Technosoft iPOS4803P Technical Reference Download

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iPOS4803P

Microdrive EtherCAT

iPOS4803PE

Microdrive EtherCAT

iPOS4803S

Microdrive EtherCAT

Intelligent Servo Drive for DC,

Brushless DC and AC Motors

Intelligent Servo Drives

Technical

Reference

Technosoft 2022

P091.020.iPOS4803.UM.0622

Summary of Contents for iPOS4803P

Page 1: ...ive EtherCAT iPOS4803PE Microdrive EtherCAT iPOS4803S Microdrive EtherCAT Intelligent Servo Drive for DC Brushless DC and AC Motors Intelligent Servo Drives Technical Reference Technosoft 2022 P091 020 iPOS4803 UM 0622 ...

Page 2: ...S4803PE Microdrive Dimensions 12 3 3 iPOS4803S Microdrive Dimensions 12 3 4 Mechanical Mounting 13 3 4 1 iPOS4803P and iPOS4803PE Microdrive 13 3 4 2 PCB Design 14 3 4 2 1 Motherboard PCB Design 15 3 4 2 2 Recommendations for the PCB Design 15 3 4 2 3 EtherCAT signals PCB routing indications 16 3 5 Connectors and Pinouts 19 3 5 1 Pinouts for iPOS4803P Microdrive 19 3 5 2 Pinouts for iPOS4803PE Mic...

Page 3: ...endations for Supply Wiring 40 3 11 1 2 Recommendations to limit over voltage during braking 40 3 12 USB connection 41 3 12 1 USB connection 41 3 13 EtherCAT Connection 42 3 13 1 Recommendations for EtherCAT Wiring 42 3 13 2 EtherCAT signals schematic considerations 44 3 14 Disabling the setup table at startup 45 3 14 1 Disabling the setup table at startup 45 3 15 LED Indicators for iPOS4803P 46 3...

Page 4: ...on 3A nominal EtherCAT iPOS4803S Microdrive EtherCAT P020 801 E222 Standalone version 3A nominal EtherCAT hardware AxisID P020 801 P222 Standalone version 3A nominal EtherCAT In order to operate the iPOS4803 drives you need to pass through 3 steps Step 1 Hardware installation Step 2 Drive setup using Technosoft EasySetUp software for drive commissioning Step 3 Motion programming using one of the o...

Page 5: ...y advantage of Technosoft drives their capability to execute complex motions without requiring an external motion controller thanks to their built in motion controller A demo version of EasyMotion Studio with EasySetUp part fully functional can be downloaded free of charge from the Technosoft web page iPOS CoE Programming part no P091 064 UM 0919 describes how to program the Technosoft intelligent...

Page 6: ...tions listed hereunder This information is intended to protect you the drive and the accompanying equipment during the product operation Incorrect handling of the drive can lead to personal injury or material damage The following safety symbols are used in this manual WARNING SIGNALS A DANGER TO THE OPERATOR WHICH MIGHT CAUSE BODILY INJURY MAY INCLUDE INSTRUCTIONS TO PREVENT THIS SITUATION CAUTION...

Page 7: ...ISO 9001 2015 Quality Austria Certificate about the application and further development of an effective Quality Management System complying with the requirements of Standard ISO 9001 2015 REACH Compliance TECHNOSOFT hereby confirms that this product comply with the legal obligations regarding Article 33 of the European REACH Regulation 1907 2006 Registration Evaluation Authorization and Restrictio...

Page 8: ...between the master and the drives in complex multi axis applications reducing both the development time and the overall communication requirements For example instead of trying to command each movement of an axis you can program the drives using TML to execute complex motion tasks and inform the master when these tasks are done Thus for each axis control the master job may be reduced at calling TM...

Page 9: ...fferential for iPOS4803S differential or single ended for iPOS4803P and iPOS4803PE Pulse direction interface for external master digital reference Absolute differential or single ended encoder Supported protocols SSI BiSS EnDAT TAMAGAWA Panasonic Nikon Sanyo Denki Separate feedback devices supported Linear Hall sensors interface digital or linear 1 analogue input 12 bit 0 5V or 10V Reference Feedb...

