Hardware Reference

EPOS4 Module/Compact 50/8 Positioning Controller | P/Ns 504384 / 520885 / 605298

Hardware Reference
CCMC | Edition 2022-04 | DocID rel10501
Table of Contents

TABLE OF CONTENTS

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

3 SETUP 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

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 accord-
ing 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 the 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!

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 Table of Contents

3.3.5.7 Digital I/O (X7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.3.5.8 Analog I/O (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.3.5.9 STO (X9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.3.5.10 RS232 (X10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3.5.11 CAN 1 (X11) & CAN 2 (X12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.3.5.12 EtherCAT IN (X14) & EtherCAT OUT (X15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.3.6 DIP Switch Configuration (SW1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.3.6.1 CAN ID (Node-ID) / DEV ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.3.6.2 CAN automatic Bit Rate Detection (Compact CAN) . . . . . . . . . . . . . . . . . . . . . . . 44
3.3.6.3 CAN Bus Termination (Compact CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.3.6.4 Digital Input Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.3.7 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.4 Connection Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.4.1 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.4.2 Logic Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.4.3 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.4.4 Hall Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.4.5 Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.4.13 USB (X13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.5 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4 MOTHERBOARD DESIGN GUIDE 83

4.1 Requirements for Components of Third-party Suppliers . . . . . . . . . . . . . . . . . . 84
4.1.1 Socket Headers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.1.2 Supply Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.1.3 Logic Supply Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.1.4 Motor Cables and Motor Chokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.1.5 RS232 Transceiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.1.6 Recommended Components and Manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.2 Design Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

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4.2.1 Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.2.2 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.3 THT Footprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

5 WIRING 93
5.1 Possible Combinations to connect a Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.2 Main Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.3 Excerpts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

LIST OF FIGURES 101

LIST OF TABLES 103

INDEX 107

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 About
About this Document

1 ABOUT

1.1 About this Document

1.1.1 Intended Purpose

Use the docu- The purpose of the present document is to familiarize you with the EPOS4 Module 50/8 and EPOS4 Com-
ment to… pact 50/8 positioning controllers. It will highlight the tasks for safe and adequate installation and/or commis-
–stay safe, sioning. Follow the described instructions …
–be fast,
• to avoid dangerous situations,
–end up with set
up and ready-to- • to keep installation and/or commissioning time at a minimum,
go equipment. • 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:

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 under-
stand and fulfill the respective work and duties.

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CCMC | 2022-04 | rel10501 1-5
About
About this Document

1.1.3 How to use

If not stated otherwise, the described details are valid for both the plug-in module and the stand-alone com-
pact 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.

Type Symbol Meaning

Indicates an imminent hazardous situation. If not
DANGER
avoided, it will result in death or serious injury.
Indicates a potential hazardous situation. If not
WARNING
Safety alert avoided, it can result in death or serious injury.
(typical) Indicates a probable hazardous situation or calls the
CAUTION attention to unsafe practices. If not avoided, it may
result in injury.

Prohibited
Indicates a dangerous action. Hence, you must not!
action
(typical)

Mandatory
Indicates a mandatory action. Hence, you must!
action
(typical)
Indicates an activity you must perform prior continuing,
Requirement /
or gives information on a particular item you need to
Note / Remark
observe.

Indicates an advice or recommendation on the easiest

Information Best practice
and best way to further proceed.

Material Indicates information particular to possible damage of

Damage the equipment.

Table 1-2 Symbols and signs

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 About
About this Document

1.1.5 Trademarks and Brand Names

For easier legibility, registered brand names are listed below and will not be further tagged with their respec-
tive trademark. It must be understood that the brands (the list below is not necessarily concluding) are pro-
tected 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 CAN in Automation e.V, DE-Nuremberg
CiA®

CLIK-Mate™
Micro-Fit™
© Molex, USA-Lisle, IL
Mini-Fit Jr.™
Mega-Fit®

EnDat © DR. JOHANNES HEIDENHAIN GmbH, DE-Traunreut

© EtherCAT Technology Group, DE-Nuremberg, licensed by Beckhoff Automation

EtherCAT®
GmbH, DE-Verl

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

Littelfuse®
© Littelfuse Inc., USA-Chicago, IL
SMD NANO2®

Windows® © Microsoft Corporation, USA-Redmond, WA

Table 1-3 Brand names and trademark owners

1.1.6 Copyright
This document is protected by copyright. Any further use (including reproduction, translation, microfilming,
and other means of electronic data processing) without prior written approval is not permitted. The men-
tioned trademarks belong to their respective owners and are protected under intellectual property rights.
© 2022 maxon. All rights reserved. Subject to change without prior notice.
CCMC | EPOS4 Module/Compact 50/8 Hardware Reference | Edition 2022-04 | DocID rel10501
maxon motor ag
Brünigstrasse 220 +41 41 666 15 00
CH-6072 Sachseln www.maxongroup.com

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About
About the Devices

1.2 About the Devices

Capabilities of the maxon’s EPOS4 Module 50/8 and EPOS4 Compact 50/8 are small-sized, full digital, smart positioning con-
device, included trol units. Their high power density allow flexible use for brushed DC and brushless EC (BLDC) motors up to
features, and sup- approximately 400 Watts with various feedback options, such as Hall sensors, incremental encoders as well
ported motors. 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 Eth-
erCAT network. In addition, the units can be operated via any USB or RS232 communication port of a Win-
dows 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 moth-
erboards 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 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 con-
nectors, including CANopen and RS232 interface
• EPOS4 CB Power EtherCAT (604594)
Connector board for initial commissioning or combination to a compact solution providing all con-
nectors, 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

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 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

all controller versions (Module and Compact) as well as other EPOS4

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.maxongroup.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

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About
About the Safety Precautions

1.3 About the Safety Precautions

Keep in mind: • Make sure that you have read and understood the note “READ THIS FIRST” on page A-2!
Safety first! • Do not engage with any work unless you possess the stated skills (chapter “1.1.2 Target Audi-
Always! ence” on page 1-5)!
• Refer to chapter “1.1.4 Symbols & Signs” on page 1-6 to understand the subsequently used indi-
cators!
• 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 equip-
ment. 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 aware that you are not entitled to perform any repair on components supplied by maxon.

Electrostatic sensitive device (ESD)

• Wear working cloth and use equipment in compliance with ESD protective measures.
• Handle device with extra care.

