital 54 STO 60 P part numbers 275851 25 275878 26 275934 27 403968 68 520852 29 520853 30 520854 31 520856 33 520857 34 520858 34 520859 22 520860 32 534130 11 534133 21 541718 11 21 590736 24 590738 76 performance data 11 pin assignment 18 power supply 38 precautions 10 prerequisites prior installation 17 prohibitive signs 6 protective measures...

Page 103: ...Compact 50 5 Hardware Reference Edition May 2018 2018 maxon motor Subject to change without prior notice T technical data 11 termination CAN bus 37 65 U USB port 68 W wiring diagrams BLDC motors 87 DC motors 80 EC motors 87 wiring examples additional inductance on Motherboard 74 DigOUT 58 ...

Page 104: ...on motor All rights reserved The present document including all parts thereof is protected by copyright Any use including reproduction translation microfilming and other means of electronic data processing beyond the narrow restrictions of the copyright law without the prior approval of maxon motor ag is not permitted and subject to prosecution under the applicable law maxon motor ag Brünigstrasse...

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