Page 10: ...OS4803P Microdrive EtherCAT Pins version 3A nominal EtherCAT hardware AxisID selection P020 001 P122 name iPOS4803P Microdrive EtherCAT Pins version 3A nominal EtherCAT P020 001 E322 name iPOS4803PE Microdrive EtherCAT Pins version 3A nominal EtherCAT hardware AxisID selection P020 001 P322 name iPOS4803PE Microdrive EtherCAT Pins version 3A nominal EtherCAT P020 801 P222 name iPOS4803S Microdrive...

Page 11: ...le ended3 or diff Yes Yes Yes Tacho Analogue input Feedback Yes 2 4 2 Dual loop configurations The motor speed control loop is closed on one feedback connected on the motor while the motor position control loop is closed on the other available feedback which is placed on the load There is usually a transmission between the load and the motor Motor type Feedback 1 Feedback 2 PMSM Incremental encode...

Page 12: ...erence 3 Hardware Installation 3 1 iPOS4803P Microdrive Dimensions Figure 4 iPOS4803P Microdrive dimensions 3 2 iPOS4803PE Microdrive Dimensions Figure 5 iPOS4803PE Microdrive dimensions 3 3 iPOS4803S Microdrive Dimensions Figure 6 iPOS4803S Microdrive dimensions ...

Page 13: ... 2 2 Watt 7 5 BTU hour worst case while driving a motor 3 4 1 iPOS4803P and iPOS4803PE Microdrive Figure 7 Recommended spacing horizontal mounting worst case non metallic closed box All dimension are expressed in mm The figures above shows the minimum spacing to assure proper airflow by natural convection If closed completely in a box ventilation openings shall be foreseen on the top and bottom si...

Page 14: ...oard PCB design use the dimensional drawing from Figure 8 iPOS4803P Microdrive PCB Footprint below Figure 8 iPOS4803P Microdrive PCB Footprint For iPOS4803PE Microdrive motherboard PCB design use the dimensional drawing from Figure 9 iPOS4803PE Microdrive PCB Footprint below Figure 9 iPOS4803PE Microdrive PCB Footprint ...

Page 15: ...POS4803P iPOS4803PE drives Motor supply and ground return tracks between iPOS4803P iPOS4803PE drive and the nearby VMOT decoupling capacitor are to be considered as EMI sources and kept to a minimum length Place the decoupling capacitors on VMOT and VLOG see also 3 10 Power Supply Connection as close as physically possible to the drive to minimize EM radiated emissions For un shielded applications...

Page 16: ...l pairs must be routed differentially i e using parallel tracks with minimal loop area A1 DAT1 A1 DAT1 B1 CLK1 B1 CLK1 Z1 Z1 A2 DAT2 A2 DAT2 B2 CLK2 B2 CLK2 CAN Hi CAN Lo When using 5VOUT as supply for external devices like encoders Hall sensors etc provide extra filtering and protection use series resettable PTC fuses to add short circuit protection use transient absorbers to protect against ESD ...

Page 17: ...of the magnetics isolated winding has a Bob Smith termination to chassis ground Bob Smith termination is used to reduce noise resulting from common mode current flows as well as reduce susceptibility to any noise from unused wire pairs on the RJ45 Bob Smith termination is different depending on Power Over Ethernet PoE compliance PoE carries up to 57V between pairs which would destroy the 75ohm ter...

Page 18: ...3 4 2 3 3 EtherCAT Bus connection Figure 13 EtherCAT bus to RJ45 connection PoE compliant Figure 14 EtherCAT bus to RJ45 connection non compliant with PoE For additional details regarding signal swapping please check the EtherCAT signals schematic considerations chapter ...

Page 19: ... Technosoft 2022 19 iPOS4803 Microdrive EtherCAT Technical Reference 3 5 Connectors and Pinouts 3 5 1 Pinouts for iPOS4803P Microdrive ...

Page 20: ... Technosoft 2022 20 iPOS4803 Microdrive EtherCAT Technical Reference 3 5 2 Pinouts for iPOS4803PE Microdrive 4 ...

Page 21: ... Technosoft 2022 21 iPOS4803 Microdrive EtherCAT Technical Reference 3 5 3 Pinouts for iPOS4803S Microdrive ...

Page 22: ...B Male 1m shielded black 9 6mm plastic width Tensility International Corp 1002333 J1 J2 Pre Crimped wires for Nano Fit Cable Assembly Nano Fit Crimp Terminal Socket to Nano Fit Crimp Terminal Socket 300mm Molex 0797582140 J3 J4 J5 J6 Pre Crimped wires for Pico Clasp Cable Assembly Pico Clasp Crimp Terminal Socket to Pico Clasp Crimp Terminal Socket 300mm Molex 0797581019 J1 J2 Pins for Nano Fit Na...