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 Specifications
Technical Data

2 SPECIFICATIONS

2.1 Technical Data

EPOS4 Module 50/8 (504384)
EPOS4 Compact 50/8 CAN (520885)
EPOS4 Compact 50/8 EtherCAT (605298)

Nominal power supply voltage +VCC 10…50 VDC

Module 10…50 VDC

Nominal logic supply voltage +VC
Compact 10…50 VDC, optional

Absolute supply voltage +Vmin / +Vmax 8 VDC / 56 VDC

Output voltage (max.) 0.9 x +VCC

Output current Icont / Imax (<5 s) 8 A / 30 A

Pulse Width Modulation frequency 50 kHz

Sampling rate PI current controller 25 kHz (40 μs)

Electrical Sampling rate PI speed controller 2.5 kHz (400 μs)

Rating Sampling rate PID positioning
2.5 kHz (400 μs)
controller

Sampling rate analog input 2.5 kHz (400 μs)

Max. efficiency 98% (Figure 2-4)

limited by max. permissible speed (motor) and

Max. speed DC motor
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)

Module —
Built-in motor choke
Compact 3 x 2.2 μH; 15 A

Digital Input 1 (general purpose) Module +2.1…+36 VDC

Digital Input 2 (general purpose) DIP switch-selectable levels:
Digital Input 3 (general purpose) Compact • Logic: +2.0…+30 VDC
Digital Input 4 (general purpose) • PLC: +9.0…+30 VDC

Digital Output 1 (general purpose) max. 36 VDC / IL ≤500 mA

Inputs Digital Output 2 (general purpose) (open collector with internal pull-up)
&
Outputs STO Input 1
+4.5…+30 VDC (optically isolated)
STO Input 2

max. 30 VDC / IL ≤15 mA (optically isolated with self-resetting short-

STO Output
circuit protection)

Analog Input 1
Resolution 12-bit, −10…+10 V, 10 kHz, differential
Analog Input 2

Continued on next page.

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Specifications
Technical Data

EPOS4 Module 50/8 (504384)

EPOS4 Compact 50/8 CAN (520885)
EPOS4 Compact 50/8 EtherCAT (605298)

Analog Output 1
Resolution 12-bit, −4…+4 V, 25 kHz, referenced to GND
Analog Output 2

Digital Hall sensor signals

+2.0…+24 VDC (internal pull-up)
H1, H2, H3

Digital incremental encoder signals

Inputs EIA RS422, max. 6.25 MHz
A, A\, B, B\, I, I\
&
Outputs Sensor signals
(continued) (choice between multiple functions)
• Digital incremental encoder 3-channel, EIA RS422, max. 6.25 MHz
• Analog incremental encoder 3-channel, resolution 12-bit, ±1.8 V, differential
SinCos
• SSI absolute encoder configurable, EIA RS422, 0.4…2 MHz
• High-speed digital input 1…4 EIA RS422, max. 6.25 MHz
• High-speed digital output 1 EIA RS422, max. 6.25 MHz

Sensor supply voltage VSensor +5 VDC / IL ≤100 mA

Voltage
Outputs Auxiliary output voltage VAux +5 VDC / IL ≤150 mA

Motor DC motor + Motor, − Motor

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

Module Compact CAN Compact EtherCAT

USB 2.0 / USB 3.0 Full Speed Full Speed Full Speed

max. 115’200 bit/s;

RS232 external transceiver max. 115’200 bit/s —
necessary
Interfaces CAN max. 1 Mbit/s max. 1 Mbit/s —

Full duplex
(100 Mbit/s) as to IEE
Full duplex
802.3 100 Base Tx;
EtherCAT — (100 Mbit/s) as to IEE
optional «EPOS4
802.3 100 Base Tx
EtherCAT Card»
required

Module Compact CAN Compact EtherCAT

Operation (green) Operation (green) Operation (green)

Device status
Status Error (red) Error (red) Error (red)
Indicators RUN state (green)
NET status — —
Error (red)

NET port — — Link activity (green)

Continued on next page.

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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 Compact CAN Compact EtherCAT

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
pluggable female
headers 2.54 mm
mounting holes for mounting holes for
Mounting or
M2.5 screws M2.5 screws
mounting holes for
M2.5 screws

Operation −30…+45 °C −30…+45 °C −30…+45 °C

Extended +45…+77 °C
Temperature
range [a] Derating −0.250 A/°C (Figure 2-3)

Storage −40…+85 °C
Environment
Operation 0…6’000 m MSL
Altitude [b] Extended 6’000…10’000 m MSL
range [a] Derating Figure 2-3

Humidity 5…90% (condensation not permitted)

[a] Operation within the extended range (temperature and altitude) is permitted. However, a respective derating (declination
of output current Icont) as to the stated values will apply.
[b] 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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 Specifications
Limitations

2.2.2 Power Dissipation and Efficiency

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

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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 Specifications
Dimensional Drawings

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

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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 Specifications
Standards

2.5 Standards
The described device has been successfully tested for compliance with the below listed standards. In prac-
tical 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.

Electromagnetic Compatibility

IEC/EN 61000-6-2 Immunity for industrial environments

Generic Emission standard for residential, commercial and light-
IEC/EN 61000-6-3
industrial environments

IEC/EN 55022
Radio disturbance characteristics / radio interference
(CISPR22)

Radiated, radio-frequency, electromagnetic field immunity test

IEC/EN 61000-4-3
Applied >10 V/m

IEC/EN 61000-4-4 Electrical fast transient/burst immunity test ±2 kV

Immunity to conducted disturbances, induced by radio-

IEC/EN 61000-4-6
frequency fields 10 Vrms

Others

Environmental testing – Test Fc: Vibration (sinusoidal,

IEC/EN 60068-2-6
Environment 10…500 Hz, 20 m/s2)

MIL-STD-810F Random transport (10…500 Hz up to 2.53 grms)

Unassembled printed circuit board

• Module: E76251; E133472; E207844; E337862
Safety UL File Number • Compact CAN: E76251; E116354; E133472; E207844;
E337862
• Compact EtherCAT: E76251; E133472; E207844; E337862

Reliability prediction of electronic equipment

Environment: Ground, benign (GB)
Ambient temperature: 298 K (25 °C)
Component stress: In accordance with circuit diagram and
Reliability MIL-HDBK-217F nominal power
Mean Time Between Failures (MTBF)
• Module: 245’451 hours
• Compact CAN: 210’109 hours
• Compact EtherCAT: 197’129 hours

Table 2-7 Standards

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Specifications
Standards

••page intentionally left blank••

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 Setup
Generally applicable Rules

3 SETUP
IMPORTANT NOTICE: PREREQUISITES FOR PERMISSION TO COMMENCE INSTALLATION
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 incorpo-
rated 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 Directive
2006/42/EC may cause serious injuries!
• Do not operate the device, unless you have made completely sure that the other machinery fully com-
plies 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

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 poten-
tial 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, bal-
ance 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 3-46.

Figure 3-11 Pin assignment

Pin Signal Description

Motor (+M) DC motor: Motor +
A1…A4**
Motor winding 1 EC motor: Winding 1
Motor (−M) DC motor: Motor −
A5…A8**
Motor winding 2 EC motor: Winding 2
A9…A12** Motor winding 3 EC motor: Winding 3
A13…A16** +VCC Power supply voltage (+10…+50 VDC)
A17 +VC 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 VSensor Sensor supply voltage (+5 VDC; IL ≤100 mA)
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

