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maxon motor control
EPOS4 Positioning Controller

Document ID: rel6852

Z-71

EPOS4 50/5 Hardware Reference

Edition: May 2017

alerts

analog incremental encoder (differential)

analog inputs

analog outputs

applicable EU directive

applicable regulations

Beckhoff TwinCAT

BiSS encoder

wiring

bit rate detection

bit rate, default

cables (prefab)

CAN-CAN Cable

CAN-COM Cable

Encoder Cable

Ethernet Cable

Hall Sensor Cable

Motor Cable

Power Cable

RS232-COM Cable

Sensor Cable 5x2core

Signal Cable 7core

Signal Cable 8core

STO Idle Connector

USB Type A - micro B Cable

CAN bus termination

CAN ID

CAN interface

connectors

EXT1

EXT2

X10

X11

X12

X13

X14

X15

X16

country-specific regulations

device condition, display of

digital high-speed inputs (differential)

digital high-speed inputs (single-ended)

digital high-speed output

digital incremental encoder (differential)

digital incremental encoder (single-ended)

digital outputs

DIP switch SW1

encoders

absolute

differential

incremental

serial

single-ended

EnDat encoder

wiring

EPOS4 Connector Set

EPOS4 EtherCAT Card

ESD

EtherCAT

network

option card

EU directive, applicable

Hall sensor

how to

calculate the required supply voltage

connect extension signals

interpret icons (and signs) used in this document

unplug an extension card

incorporation into surrounding system

informatory signs

inputs

analog

high-speed digital

STO

interfaces

CAN

location and designation

RS232

USB

LEDs, interpretation of

NDEX

Summary of Contents for EPOS4 50/5

Page 1: ...263 CH 6072 Sachseln Phone 41 41 666 15 00 Fax 41 41 666 16 50 www maxonmotor com Edition May 2017 EPOS4 Positioning Controller Hardware Reference maxon motor control Positioning Controller P N 54604...

Page 2: ...13 49 3 3 13 Extension NET IN X14 Extension NET OUT X15 50 3 3 14 Extension Signal X16 52 TABLE OF CONTENTS READ THIS FIRST These instructions are intended for qualified technical personnel Prior comm...

Page 3: ...Spare Parts 56 3 4 Status Indicators 57 4 Wiring 59 4 1 Possible Combinations to connect a Motor 60 4 2 Main Wiring Diagram 62 4 3 Excerpts 63 4 3 1 Power Logic Supply 63 4 3 2 DC Motor 63 4 3 3 EC BL...

Page 4: ...ontrol A 4 Document ID rel6852 EPOS4 Positioning Controller Edition May 2017 EPOS4 50 5 Hardware Reference 2017 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...

Page 5: ...missioning 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 equipme...

Page 6: ...cates 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...

Page 7: ...dback options such as Hall sensors incremental encoders as well as abso lute sensors in a multitude of drive applications The device is specially designed to be commanded and controlled as a slave nod...

Page 8: ...apparatus cannot be considered fail safe Therefore you must make sure that any machine apparatus has been fitted with independent monitoring and safety equipment If the machine apparatus should break...

Page 9: ...15 H 5 A Inputs Outputs Digital Input 1 general purpose Digital Input 2 general purpose Digital Input 3 general purpose Digital Input 4 general purpose DIP switch selectable levels Logic 2 0 30 VDC PL...

Page 10: ...y green LED Physical Weight approx 206 g Dimensions L x W x H 105 0 x 83 0 x 38 7 mm Mounting mounting holes for M4 screws Environ mental Conditions Temperature Operation 30 50 C Extended range 1 50 8...

Page 11: ...l EPOS4 Positioning Controller Document ID rel6852 2 11 EPOS4 50 5 Hardware Reference Edition May 2017 2017 maxon motor Subject to change without prior notice 2 2 Thermal Data 2 2 1 Derating of Output...

Page 12: ...erence 2017 maxon motor Subject to change without prior notice 2 2 2 Power Dissipation and Efficiency Figure 2 3 Power dissipation and efficiency 2 3 Limitations Table 2 5 Limitations Protection funct...