Page 23: ...onnection diagrams 3 6 1 iPOS4803P and iPOS4803PE connection diagram 4 Figure 15 iPOS4803P and iPOS4803PE Microdrive Connection diagram For other available feedback motor options check the detailed diagrams below Pins are software selectable individually as NPN inputs outputs ...

Page 24: ...hnical Reference 3 6 2 iPOS4803S connection diagram Figure 16 iPOS4803S Microdrive Connection diagram For other available feedback motor options check the detailed connection diagrams below Pins are software selectable individually as NPN inputs outputs ...

Page 25: ...803P and iPOS4803PE Figure 18 Digital NPN Inputs connection for iPOS4803S Remarks 1 The inputs are compatible with NPN type outputs input must be pulled to GND to change its default state 2 The I O pins are software selectable individually as inputs outputs 3 The length of the cables must be up to 30m reducing the exposure to voltage surges in industrial environment ...

Page 26: ...ts connection for iPOS4803P and iPOS4803PE Figure 20 Digital NPN Outputs connection for iPOS4803S Remarks 1 The outputs are compatible with NPN type inputs load is tied to common VLOG output pulls to GND when active and is floating when inactive 2 The I O pins are software selectable individually as inputs outputs ...

Page 27: ...lenoid driver connection for IPOS4803S Remarks 1 The firmware can control the Brake output automatically to engage disengage a mechanical brake when motor control is started stopped 2 The Brake pin can also be used as the NPN digital output OUT0 3 To enable the mechanical brake functionality select the following checkbox from EasyMotion Studio Figure 23 Motor brake checkbox in EasyMotion Studio ...

Page 28: ... be connected to the drive ground terminal b If the analogue signal source is differential and the signal source ground is isolated from the drive GND use a 2 wire twisted shielded cable as follows 1st wire connects the source plus positive in phase to the drive analogue input 2nd wire connects the source minus negative out of phase to the drive ground GND Shield is connected only at the drive sid...

Page 29: ... iPOS4803 Microdrive EtherCAT Technical Reference 3 9 Motor connections 3 9 1 Brushless Motor connection Figure 26 Brushless motor connection for iPOS4803P and iPOS4803PE Figure 27 Brushless motor connection for iPOS4803S ...

Page 30: ...on cannot be avoided use a shielded cable for the motor wires b The parasitic capacitance between the motor wires must not bypass 10nF If very long cables tens of meters are used this condition may not be met In this case add series inductors between the iPOS4803 Microdrive outputs and the cable The inductors must be magnetically shielded toroidal for example and must be rated for the motor surge ...

Page 31: ...J2 12 and J2 18 They might pick up unwanted noise and give false encoder readings Encoder cable shield must be connected to system GND to avoid disturbances noise induced by nearby cables Figure 31 Feedback 1 Single ended Incremental Encoder Connection for iPOS4803S CAUTION Do not connect unterminated wires to pins J3 9 J3 13 and J3 17 They might pick up unwanted noise and give false encoder readi...

Page 32: ...r iPOS4803P and iPOS4803PE Feedback 1 differential connection 120Ω 0 25W terminators must be connected for long encoder cables or noisy environments 2 For iPOS4803S Feedback 1 differential connection 120Ω 0 25W terminators are internally added by putting the SW1 pins 1 2 and 3 on ON position 3 The length of the cables must be up to 30m reducing the exposure to voltage surges in industrial environm...

Page 33: ...rminated wires to pins J2 14 and J2 16 They might pick up unwanted noise and give false encoder readings Encoder cable shield must be connected to system GND to avoid disturbances noise induced by nearby cables 3 10 4 Feedback 2 Differential Incremental Encoder Connection Figure 35 Feedback 2 Differential Incremental Encoder Connection for iPOS4803P and iPOS4803PE Figure 36 Feedback 2 Differential...

Page 34: ...0 5 Feedback 1 Absolute Encoder Connection SSI BiSS Panasonic Tamagawa EnDAT Nikon Sanyo Denki Figure 37 Feedback 1 Absolute Encoder Connection for iPOS4803P and iPOS4803PE Figure 38 Feedback 1 Absolute Encoder Connection for iPOS4803S Remarks 1 For iPOS4803P and iPOS4803PE Feedback 1 absolute connection 120Ω 0 25W terminators must be connected for long encoder cables or noisy environments 2 For i...