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
Channel A Digital/analog incremental encoder channel A
B7
HsDigIN1 High-speed digital input 1
Channel A\ Digital/analog incremental encoder channel A complement
B8
HsDigIN1\ High-speed digital input 1 complement
Channel B Digital/analog incremental encoder channel B
B9
HsDigIN2 High-speed digital input 2
Channel B\ Digital/analog incremental encoder channel B complement
B10
HsDigIN2\ High-speed digital input 2 complement
Channel I Digital/analog incremental encoder channel I
HsDigIN3 High-speed digital input 3
B11
Clock Clock (SSI)
HsDigOUT1 High-speed digital output 1
Channel I\ Digital/analog incremental encoder channel I complement
HsDigIN3\ High-speed digital input 3 complement
B12
Clock\ Clock (SSI) complement
HsDigOUT1\ High-speed digital output 1 complement
Data Data (SSI)
B13
HsDigIN4 High-speed digital input 4
Data\ Data (SSI) complement
B14
HsDigIN4\ High-speed digital input 4 complement
B15 VAux Auxiliary output voltage (+5 VDC; IL ≤150 mA)
B16 GND Ground
B17 STO-IN1+ Safe Torque Off input 1, positive signal
B18 STO-IN1− Safe Torque Off input 1, negative signal
B19 STO-IN2+ Safe Torque Off input 2, positive signal
B20 STO-IN2− Safe Torque Off input 2, negative signal
B21 STO-OUT+ Safe Torque Off output, positive signal
B22 STO-OUT− Safe Torque Off output, negative signal
B23 AnIN1+ Analog input 1, positive signal
B24 AnIN1− Analog input 1, negative signal
B25 AnIN2+ Analog input 2, positive signal
B26 AnIN2− Analog input 2, negative signal
B27 AnOUT1 Analog output 1
B28 AnOUT2 Analog output 2
B29 ID 1 CAN ID / DEV ID 1 (valence = 1)
B30 ID 2 CAN ID / DEV ID 2 (valence = 2)
Continued on next page.

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Setup
Pin Assignment for Module Version

Pin Signal Description

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 [c] DSP_RxD Serial communication interface receive (UART)
B40 DSP_TxD Serial communication interface transmit (UART)
B41 [d] SPI_CLK Serial Peripheral Interface clock
B42 [d] SPI_IRQ Serial Peripheral Interface interrupt request
B43 [d] SPI_SOMI Serial Peripheral Interface Slave output, Master input
B44 [d] SPI_SIMO Serial Peripheral Interface Slave input, Master output
B45 [d] SPI_CS2 Serial Peripheral Interface chip select 2
B46 [d] SPI_CS1 Serial Peripheral Interface chip select 1
[c] connect to sensor supply voltage VSensor (A26) when RS232 is not in use
[d] 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 com-
bine the Module to Compact versions. They comprise all required connections.
For in-depth details on connections chapter “3.4 Connection Specifications” on page 3-46.

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

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

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.

Connector Prefab Cable Assembly

Compact Compact Part
Designation Page
CAN EtherCAT Number
Power Cable High Current
X1 520850 3-29
Mandatory for supply of power stage!
Power Cable
X2 275829 3-30
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 3-36
X8 Signal Cable 7core 520854 3-37
X9 Signal Cable 8core 520853 3-36
X10 — RS232-COM Cable 520856 3-39
CAN-COM Cable 520857 3-40
X11 —
CAN-CAN Cable 520858 3-40
CAN-COM Cable 520857 3-40
X12 —
CAN-CAN Cable 520858 3-40
USB Type A - micro B Cable
X13 403968 3-78
(located at the Module)
— X14 Ethernet Cable 422827 3-42
— X15 Ethernet Cable 422827 3-42

Table 3-10 Prefab maxon cables

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Pin Assignment for Connector Boards & Compact Versions

MAKE&BAKE YOUR OWN

If you decide not to employ maxon’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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Pin Assignment for Connector Boards & Compact Versions

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

EPOS4 CB Power CAN

X1 Power Supply page 3-29

X2 Logic Supply page 3-30

X3a Motor page 3-31

X3b Motor page 3-31

X4 Hall Sensor page 3-33

X5 Encoder page 3-34

X6 Sensor page 3-35

X7 Digital I/O page 3-36

EPOS4 CB Power EtherCAT
X8 Analog I/O page 3-37

X9 STO page 3-38

X10 RS232 page 3-39

X11 CAN 1 page 3-40

X12 CAN 2 page 3-40

X14 EtherCAT IN page 3-41

X15 EtherCAT OUT page 3-41

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)

Use of X1 is mandatory
You must employ X1 to connect the controller to the electrical supply. Use X2 only if you wish to connect an
optional, separately wired logic supply.

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

Figure 3-15 Power supply connector X1

X1 Prefab
Head B
Head A Cable Signal Description
Pin Color Pin
1 black − GND Ground
2 black + +VCC 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 3m
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 mm2
Table 3-14 Power Cable High Current

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Pin Assignment for Connector Boards & Compact Versions

3.3.5.2 Logic Supply (X2)

Figure 3-16 Logic supply connector X2

X2 Prefab
Head B
Head A Cable Signal Description
Pin Color Pin
1 black − GND Ground
2 black + +VC Logic supply voltage (+10…+50 VDC)

Table 3-15 Logic supply connector X2 – Pin assignment

Power Cable (275829)

Cross-section 2 x 0.75 mm2, grey

Length 3m
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 mm2
Table 3-16 Power Cable

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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: Icont ≤11 A
• X3b: Icont ≤15 A

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

X3a
Prefab
X3b Head B
Cable Signal Description
Head A
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
Prefab
X3b Head B
Cable Signal Description
Head A
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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Pin Assignment for Connector Boards & Compact Versions

Motor Cable for X3a (275851)

Cross-section 3 x 0.75 mm2, shielded, grey

Length 3m
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 mm2

Table 3-19 Motor Cable

Motor Cable High Current for X3b (520851)

Cross-section 3 x 2.5 mm2, shielded, grey

Length 3m
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 mm2
Table 3-20 Motor Cable High Current

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Pin Assignment for Connector Boards & Compact Versions

3.3.5.4 Hall Sensor (X4)

Figure 3-18 Hall sensor connector X4

X4 Prefab
Head B
Head A Cable 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
Table 3-21 Hall sensor connector X4 – Pin assignment

Hall Sensor Cable (275878)

Cross-section 5 x 0.14 mm2, shielded, grey

Length 3m
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 mm2

Table 3-22 Hall Sensor Cable

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Pin Assignment for Connector Boards & Compact Versions

3.3.5.5 Encoder (X5)

Figure 3-19 Encoder connector X5

X5 Prefab
Head B
Head A Cable Signal Description
Pin Color Pin
1 brown 1 – not connected
2 white 2 VSensor Sensor supply voltage (+5 VDC; IL ≤100 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
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 Retainer
For sockets without strain relief:
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, flat cable, pitch 1.27 mm

Length 3m
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

X6 Prefab
Head B
Head A Cable Signal Description
Pin Color Pin
Channel A Digital/analog incremental encoder channel A
1 white 1
HsDigIN1 High-speed digital input 1
Digital/analog incremental encoder channel A
Channel A\
2 brown 2 complement
HsDigIN1\ High-speed digital input 1 complement
Channel B Digital/analog incremental encoder channel B
3 green 3
HsDigIN2 High-speed digital input 2
Digital/analog incremental encoder channel B
Channel B\
4 yellow 4 complement
HsDigIN2\ High-speed digital input 2 complement
Channel I Digital/analog incremental encoder channel I
HsDigIN3 High-speed digital input 3
5 grey 5
Clock Clock (SSI)
HsDigOUT1 High-speed digital output 1
Digital/analog incremental encoder channel I
Channel I\
complement
6 pink 6 HsDigIN3\ High-speed digital input 3 complement
Clock\ Clock (SSI) complement
HsDigOUT1\ High-speed digital output 1 complement
Data Data (SSI)
7 blue 7
HsDigIN4 High-speed digital input 4
Data\ Data (SSI) complement
8 red 8
HsDigIN4\ High-speed digital input 4 complement
9 black 9 GND Ground
10 violet 10 VAux Auxiliary output voltage (+5 VDC; IL ≤150 mA)

Table 3-26 Sensor connector X6 – Pin assignment

Continued on next page.