Page 13: ...maxon motor control EPOS4 Positioning Controller Document ID rel6852 2 13 EPOS4 50 5 Hardware Reference Edition May 2017 2017 maxon motor Subject to change without prior notice 2 4 Dimensional Drawing...

Page 14: ...whole Table 2 6 Standards Electromagnetic Compatibility Generic IEC EN 61000 6 2 Immunity for industrial environments IEC EN 61000 6 3 Emission standard for residential commercial and light industria...

Page 15: ...rface 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...

Page 16: ...ce to get the cable s pin assignment Table 3 7 Prefab maxon cables Connector Prefab Cable Assembly Designation Part Number Page X1 Power Cable 275829 3 19 X2 Power Cable 275829 3 19 X3 Motor Cable 275...

Page 17: ...oles 171692 0104 1 X4 Molex Micro Fit 3 0 6 poles 430 25 0600 1 X6 X16 Molex CLIK Mate dual row 10 poles 503149 1000 1 X7 X9 Molex CLIK Mate single row 8 poles 502578 0800 2 X8 Molex CLIK Mate single...

Page 18: ...pins as well as details on the available prefab cables The first column describes both the pin number of the connector and of the matching prefab maxon cable s Head A The second column describes the c...

Page 19: ...nector X1 Table 3 10 Power supply connector X1 Pin assignment Table 3 11 Power Cable Continued on next page X1 Head A Prefab Cable Head B Signal Description Pin Color Pin 1 black GND Ground 2 black VC...

Page 20: ...le 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 ino...

Page 21: ...t meets the below stated minimum requirement If not supplied separately the logic supply is internally connected to the power supply Figure 3 7 Logic supply connector X2 Table 3 12 Logic supply connec...

Page 22: ...nt for maxon EC motor Table 3 15 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...

Page 23: ...ment Table 3 17 Hall Sensor Cable Continued on next page 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 in...

Page 24: ...or Subject to change without prior notice Figure 3 10 Hall sensor 1 input circuit analogously valid for Hall sensors 2 3 Hall sensor Sensor supply voltage VSensor 5 VDC Max Hall sensor supply current...

Page 25: ...to use only 3 channel versions Figure 3 11 Encoder connector X5 Table 3 18 Encoder connector X5 Pin assignment Table 3 19 Encoder connector X5 Accessories Continued on next page X5 Head A Prefab Cabl...

Page 26: ...Ch I Continued on next page 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 stra...

Page 27: ...it 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...

Page 28: ...hannel A High speed digital input 1 2 brown 2 Channel A HsDigIN1 Digital analog incremental encoder channel A complement High speed digital input 1 complement 3 green 3 Channel B HsDigIN2 Digital anal...

Page 29: ...l analogously valid for Ch B Continued on next page 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 Co...

Page 30: ...3 30 Document ID rel6852 EPOS4 Positioning Controller Edition May 2017 EPOS4 50 5 Hardware Reference 2017 maxon motor Subject to change without prior notice Figure 3 16 Digital incremental encoder inp...

Page 31: ...id 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...

Page 32: ...3 32 Document ID rel6852 EPOS4 Positioning Controller Edition May 2017 EPOS4 50 5 Hardware Reference 2017 maxon motor Subject to change without prior notice Figure 3 18 Digital incremental encoder inp...

Page 33: ...log 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 supp...

Page 34: ...ment ID rel6852 EPOS4 Positioning Controller Edition May 2017 EPOS4 50 5 Hardware Reference 2017 maxon motor Subject to change without prior notice Figure 3 20 Analog incremental encoder input circuit...

Page 35: ...I Absolute Encoder Figure 3 21 SSI absolute encoder data input Figure 3 22 SSI absolute encoder clock output SSI absolute encoder Auxiliary output voltage VAux 5 VDC Max auxiliary supply current 150 m...

Page 36: ...Figure 3 24 HsDigIN1 circuit single ended analogously valid for HsDigIN2 4 Continued on next page High speed digital input 1 4 differential Max input voltage 12 VDC Min differential input voltage 200...