Page 35: ...r iPOS4803S Remarks 1 For iPOS4803P and iPOS4803PE Feedback 2 absolute connection 120Ω 0 25W terminators must be connected for long encoder cables or noisy environments 2 For iPOS4803S Feedback 2 input has internal terminators equivalent to 120Ω 0 25W present in the drive 3 The length of the cables must be up to 30m reducing the exposure to voltage surges in industrial environment CAUTION Encoder ...

Page 36: ...chnosoft 2022 36 iPOS4803 Microdrive EtherCAT Technical Reference 3 10 7 Linear Hall Connection Figure 41 Linear Hall connection for iPOS4803P and iPOS4803PE Figure 42 Linear Hall connection for iPOS4803S ...

Page 37: ...required when using Hall start method BLDC or PMSM and also for the Trapezoidal commutation method The digital halls are not used in this case as a feedback measurement device The actual motor control is done with an incremental encoder 2 The iPOS4803 drives are equipped with a feature that detects breakage of Hall wires and or of incremental absolute encoder wires 3 The length of the cables must ...

Page 38: ...ositive and negative signals when the position sensor is differential and provides them Use one twisted pair for each differential group of signals as follows A1 DAT1 with A1 DAT1 B1 CLK1 with B1 CLK1 Z1 with Z1 A2 DAT2 with A2 DAT2 and B2 CLK2 with B2 CLK2 Use another twisted pair for the 5V supply and GND b Always use shielded cables to avoid capacitive coupled noise when using single ended enco...

Page 39: ... and iPOS4803PE Figure 48 Supply connection for iPOS4803S Remarks 1 The Vlog inputs can be supplied from the same power source as long as its output voltage is 6 to 48V DC from a SELV PELV power supply 2 An external electrolytic capacitor may be added between Vmot and GND to help reduce over voltage during load braking reversals See paragraph 3 10 1 1 for details ...

Page 40: ...igger than the maximum expected over voltage and can be sized with the formula 2 2 2 NOM MAX M U U E C where UMAX 52V is the over voltage protection limit UNOM is the nominal motor supply voltage EM the overall energy flowing back to the supply in Joules In case of a rotary motor and load EM can be computed with the formula F M d d Ph 2 M f inal initial L M 2 M L M M T 2 t t R 3I h g h m m J J 2 1...

Page 41: ...be routed as differential pairs with controlled impedance microstrip or stripline Figure 50 USB connection for iPOS4803S For the USB connection a standard USB cable is required The drivers are found automatically in Windows 10 and the device is identified as a COM port In Easy Motion studio choose the following communication settings Figure 51 USB connection Instead of COM1 choose the new COM valu...

Page 42: ...k to the master controller on the 2nd port of the master This topology consists of the linear topology described above plus an extra connection between the master which has two RJ45 ports to OUT of the last drive See Figure 47 for a visual representation of the ring topology Ring topology is preferred for its added security since it is insensitive to one broken cable connection along the ring re r...

Page 43: ...quence it is possible to connect EtherCAT devices either by patch cables 1 1 wiring or by cross over cables pair 1 2 swapped with 3 6 This feature is already used in the proposed schematics where channels of Port 0 IN have different allocation than channels of Port 1 OUT For all 4 differential channels positive and negative lines can be swapped freely For example it is possible to swap Tx0 with Tx...

Page 44: ...sly To recover from this state the setup table must be invalidated by connecting all digital Hall inputs to GND On the next power on the drive will load the default settings and set bit 2 from Motion Error Register Invalid Setup Data After a new valid setup table is loaded onto the drive disconnect the hall sensors from GND and execute a new power off power on cycle Figure 58 Temporary connection ...

Page 45: ...tivity for ECAT IN and OUT ports LED6 ECAT ACT1 YELLOW 3 15 1 EtherCAT RUN and ERROR LED Indicators The RUN states are displayed with a 180 degree phase shift to the ERROR states as noted in Figure 61 STATUS indicator Example The behavior of the RUN indicator is specified in Table 2 RUN Indicator States and the behavior of the ERROR indicator specified in Table 3 ERROR Indicator States Figure 61 S...