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Sensor Cable 5x2core (520852)

Cross-section 5 x 2 x 0.14 mm2, twisted pair, grey

Length 3m
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 mm2

Table 3-27 Sensor Cable 5x2core

3.3.5.7 Digital I/O (X7)

Figure 3-21 Digital I/O connector X7

X7 Prefab
Head B
Head A Cable 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)

Table 3-28 Digital I/O connector X7 – Pin assignment

Signal Cable 8core (520853)

Cross-section 8 x 0.14 mm2, grey

Length 3m
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 mm2

Table 3-29 Signal Cable 8core

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3.3.5.8 Analog I/O (X8)

Figure 3-22 Analog I/O connector X8

X8 Prefab
Head B
Head A Cable 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 mm2, grey

Length 3m
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 mm2
Table 3-31 Signal Cable 7core

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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.

X9 Prefab
Head B
Head A Cable 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)
8 red 8 VSTO
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 3-36.

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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3.3.5.10 RS232 (X10)

Figure 3-24 RS232 connector X10

X10 Prefab
Head B
Head A Cable 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 mm2, twisted pair, shielded

Length 3m
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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3.3.5.11 CAN 1 (X11) & CAN 2 (X12)

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

X11/X12 Prefab 520857 520858

Head A Cable Head B Head B Signal Description
Pin Color Pin Pin
1 white 7 1 CAN high CAN high bus line
2 brown 2 2 CAN low CAN low bus line
3 green 3 3 GND Ground
4 Shield 5 4 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 mm2, twisted pair, shielded

Length 3m
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 mm2, twisted pair, shielded

Length 3m
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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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 see separate document «EPOS4 Communication Guide».

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

X14
Prefab
X15 Head B
Cable Signal Description
Head A
Pin Color Pin
white/
1 1 TX+ Transmission Data+
orange
2 orange 2 TX− Transmission Data−
white/
3 3 RX+ Receive Data+
green
4 blue 4 – not applicable
white/
5 5 – not applicable
blue
6 green 6 RX− Receive Data−
white/
7 7 – not applicable
brown
8 brown 8 – not applicable
Table 3-39 EtherCAT IN & EtherCAT OUT connectors X14 & X15 – Pin assignment

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Ethernet Cable (422827)

Cross-section Cat. 5e SF/UTP (ISO/IEC 11801), 1:1 patch cable, green

Length 2m
Head A RJ45 (8P8CS) EIA/TIA-568B
Head B RJ45 (8P8CS) EIA/TIA-568B

Table 3-40 Ethernet Cable

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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 Compact Switch Binary Code Valence
CAN EtherCAT
1 20 1
2 2 1 2
3 22 4
4 2 3 8
(factory setting) (factory setting)
5 2 4 16

Table 3-41 DIP switch SW1 – Binary code values

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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 Compact ID
1 2 3 4 5
CAN EtherCAT

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”

Table 3-42 DIP switch SW1 – Examples

3.3.6.2 CAN automatic Bit Rate Detection (Compact CAN)

Controller Switch OFF ON

Compact
6
CAN
Automatic bit rate detection Automatic bit rate detection activated
deactivated (factory setting)

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

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3.3.6.3 CAN Bus Termination (Compact CAN)

Controller Switch OFF ON

Compact
7
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
8
CAN
Logic level PLC level
(factory setting)

Compact
6
EtherCAT
Logic level PLC 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

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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 5-93)
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.

Module Compact/CB
Header Connector Signal Description
Pin Pin
A13…A16** X1 | 2 +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
Table 3-48 Power supply requirements

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 pro-
tection circuit is configured inoperative within the operating range.
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The formula already takes the following into account:

• Maximum PWM duty cycle of 90%
• Controller’s max. voltage drop of 1 V @ 8 A

KNOWN VALUES:
• Operating torque M [mNm]
• Operating speed n [rpm]
• Nominal motor voltage UN [Volt]
• Motor no-load speed at UN; nO [rpm]
• Speed/torque gradient of the motor Δn/ΔM [rpm/mNm]

SOUGHT VALUE:
• Supply voltage +VCC [Volt]

SOLUTION:

UN Δn
V CC ≥ ------- ⋅  n + --------- ⋅ M ⋅ ------- + 1 [ V ]
1
nO ΔM 0.9

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 supply 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 Compact/CB
Header Connector Signal Description
Pin Pin
A17 X2 | 2 +VC Logic supply voltage (+10…+50 VDC)
A18…A22** X2 | 1 GND Ground
** Connect all pins in respect to the individual pin current rating.

Table 3-49 Logic supply – Pin assignment

Power supply requirements

Output voltage +VC 10…50 VDC
Absolute supply voltage min. 8 VDC; max. 56 VDC
Min. output power PC min. 3.5 W

Table 3-50 Logic supply requirements

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

Module Compact/CB
Header Connector Signal Description
Pin Pin
X3a | 1
A1…A4** Motor (+M) Motor +
X3b | 1
X3a | 2
A5…A8** Motor (−M) Motor −
X3b | 2
X3a | 3
– – not connected
X3b | 3
X3a | 4
– Motor shield Cable shield
X3b | 4
** Connect all pins in respect to the individual pin current rating.
Table 3-51 DC motor – Pin assignment

Module Compact/CB
Header Connector Signal Description
Pin Pin
X3a | 1
A1…A4** Motor winding 1 Winding 1
X3b | 1
X3a | 2
A5…A8** Motor winding 2 Winding 2
X3b | 2
X3a | 3
A9…A12** Motor winding 3 Winding 3
X3b | 3
X3a | 4
– Motor shield Cable shield
X3b | 4
** Connect all pins in respect to the individual pin current rating.
Table 3-52 EC motor – Pin assignment

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3.4.4 Hall Sensor

Module Compact/CB
Header Connector Signal Description
Pin Pin
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 VSensor Sensor supply voltage (+5 VDC; IL ≤100 mA)
– X4 | 6 Hall shield Cable shield

Table 3-53 Hall sensor – Pin assignment

Hall sensor
Sensor supply voltage (VSensor) +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)

Table 3-54 Hall sensor specification

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

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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 sin-
gle-ended (unsymmetrical).
• For best performance, we strongly recommend using encoders with a line driver. Otherwise, limita-
tions may apply due to slow switching edges.
• Even though 2-channel will do, we strongly recommend to use only 3-channel versions.

Module Compact/CB
Header Connector Signal Description
Pin Pin
A18…A22 X5 | 3 GND Ground
A26 X5 | 2 VSensor Sensor supply voltage (+5 VDC; IL ≤100 mA)
A27 X5 | 6 Channel A Digital incremental encoder channel A
Digital incremental encoder channel A
A28 X5 | 5 Channel A\
complement
A29 X5 | 8 Channel B Digital incremental encoder channel B
Digital incremental encoder channel B
A30 X5 | 7 Channel B\
complement
A31 X5 | 10 Channel I Digital incremental encoder channel I
Digital incremental encoder channel I
A32 X5 | 9 Channel I\
complement
Table 3-55 Encoder – Pin assignment

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Encoder (differential)
Sensor supply voltage (VSensor) +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

Table 3-56 Differential encoder specification

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

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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
Push-pull 6.25 MHz
Max. input frequency 40 kHz (internal pull-up only)
Open collector
150 kHz (additional external 3k3 pull-up)
Table 3-57 Single-ended encoder specification

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

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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 (VSensor) in parallel to the auxiliary output voltage (VAux).