Page 37: ...are Reference Edition May 2017 2017 maxon motor Subject to change without prior notice Figure 3 25 HsDigOUT1 output circuit High speed digital output 1 Min differential output voltage 1 8 V external l...

Page 38: ...page 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...

Page 39: ...ure 3 28 DigIN1 circuit analogously valid for DigIN2 4 PLC level setting Continued on next page Digital inputs 1 4 Logic level setting Input voltage 0 30 VDC Max input voltage 30 VDC Logic 0 0 8 V Log...

Page 40: ...ntroller Edition May 2017 EPOS4 50 5 Hardware Reference 2017 maxon motor Subject to change without prior notice Figure 3 29 DigOUT1 circuit analogously valid for DigOUT2 Continued on next page Digital...

Page 41: ...without prior notice WIRING EXAMPLES Figure 3 30 DigOUT1 sinks analogously valid for DigOUT2 Figure 3 31 DigOUT1 source analogously valid for DigOUT2 DigOUT sinks Max input voltage 36 VDC Max load cu...

Page 42: ...page 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 positiv...

Page 43: ...s 1 2 Input voltage 10 VDC differential Max input voltage 24 VDC Common mode voltage 5 10 VDC referenced to GND Input resistance 80 k differential 65 k referenced to GND A D converter 12 bit Resolutio...

Page 44: ...e Connec tor Table 3 28 must be plugged Table 3 27 STO connector X9 Pin assignment For the matching prefab cable assembly Table 3 24 on page 3 38 Table 3 28 STO Idle Connector Continued on next page X...

Page 45: ...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 Safe Torq...

Page 46: ...lor 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 sectio...

Page 47: ...configuration DIP Switch Configuration SW1 on page 3 54 Figure 3 39 CAN 1 connector X11 and CAN 2 connector X12 Table 3 32 CAN 1 connector X11 CAN 2 connector X12 Pin assignment Table 3 33 CAN COM Ca...

Page 48: ...oth ends of the CAN bus For detailed CAN information separate document EPOS4 Communication Guide CAN CAN Cable 520858 Cross section 2 x 2 x 0 14 mm2 twisted pair shielded Length 3 m Head A Plug Molex...

Page 49: ...ller and PC Notebook or if possible balance them Insert the USB connector first then switch on the power supply of the controller Figure 3 40 USB connector X13 Table 3 35 USB connector X13 Pin assignm...

Page 50: ...ared for identical external wiring make sure to always connect them as follows Use only standard Cat5 cables with RJ45 plug such as maxon s Ethernet Cable 422827 Use NET IN X14 as Input Use NET OUT X1...

Page 51: ...1 EPOS4 50 5 Hardware Reference Edition May 2017 2017 maxon motor Subject to change without prior notice Table 3 38 Ethernet Cable Ethernet Cable 422827 Cross section Cat 5e SF UTP ISO IEC 11801 1 1 p...

Page 52: ...for addi tional absolute sensors or customized signal extensions The pin assignment is directly related to the corresponding extension card Figure 3 42 Extension Signal connector X16 Table 3 39 Extens...

Page 53: ...sensors or customized signal extensions Using the respective optionally available EPOS4 cards additional functions can be directly accessed via the connector Extension Signal X16 on page 3 52 Figure 3...

Page 54: ...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...

Page 55: ...1 Examples 3 3 16 2 CAN automatic Bit Rate Detection Table 3 43 DIP switch SW1 CAN automatic bit rate detection 3 3 16 3 CAN Bus Termination Table 3 44 DIP switch SW1 CAN bus termination Continued on...

Page 56: ...2017 maxon motor Subject to change without prior notice 3 3 16 4 Digital Input Level For details chapter 3 3 7 Digital I O X7 on page 3 38 Table 3 45 DIP switch SW1 Digital input level 3 3 17 Spare Pa...

Page 57: ...45 A display the actual status and possible errors of the EPOS4 in respect to the NET network Green LED shows the RUN state Red LED indicates errors Table 3 47 NET Status LEDs LED Description Green Re...