Page 46: ...drives support all EtherCAT standard addressing modes In case of device addressing mode based on node address the drive sets the configured station alias address with its AxisID value The drive AxisID value is set after power on by Software setting via EasySetUp a specific AxisID value in the range 1 255 Hardware by setting h w in Easy setup under Axis ID value and selecting a value between 1 255 ...

Page 47: ... the Drive Setup dialogue The AxisID on iPOS4803S P020 801 E222 can be set also by hardware with the SW1 switch Figure 62 Axis ID pins for EtherCAT P020 801 E222 only SW1 Position 4 SW2 AxisID OFF OFF 255 the EtherCAT register called configured station alias will be 0 OFF ON 1 ON OFF 128 ON ON 129 Figure 63 Axis ID selection for EtherCAT P020 801 E222 only Remarks 1 The drive axis address number i...

Page 48: ...ed mating connectors TBD TBD N Extraction force TBD TBD N 3 17 4 3BEnvironmental Characteristics Min Typ Max Units Size Length x Width x Height Global size Without connectors iPOS4803P Microdrive 38 1 x 25 x 8 4 mm 1 5 x 0 98 x 0 33 inch iPOS4803PE Microdrive 38 3 x 26 8 x 11 3 mm 1 5 x 1 05 x 0 44 inch iPOS4803S Microdrive 40 6 x 38 6 x 22 8 mm 1 6 x 1 52 x 0 9 inch Weight iPOS4803P Microdrive TB...

Page 49: ...rement range VMOT 48 V FPWM 20 kHz TBD H FPWM 40 kHz TBD FPWM 60 kHz TBD FPWM 80 kHz TBD FPWM 100 kHz TBD Absolute minimum value limited by short circuit protection VMOT 48 V FPWM 20 kHz TBD H FPWM 40 kHz TBD FPWM 60 kHz TBD FPWM 80 kHz TBD FPWM 100 kHz TBD Motor electrical time constant L R Recommended value for 5 current measurement error due to ripple FPWM 20 kHz TBD µs FPWM 40 kHz TBD FPWM 60 ...

Page 50: ...t current Logic LOW Pull to GND 2 3 mA Logic HIGH Internal 2 2K pull up to 5 0 Minimum pulse width 70 µs ESD protection Human body model 15 kV 3 17 4 11BEncoder Inputs A1 A1 B1 B1 Z1 Z1 A2 A2 B2 B2 Z2 Z2 Min Typ Max Units Differential mode compliance For full RS422 compliance see 6F 1 TIA EIA 422 A Input voltage Hysteresis 0 06 0 1 0 2 V Differential mode 14 14 Common mode range A to GND etc 11 14...

Page 51: ...crodrive EtherCAT Technical Reference Offset error Common mode voltage 0 10 V 0 2 0 5 FSErro r Bookmark not defined Gain error Common mode voltage 0 10 V 0 5 3 FSErro r Bookmark not defined Bandwidth 3dB Software selectable 0 5 5 kHz ...

Page 52: ...1 m MSB LSB m multi turn bits n n 1 n 2 n 3 n 4 4 3 2 1 m 1 m 2 m 3 m 4 m 5 m n 3 m n 2 m n 1 m n MSB LSB n single turn bits CK and DT signals have the same form with CK and DT but with opposite polarity 3 17 7 Supply Output 5V Min Typ Max Units 5V output voltage Current sourced 400mA 4 9 5 5 2 V 5V output current6F 1 TBD mA Short circuit protection Yes Over voltage protection NOT protected ESD pr...

Page 53: ... with motor supply Figure 67 iPOS4803 Microdrive Output Voltage De rating with PWM frequency 0 2 4 6 0 50 100 150 200 Current amplitude A PWM Frequency KHz Micro 24V 0 2 4 6 0 15 30 45 60 75 Current amplitude A Ambient Temperature ºC Micro 20KHz 24V 0 1 2 3 4 5 6 0 5 10 15 20 25 30 35 40 45 50 Current amplitude A Vmot V Micro 20KHz 0 50 100 0 50 100 150 200 Output Voltage V OUT V MOT PWM Frequency...

Page 54: ...run time The E2 ROM is mapped in the address range 2000h to 7FFFh It is used to keep in a non volatile memory the TML programs the cam tables and the drive setup information Remark EasyMotion Studio handles automatically the memory allocation for each motion application The memory map can be accessed and modified from the Memory Settings dialogue of each application Figure 68 iPOS4803 Microdrive M...

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