3.4.6.1 Incremental Encoder

Module Compact/CB
Header Connector Signal Description
Pin Pin
B7 X6 | 1 Channel A Digital/analog incremental encoder channel A
Digital/analog incremental encoder channel A
B8 X6 | 2 Channel A\
complement
B9 X6 | 3 Channel B Digital/analog incremental encoder channel B
Digital/analog incremental encoder channel B
B10 X6 | 4 Channel B\
complement
B11 X6 | 5 Channel I Digital/analog incremental encoder channel I
Digital/analog incremental encoder channel I
B12 X6 | 6 Channel I\
complement
B15 X6 | 10 VAux Auxiliary output voltage (+5 VDC; IL ≤150 mA)
B16 X6 | 9 GND Ground
Table 3-58 Incremental encoder – Pin assignment

Digital incremental encoder (differential)

Auxiliary output voltage (VAux) +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

Table 3-59 Differential digital incremental encoder specification

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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 (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
typically 210 μA @ +5 VDC (channel A, B)
Input high current
typically 60 μA @ +5 VDC (channel I)
typically −80 μA @ 0 VDC (channel A, B)
Input low current
typically −7 μA @ 0 VDC (channel I)
Push-pull 6.25 MHz
Max. input frequency
Open collector 100 kHz (additional external 3k3 pull-up)

Table 3-60 Single-ended digital incremental encoder specification

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

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Figure 3-34 Digital incremental encoder input circuit Ch I

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Analog incremental encoder SinCos (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
Resolution 0.88 mV
Bandwidth 10 kHz

Table 3-61 Differential analog incremental encoder specification

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

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

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3.4.6.2 SSI Absolute Encoder

Module Compact/CB
Header Connector Signal Description
Pin Pin
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

Table 3-62 SSI absolute encoder – Pin assignment

SSI absolute encoder

Auxiliary output voltage (VAux) +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

Table 3-63 SSI absolute encoder specification

Figure 3-37 SSI absolute encoder data input

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Figure 3-38 SSI absolute encoder clock output

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3.4.6.3 High-speed Digital I/Os

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

Module Compact/CB
Header Connector Signal Description
Pin Pin
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
HsDigIN3 High-speed digital input 3
B11 X6 | 5
HsDigOUT1 High-speed digital output 1
HsDigIN3\ High-speed digital input 3 complement
B12 X6 | 6
HsDigOUT1\ 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 VAux Auxiliary output voltage (+5 VDC; IL ≤150 mA)
B16 X6 | 9 GND Ground
Table 3-64 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
Table 3-65 Differential high-speed digital input specification

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

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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
typically 210 μA @ +5 VDC (HsDigIN1, 2)
Input high current
typically 60 μA @ +5 VDC (HsDigIN3, 4)
typically −80 μA @ 0 VDC (HsDigIN1, 2)
Input low current
typically −7 μA @ 0 VDC (HsDigIN3, 4)
Max. input frequency 6.25 MHz

Table 3-66 Single-ended high-speed digital input specification

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

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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

Table 3-67 High-speed digital output specification

Figure 3-41 HsDigOUT1 output circuit

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3.4.7 Digital I/Os

3.4.7.1 Module

Module
Header Signal Description
Pin
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
Table 3-68 Digital I/Os – Pin assignment – Module

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
Table 3-69 Digital input specification

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
Pin
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)

Table 3-70 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

Table 3-71 Digital input specification – Logic level setting

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

Continued on next page.

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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
>2 mA @ 9 VDC
Input current at logic 1
typically 3.5 mA @ 24 VDC
Switching delay <300 μs @ 24 VDC

Table 3-72 Digital input specification – PLC level setting

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

For pin assignment of digital outputs Table 3-68 and Table 3-70.

Digital outputs 1…2

Open drain (internal pull-up resistor 2k2 and diode
Circuit
to +5.45 VDC
Table 3-73 Digital output specification

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
Table 3-74 Digital output – Sinks

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

DigOUT “source”
Output voltage UOut = 5.45 V − 0.75 V − (ILoad x 2200 Ω)
Max. load current ILoad ≤2 mA

Table 3-75 Digital output – Source

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

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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 see separate document «EPOS4 Application Notes».

Non-certified STO functionality

The implemented STO functionality will not be certified.

Activation of power stage

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

Module Compact/CB
Header Connector Signal Description
Pin Pin
Activation voltage for STO inputs (+5 VDC)
– X9 | 8 VSTO 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 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 3-76 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
>2 mA @ 5 VDC
Input current at logic 1
typically 3.2 mA @ 24 VDC
Reaction time <25 ms
Table 3-77 STO input specification

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

Safe Torque Off output

Optically isolated output with self-resetting short-
Circuit type
circuit protection
Max. input voltage ±30 VDC
Max. load current 15 mA
Leakage current <10 μA @ +30 VDC
1.3 V @ 2 mA
Max. voltage drop
2.5 V @ 15 mA

Table 3-78 STO output specification

Figure 3-49 STO-OUT circuit

STO Logic State

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 3-79 STO logic state

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3.4.9 Analog I/Os

Module Compact/CB
Header Connector Signal Description
Pin Pin
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 3-80 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)
80 kΩ (differential)
Input resistance
65 kΩ (referenced to GND)
A/D converter 12-bit
Resolution 5.64 mV
Bandwidth 10 kHz
Table 3-81 Analog input specification

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

Table 3-82 Analog output specification

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 non-
return-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 Signal Description
Pin
B38 GND Ground
B39 [e] DSP_RxD Serial communication interface receive (UART)
B40 DSP_TxD Serial communication interface transmit (UART)
[e] connect to sensor supply voltage VSensor (A26) when RS232 is not in use

Table 3-83 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
Series resistance (both lines) 10 kΩ
Max. bit rate 115’200 bit/s
Data format NRZ (non-return-to-zero)
Table 3-84 SCI specification

Figure 3-52 SCI circuit

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3.4.10.2 Compact CAN

Compact/CB
Connector Signal Description
Pin
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 3-85 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

Table 3-86 RS232 interface specification

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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 Compact/CB
Header Connector Signal Description
Pin Pin
X11 | 1
B35 CAN high CAN high bus line
X12 | 1
X11 | 2
B36 CAN low CAN low bus line
X12 | 2
X11 | 3
B37 GND Ground
X12 | 3
X11 | 4
– Shield Cable shield
X12 | 4
Table 3-87 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
Module By external wiring or software
Node-ID setting
Compact CAN By DIP switch or software
Table 3-88 CAN interface specification

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 ver-
sions, automatic bit rate detection is set.
• Use 120 Ω termination resistor at both ends of the CAN bus.
• For detailed CAN information see 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 3-43.
• 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
Pin
B29 ID 1 CAN ID / DEV ID 1 20 1
B30 ID 2 CAN ID / DEV ID 2 2 1 2
B31 ID 3 CAN ID / DEV ID 3 2 2 4
B32 ID 4 CAN ID / DEV ID 4 23 8
B33 ID 5 CAN ID / DEV ID 5 2 4 16
B37 GND Ground

Table 3-89 ID – Pin assignment

CAN ID / DEV ID
Max. input voltage 3.3 VDC
Logic 1 connected to GND
Logic 0 not connected

Table 3-90 CAN ID / DEV ID specification

Important
The internal circuit of the ID pins (B29…B33) is based on an analog voltage measurement. Ensure a proper
ground connection (0.0 V) when Logic 1 state is intended and a high impedance for Logic 0 state.