Page 58: ...nd X15 OUT Green LED indicates link activity Table 3 49 NET Port LED LED Description Green Red Slow OFF Power stage is disabled The EPOS4 is in status Switch ON Disabled Ready to Switch ON Switched ON...

Page 59: ...h to use the connection overviews for either DC motor or EC BLDC motor that will assist you in determining the wiring for your particular motor type and the appropriate feedback signals Figure 4 46 In...

Page 60: ...g method and go to the respective table for DC motor Table 4 50 for EC BLDC motor Table 4 51 4 Pick the row with the corresponding wiring method and follow the link or links to the stated figure s to...

Page 61: ...incremental encoder Method EC6 Hall sensors Digital encoder SSI absolute encoder Method EC7 Digital incremental encoder Method EC8 Digital incremental encoder Digital incremental encoder Method EC9 D...

Page 62: ...on motor control 4 62 Document ID rel6852 EPOS4 Positioning Controller Edition May 2017 EPOS4 50 5 Hardware Reference 2017 maxon motor Subject to change without prior notice 4 2 Main Wiring Diagram Fi...

Page 63: ...4 50 5 Hardware Reference Edition May 2017 2017 maxon motor Subject to change without prior notice 4 3 Excerpts 4 3 1 Power Logic Supply Figure 4 48 Power logic supply 4 3 2 DC Motor Figure 4 49 DC mo...

Page 64: ...ware Reference 2017 maxon motor Subject to change without prior notice 4 3 5 Digital Incremental Encoder Figure 4 52 Digital incremental encoder 4 3 6 Digital Digital Incremental Encoder Figure 4 53 D...

Page 65: ...50 5 Hardware Reference Edition May 2017 2017 maxon motor Subject to change without prior notice 4 3 8 Digital Incremental SSI Encoder Figure 4 55 Digital incremental SSI encoder 4 3 9 Analog Increme...

Page 66: ...motor control 4 66 Document ID rel6852 EPOS4 Positioning Controller Edition May 2017 EPOS4 50 5 Hardware Reference 2017 maxon motor Subject to change without prior notice p a g e i n t e n ti o n a l...

Page 67: ...re 3 19 Analog incremental encoder input circuit Ch A differential analogously valid for Ch B 33 Figure 3 20 Analog incremental encoder input circuit Ch I digital evaluation 34 Figure 3 21 SSI absolut...

Page 68: ...57 Figure 4 46 Interfaces Designations and location 59 Figure 4 47 Main wiring diagram 62 Figure 4 48 Power logic supply 63 Figure 4 49 DC motor 63 Figure 4 50 EC BLDC motor 63 Figure 4 51 Hall sensor...

Page 69: ...nnector X5 Pin assignment 25 Table 3 19 Encoder connector X5 Accessories 25 Table 3 20 Encoder Cable 26 Table 3 21 Sensor connector X6 Pin assignment 28 Table 3 22 Sensor Cable 5x2core 29 Table 3 23 D...

Page 70: ...W1 CAN automatic bit rate detection 55 Table 3 44 DIP switch SW1 CAN bus termination 55 Table 3 45 DIP switch SW1 Digital input level 56 Table 3 46 Spare parts list 56 Table 3 47 NET Status LEDs 57 Ta...

Page 71: ...23 X5 25 X6 28 X7 38 X8 42 X9 44 X10 46 X11 47 X12 47 X13 49 X14 50 X15 50 X16 52 country specific regulations 8 D device condition display of 57 digital high speed inputs differential 36 digital high...

Page 72: ...requirements 21 precautions 8 prerequisites prior installation 15 prohibitive signs 6 protective measures ESD 8 purpose of the device 7 of the document 5 R regulations applicable 8 Requirements of po...

Page 73: ...n motor control EPOS4 Positioning Controller Document ID rel6852 Z 73 EPOS4 50 5 Hardware Reference Edition May 2017 2017 maxon motor Subject to change without prior notice p age intentionally left bl...

Page 74: ...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 bey...

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