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

CAN ID / DEV ID
ID
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* = ID input line not connected 1** = ID input line externally connected to GND

Table 3-91 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).

CAN AUTOMATIC BIT RATE DETECTION

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

Bit rate detection

Auto Bit Rate Pin B34
GND Pin B38
Max. input voltage 3.3 VDC
Logic 1 connected to GND
Logic 0 not connected

Table 3-92 Bit rate detection specification

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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!

Module
Header Signal Description
Pin
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 3-93 SPI – Pin assignment

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3.4.13 USB (X13)

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 poten-
tial 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, bal-
ance them.
• Insert the USB connector first, then switch on the power supply of the controller.

Figure 3-53 USB connector X13

Compact
PC’s USB
Connector Signal Description
Terminal
Pin
X13 | 1 1 VBUS 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 3-94 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 3-95 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
Table 3-96 USB interface specification

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Status Indicators

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 see separate document «EPOS4 Firmware Specification».

Figure 3-54 LEDs – Location

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3.5.1 NET Status

The LEDs (Figure 3-54; 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
An application watchdog timeout has occurred
— Double flash
Example: Timeout of Sync Manager Watchdog
EPOS4 has changed the COM state due to an internal error
— Single flash
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 3-97 NET Status LEDs

3.5.2 Device Status

The LEDs (Figure 3-54; 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…
• “Switch ON Disabled”
Slow OFF
• “Ready to Switch ON”
• “Switched ON”
Power stage is enabled. The EPOS4 is in status…
ON OFF • “Operation Enable”
• “Quick Stop Active”
FAULT state. The EPOS4 is in status…
OFF ON
• “Fault”
Power stage is enabled. The EPOS4 is in temporary status…
ON ON
• “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 3-98 Device Status LEDs

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3.5.3 EtherCAT Port

The LED (Figure 3-54; 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 3-99 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 sup-
port for this point.
maxon will be happy to provide you with a quote for designing and manufacturing a motherboard for your
specific application.

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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 4-100.

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 4-55 Wiring of power supply

INPUT 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.

TVS DIODE (D1)

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

CAPACITOR (C1)
The function of the Module does not necessarily require the use of an external capacitor. Nevertheless, to
further reduce voltage ripple or to buffer feedback currents (typically present during motor deceleration), 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 by the Module’s built-in
capacitors that could lead to a voltage overshoot at power plug-in.

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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 4-56 Wiring of logic supply

TVS DIODE (D2)

If the logic supply voltage is sourced separately, a transient voltage suppressor diode (D2) at the logic sup-
ply 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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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:

V CC
L Phase ≥ --- ⋅  ----------------------------- – ( 0.3 ⋅ L Motor )
1
2 6 ⋅ f PWM ⋅ I N

L Phase [ H ] Additional external inductance per phase

V CC [ V ] Operating voltage +VCC

f PWM [ Hz ] Switching frequency of the power stage = 50’000 Hz

IN [ A ] Nominal current of the motor (line 6 in the maxon catalog)

L Motor [ H ] 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 electromag-
netic 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.maxongroup.com.
Example 1

Continued on next page.

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Example 2

Figure 4-57 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 4-58 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] (sen-
sor supply voltage VSensor )!

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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 = Icont / 4, contact material: gold

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
• E-Tec (BL2-032-S842-55) THT, 3 A per pin, 8.50 mm
Socket header
• 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
• Littelfuse 456 series, SMD NANO2 Fuse 20 A, 18 A2sec (0456 020)
(FU1)

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

TVS Diode
• Fairchild (SMBJ54A) UR = 54 V, UBR = 60.0…66.6 V @ 1 mA, UC = 87.1 V @ 6.9 A
(D1; D2)
• Littelfuse (SMBJ54A) UR = 54 V, UBR = 60.0…66.6 V @ 1 mA, UC = 87.1 V @ 6.9 A

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 Icont / 2. Use capacitors with rated voltage
≥ 63 V and adequate ripple current to avoid overheat or life time reduction.
Remark: If there is an excessive amount of reversed energy present (for example during deceleration of
Capacitor loads with a high inertia or during a vertical movement downwards), there might be the need to add an
(C1) additional capacitor with a much higher capacitance (for example up to 10'000…47'000 μF) and/or to add a
brake chopper, for example maxon DSR 70/30 (235811).
Example for C1 worst-case dimensioning:
Icont = 12 A  3x Panasonic (EEU-FR1J391); 390 μF, 63 V, 2000 mA r.m.s., ØxL 12.5 x 25 mm

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.
Capacitor
• Rubicon (63ZLH47MEFCTA6.3X11) or (63YXJ47M6.3X11)
(C2)
• Panasonic (EEU-FR1J470B)
• Nippon Chemicon (EKYB630ELL330MF11D) or (EKY-630 ELL330MF11D)

Inductance: “Motor Cables and Motor Chokes” on page 4-86

Rated current: Irms ≥ Icont; Isat ≥ Ipeak
Construction: shielded
2.2 μH:
Motor Choke • Bourns (SRP1265A-2R2M) Irms 22 A, Isat 37 A, 12.5 x 13.5 x 6.4 mm
(L)
• Vishay (IHLP5050FDER2R2M01) Irms 22 A, Isat 40 A, 12.9 x 13.2 x 6.5 mm
• Laird (MGV12072R2M-10) Irms 22 A, Isat 40 A, 12.6 x 13.5 x 6.5 mm

22 μH:
• Würth (WE-PD-XXL / 7447709220) Irms 5.3 A, Isat 6.5 A, 12.5 x 12.5 x 10 mm

Continued on next page.

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 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
Motor Filter
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)

RS232 • Texas Instruments (MAX202IPW)
(IC1) • ST Microelectronics (ST202EBTR)
(C3…C7) Capacitors (C3…C7)
• 100 nF, X7R, 16 V

Table 4-100 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 mother-
board 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 custom-
ary to equip the motherboard with a ground plane. All ground connections should be connected to the volt-
age supply ground via wide conductive tracks.

Pin Signal Description

A18…A22 GND Ground
B16 GND Ground
B37…B38 GND Ground

Table 4-101 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 +VCC (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; VSensor) when
RS232 is not in use.
• The width of the conductive tracks and the copper coating thickness of the conductors for supply
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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 Motherboard Design Guide
THT Footprint

4.3 THT Footprint

Possible dimensional differences in STEP files
For conversion reasons, the below stated dimensions may slightly differ from the dimensions specified in
the downloadable STEP file. Use only the below stated dimensions for your design.

Figure 4-59 THT footprint [mm] – Top View

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Motherboard Design Guide
THT Footprint

••page intentionally left blank••

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 Wiring

5 WIRING
In this section you will find the wiring information for the setup you are using. You can either use the consol-
idated wiring diagrams (Figure 5-61 and Figure 5-62) 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 5-60 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 5-102, for EC (BLDC) motor Table 5-103.
4) Pick the row with the corresponding wiring method # and follow the link (or links) to the stated fig-
ure(s) to find the relevant wiring information.

5.1.1 DC Motor
Power supply & optional logic supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-63

Motor & feedback signals

Without sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # DC1
Digital incremental encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # DC2 or DC3
Analog incremental encoder SinCos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # DC4
SSI absolute encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # DC5
Digital incremental encoder & Digital incremental encoder . . . . . . . . . . . . . . . . . . . . . . . . Method # DC6
Digital incremental encoder & Analog incremental encoder SinCos . . . . . . . . . . . . . . . . . Method # DC7
Digital incremental encoder & SSI absolute encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # DC8

Digital Digital Analog SSI

Incremental Incremental Incremental Absolute
Method Encoder 1 Encoder 2 Encoder Encoder 
# (Sensor 1) (Sensor 2) (Sensor 2) (Sensor 2) Figure(s)

X5 X6 X6 X6

DC1 5-64

5-64
DC2 
5-67
5-64
DC3 
5-68
5-64
DC4 
5-69
5-64
DC5 
5-70
5-64
DC6  
5-67 / 5-68
5-64
DC7  
5-67 / 5-69
5-64
DC8  
5-67 / 5-70

Table 5-102 Possible combinations of feedback signals for DC motor

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 Wiring
Possible Combinations to connect a Motor

5.1.2 EC (BLDC) Motor

Power supply & optional logic supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-63

Motor & feedback signals

Hall sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # EC1
Hall sensors & Digital incremental encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # EC2 or EC3
Hall sensors & Analog incremental encoder SinCos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 SinCos . . . . . Method # EC7
Hall sensors & Digital encoder & SSI absolute encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . Method # EC8
Digital incremental encoder & SSI absolute encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # EC9
SSI absolute encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method # EC10

Digital Digital Analog SSI

Hall
Incremental Incremental Incremental Absolute
Method sensors 
Encoder 1 Encoder 2 Encoder Encoder
# (Sensor 3) Figure(s)
(Sensor 1) (Sensor 2) (Sensor 2) (Sensor 2)
X4 X5 X6 X6 X6
5-65
EC1 
5-66
5-65
EC2  
5-66 / 5-67
5-65
EC3  
5-66 / 5-68
5-65
EC4  
5-66 / 5-69
5-65
EC5  
5-66 / 5-70
5-65
EC6   
5-66 / 5-67 /5-68
5-65
EC7   
5-66 / 5-67 / 5-69
5-65
EC8   
5-66 / 5-67 / 5-70
5-65
EC9  
5-67 / 5-70
5-65
EC10 
5-70
Table 5-103 Possible combinations of feedback signals for EC (BLDC) motor

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Wiring
Main Wiring Diagrams

5.2 Main Wiring Diagrams

5.2.1 Module & Compact CAN

Figure 5-68
Figure 5-69
Figure 5-70

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

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 Wiring
Main Wiring Diagrams

5.2.2 Module & Compact EtherCAT

Figure 5-68
Figure 5-69
Figure 5-70

Figure 5-62 Main wiring diagram – Module & Compact EtherCAT

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Wiring
Excerpts

5.3 Excerpts

5.3.1 Power & Logic Supply

Figure 5-63 Power & logic supply

5.3.2 DC Motor

Figure 5-64 DC motor

5.3.3 EC (BLDC) Motor

Figure 5-65 EC (BLDC) motor

5.3.4 Hall Sensors (Sensor 3)

Figure 5-66 Hall sensors (Sensor 3)

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Excerpts

5.3.5 Digital Incremental Encoder 1 (Sensor 1)

Figure 5-67 Digital incremental encoder 1 (Sensor 1)

5.3.6 Digital Incremental Encoder 2 (Sensor 2)

Figure 5-68 Digital incremental encoder 2 (Sensor 2)

5.3.7 Analog incremental encoder SinCos (Sensor 2)

Figure 5-69 Analog incremental encoder (Sensor 2)

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Wiring
Excerpts

5.3.8 SSI Encoder (Sensor 2)

Figure 5-70 SSI encoder (Sensor 2)

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 List of Figures

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 3-22 Analog I/O connector X8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 3-23 STO connector X9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 3-24 RS232 connector X10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 3-25 CAN 1 connector X11/CAN 2 connector X12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 3-26 EtherCAT IN & EtherCAT OUT connectors X14 & X15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 3-27 DIP switch SW1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 3-28 Hall sensor 1 input circuit (analogously valid for Hall sensors 2 & 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 3-29 Encoder input circuit Ch A “differential” (analogously valid for Ch B & Ch I). . . . . . . . . . . . . . . . . . . . . . . . . . 51
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

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List of Figures

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

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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
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 SCI circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 3-53 USB connector X13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 3-54 LEDs – Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 4-55 Wiring of power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 4-56 Wiring of logic supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 4-57 Wiring of motor winding 1 (analogously valid also for motor windings 2 & 3). . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 4-58 Wiring of RS232 transceiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 4-59 THT footprint [mm] – Top View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 5-60 Interfaces – Designations and location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 5-61 Main wiring diagram – Module & Compact CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 5-62 Main wiring diagram – Module & Compact EtherCAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 5-63 Power & logic supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Figure 5-64 DC motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Figure 5-65 EC (BLDC) motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Figure 5-66 Hall sensors (Sensor 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Figure 5-67 Digital incremental encoder 1 (Sensor 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Figure 5-68 Digital incremental encoder 2 (Sensor 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Figure 5-69 Analog incremental encoder (Sensor 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Figure 5-70 SSI encoder (Sensor 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

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LIST OF TABLES

Table 1-1 Notation used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Table 1-2 Symbols and signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 1-3 Brand names and trademark owners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table 1-4 Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Table 2-5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Table 2-6 Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Table 2-7 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Table 3-8 Pin assignment A1…A32 (X1…X5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Table 3-9 Pin assignment B1…B46 (X6…X12). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Table 3-10 Prefab maxon cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Table 3-11 EPOS4 Connector Set – Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table 3-12 Recommended tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table 3-13 Power supply connector X1 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Table 3-14 Power Cable High Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Table 3-15 Logic supply connector X2 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Table 3-16 Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Table 3-17 Motor connector X3a / X3b – Pin assignment for maxon DC motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Table 3-18 Motor connector X3a / X3b – Pin assignment for maxon EC motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Table 3-19 Motor Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Table 3-20 Motor Cable High Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Table 3-21 Hall sensor connector X4 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Table 3-22 Hall Sensor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Table 3-23 Encoder connector X5 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Table 3-24 Encoder connector X5 – Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Table 3-25 Encoder Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Table 3-26 Sensor connector X6 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Table 3-27 Sensor Cable 5x2core. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Table 3-28 Digital I/O connector X7 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Table 3-29 Signal Cable 8core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Table 3-30 Analog I/O connector X8 – Pin assignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Table 3-31 Signal Cable 7core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Table 3-32 STO connector X9 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Table 3-33 STO Idle Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Table 3-34 RS232 connector X10 – Pin assignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Table 3-35 RS232-COM Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Table 3-36 CAN 1 connector X11/CAN 2 connector X12 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Table 3-37 CAN-COM Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Table 3-38 CAN-CAN Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Table 3-39 EtherCAT IN & EtherCAT OUT connectors X14 & X15 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Table 3-40 Ethernet Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Table 3-41 DIP switch SW1 – Binary code values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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Table 3-42 DIP switch SW1 – Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Table 3-43 DIP switch SW1 – CAN automatic bit rate detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Table 3-44 DIP switch SW1 – CAN bus termination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Table 3-45 DIP switch SW1 – Digital input level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Table 3-46 Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Table 3-47 Power supply – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Table 3-48 Power supply requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Table 3-49 Logic supply – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Table 3-50 Logic supply requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Table 3-51 DC motor – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Table 3-52 EC motor – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Table 3-53 Hall sensor – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Table 3-54 Hall sensor specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Table 3-55 Encoder – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Table 3-56 Differential encoder specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Table 3-57 Single-ended encoder specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Table 3-58 Incremental encoder – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Table 3-59 Differential digital incremental encoder specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Table 3-60 Single-ended digital incremental encoder specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Table 3-61 Differential analog incremental encoder specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Table 3-62 SSI absolute encoder – Pin assignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Table 3-63 SSI absolute encoder specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Table 3-64 High-speed digital I/Os – Pin assignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Table 3-65 Differential high-speed digital input specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Table 3-66 Single-ended high-speed digital input specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Table 3-67 High-speed digital output specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Table 3-68 Digital I/Os – Pin assignment – Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Table 3-69 Digital input specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Table 3-70 Digital I/Os – Pin assignment – Compact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Table 3-71 Digital input specification – Logic level setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Table 3-72 Digital input specification – PLC level setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Table 3-73 Digital output specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Table 3-74 Digital output – Sinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Table 3-75 Digital output – Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Table 3-76 STO I/Os – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Table 3-77 STO input specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Table 3-78 STO output specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Table 3-79 STO logic state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Table 3-80 Analog I/Os – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Table 3-81 Analog input specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Table 3-82 Analog output specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Table 3-83 SCI – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Table 3-84 SCI specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Table 3-85 RS232 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

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Table 3-86 RS232 interface specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Table 3-87 CAN bus line / CAN 1 / CAN 2 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Table 3-88 CAN interface specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Table 3-89 ID – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Table 3-90 CAN ID / DEV ID specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Table 3-91 ID – Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Table 3-92 Bit rate detection specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Table 3-93 SPI – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Table 3-94 USB connector X13 – Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Table 3-95 USB Type A - micro B Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Table 3-96 USB interface specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Table 3-97 NET Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Table 3-98 Device Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Table 3-99 EtherCAT Port LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Table 4-100 Motherboard Design Guide – Recommended components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Table 4-101 Motherboard Design Guide – Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Table 5-102 Possible combinations of feedback signals for DC motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Table 5-103 Possible combinations of feedback signals for EC (BLDC) motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

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List of Tables

••page intentionally left blank••

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 Index

INDEX

X10 39
A X11 40
abbreviations used 9 X12 40
alerts 6 X13 78
X14 41
analog incremental encoder (differential) 57
X15 41
analog inputs 70
country-specific regulations 10
analog outputs 71
applicable EU directive 21
applicable regulations 10
D
D1 (DVS diode) 84
B D2 (DVS diode) 85
DC motor, connection 22, 48
BiSS encoder, wiring 100
DEV ID (see “ID”)
bit rate detection 44, 76
device condition, display of 79
bit rate, default 74
digital high-speed inputs (differential) 61
BLDC motor, connection 22, 48
digital high-speed inputs (single-ended) 62
digital high-speed output 63
C digital incremental encoder (differential) 53
C1 (capacitor) 84 digital incremental encoder (single-ended) 55
C2 (capacitor) 85 digital inputs 64
cables (prefab) digital outputs 66
CAN-CAN Cable 40 DIP switch SW1 43
CAN-COM Cable 40
Encoder Cable 34
Ethernet Cable 42
E
Hall Sensor Cable 33 EC motor, connection 22, 48
Motor Cable 32 encoders
Motor Cable High Current 32 absolute 59
Power Cable 30 differential 51
Power Cable High Current 29 incremental 53
RS232-COM Cable 39 serial 59
Sensor Cable 5x2core 36 SinCos 57
Signal Cable 7core 37 single-ended 52
Signal Cable 8core 36 EnDat encoder, wiring 100
STO Idle Connector 38 EPOS4 Connector Set 27
USB Type A - micro B Cable 78 ESD 10
CAN bus termination 45, 74 EU directive, applicable 21
CAN ID (see “ID”)
CAN interface 74 F
choke, motor 86
FU1 (input fuse) 84
connectors
X1 29
X2 30 H
X3a 31 Hall sensor 49
X3b 31 how to
X4 33 calculate the required supply voltage 46
X5 34 get help in designing the motherboard 83
X6 35 interpret icons (and signs) used in this document 6
X7 36
X8 37
X9 38

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Index

I P
ID (of the device) 43 part numbers
incorporation into surrounding system 21 275829 30
incremental encoder 53 275851 32
informatory signs 6 275878 33
inputs 275934 34
analog 70 403968 78
digital 64 422827 42
high-speed digital 61 504384 8
STO 68 520850 29
520851 32
interfaces
520852 36
CAN 40, 74
520853 36
EtherCAT 41
520854 37
location and designation 93
520856 39
RS232 39, 72
520857 40
SCI 72
520858 40
SPI 77
520859 27
USB 78
520860 38
internal motor chokes 86
520884 8, 25
520885 8, 25
L 604594 8, 25
LEDs, interpretation of 79 605298 8, 25
logic supply 47 performance data 11
pin assignment 22
M power supply 46
mandatory action signs 6 precautions 10
motor choke 86 prerequisites prior installation 21
motor types, supported 8 prohibitive signs 6
protective measures (ESD) 10
N purpose
of the device 8
naming of components 9 of the document 5
node address (see “ID”)
Node-ID (see “ID”) R
notations used 6
regulations, applicable 10
RS232 transceiver 87
O
operating license 21 S
outputs
Safe Torque Off (STO) 68
analog 71
digital 66 safety alerts 6
high-speed digital 63 safety first! 10
STO 69 SCI (Serial Communication Interface) 72
Serial Communication Interface (SCI) 72
serial encoder 59
signs used 6
SPI (Serial Peripheral Interface) 77
SSI absolute encoder 59
SSI encoder, wiring 100
standards, fulfilled 19
status LEDs 79
STO (Safe Torque Off) 68
supply voltage, required 46
SW1 43
symbols used 6

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 Index

T
technical data 11
termination (CAN bus) 45, 74

U
USB port 78

W
wiring examples
additional inductance on Motherboard 86
analog incremental encoder 99
DC motor 98
digital & digital incremental encoder 99
digital incremental encoder 99
DigOUT 67
EC (BLDC) motor 98
Hall sensors 98
power & logic supply 98
SSI encoder 100

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