About About this Document ABOUT About this Document 1.1.1 Intended Purpose The purpose of the present document is to familiarize you with the EPOS4 70/15 positioning controller. It docu- will highlight the tasks for safe and adequate installation and/or commissioning. Follow the described ment to…...
About About this Document 1.1.3 How to use Throughout the document, the following notations and codes will be used. Notation Meaning 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...
– 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) •...
Specifications Technical Data SPECIFICATIONS Technical Data EPOS4 70/15 (594385) Nominal power supply voltage +V 10…70 VDC Nominal logic supply voltage +V 10…70 VDC Absolute supply voltage +V / +V 8 VDC / 75 VDC Output voltage (max.) 0.9 x +V Output current I (<60 s) 15 A / 30 A...
Specifications Thermal Data Thermal Data 2.2.1 Derating of Output Current Figure 2-2 Derating of output current EPOS4 70/15 Hardware Reference 2-11 CCMC | 2019-11 | rel8611...
Specifications Limitations 2.2.2 Power Dissipation and Efficiency Figure 2-3 Power dissipation and efficiency Limitations Protection functionality Switch-off threshold Recovery threshold Undervoltage 8.0 V 8.5 V Overvoltage 78 V 75 V Overcurrent 40 A — Thermal overload 95 °C 85 °C Table 2-5 Limitations EPOS4 70/15 Hardware Reference...
Specifications Standards 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.
Setup Generally applicable Rules SETUP IMPORTANT NOTICE: PREREQUISITES FOR PERMISSION TO COMMENCE INSTALLATION The EPOS4 70/15 positioning controller is considered as partly completed machinery according to EU Directive 2006/42/EC, Article 2, Clause (g) and is intended to be incorporated into or assembled with other machinery or other partly completed machinery or equipment.
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.
Setup Cabling 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...
In the later course of the document you will find tables containing information on the EPOS4’s hardware connectors, their wired signals and assigned pins as well as details on the available prefab cables. • The first column describes both the pin number of the connector and of the matching prefab maxon cable’s Head A.
Setup Connections 3.3.1 Power Supply (X1) Basically, any power supply may be used provided that it meets the stated minimum requirements. Best practice Keep the motor mechanically disconnected during the setup and adjustment phase. Figure 3-6 Power supply connector X1 Prefab Head B Head A...
Page 20
Setup Connections Use the formula below to calculate the required voltage under load. Choose a power supply according to the calculated voltage. Thereby consider: During braking of the load, the power supply must be capable of buffering the recovered kinetic energy (for example, in a capacitor). If you are using an electronically stabilized power supply, make sure that the overcurrent pro- tection circuit is configured inoperative within the operating range.
Setup Connections 3.3.2 Logic Supply (X2) 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 requirement: If not supplied separately, the logic supply is internally connected to the power supply. Figure 3-7 Logic supply connector X2 Prefab...
Connections 3.3.3 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: ≤...
Setup Connections Motor Cable for X3a (275851) Cross-section 3 x 0.75 mm , shielded, grey Length Plug Molex Mini-Fit Jr., 4 poles (39-01-2040) Head A Contacts Molex Mini-Fit Jr. female crimp terminals (45750) Head B Wire end sleeves 0.75 mm Table 3-18 Motor Cable Motor Cable High Current for X3b (520851)
Setup Connections 3.3.4 Hall Sensor (X4) Suitable Hall effect sensors IC use «Schmitt trigger» with open collector output. Figure 3-9 Hall sensor connector X4 Prefab Head B Head A Cable Signal Description Color green Hall sensor 1 Hall sensor 1 input brown Hall sensor 2 Hall sensor 2 input...
Setup Connections Hall sensor Sensor supply voltage (V +5 VDC Sensor 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 2.7 kΩ...
Setup Connections 3.3.5 Encoder (X5) 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.
Setup Connections Encoder Cable (275934) Cross-section 10 x AWG28, round-jacket, twisted pair flat cable, pitch 1.27 mm, grey Length 3.2 m Head A DIN 41651 female, pitch 2.54 mm, 10 poles, with strain relief Head B DIN 41651 plug, pitch 2.54 mm, 10 poles, with strain relief Table 3-25 Encoder Cable Encoder (differential)
Setup Connections Encoder (single-ended) Sensor supply voltage (V +5 VDC Sensor 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 = typically +250 μA @ 5 V Input high current = typically −330 μA @ 0 V Input low current...
Setup Connections 3.3.6 Sensor (X6) Additional sensors, both incremental and serial encoders, can be connected. Check on the applied sensor’s data sheet If the specified inrush current or the maximum continuous current of the sensor should exceed 150 mA, you can connect the sensor supply voltage (V ) in parallel to the auxiliary output voltage (V Sensor...
Setup Connections Sensor Cable 5x2core (520852) Cross-section 5 x 2 x 0.14 mm , twisted pair, grey Length Plug Molex CLIK-Mate, dual row, 10 poles (503149-1000) Head A Contacts Molex CLIK-Mate crimp terminals (502579) Head B Wire end sleeves 0.14 mm Table 3-29 Sensor Cable 5x2core 3.3.6.1...
Setup Connections Figure 3-16 Digital incremental encoder input circuit Ch I Continued on next page. EPOS4 70/15 Hardware Reference 3-31 CCMC | 2019-11 | rel8611...
Setup Connections Digital incremental encoder (single-ended) Auxiliary output voltage (V +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)
Setup Connections Figure 3-18 Digital incremental encoder input circuit Ch I Continued on next page. EPOS4 70/15 Hardware Reference 3-33 CCMC | 2019-11 | rel8611...
Setup Connections Analog incremental encoder SinCos (differential) Auxiliary output voltage (V +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...
Setup Connections 3.3.6.2 SSI Absolute Encoder SSI absolute encoder Auxiliary output voltage (V +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...
Setup Connections 3.3.6.3 High-speed Digital I/Os Alternatively, the sensor interface can be used for high-speed digital I/O operation. 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.
Setup Connections 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 3-36 High-speed digital output specification Figure 3-25 HsDigOUT1 output circuit EPOS4 70/15 Hardware Reference 3-39...
Setup Connections 3.3.7 Digital I/O (X7) Figure 3-26 Digital I/O connector X7 Prefab Head B Head A Cable Signal Description Color white DigIN1 Digital input 1 brown DigIN2 Digital input 2 green DigIN3 Digital input 3 yellow DigIN4 Digital input 4 grey DigOUT1 Digital output 1...
Setup Connections Digital outputs 1…2 Open drain (internal pull-up resistor 2k2 and diode Circuit to +5.45 VDC Table 3-41 Digital output specification Figure 3-29 DigOUT1 circuit (analogously valid for DigOUT2) Continued on next page. EPOS4 70/15 Hardware Reference 3-42 CCMC | 2019-11 | rel8611...
Setup Connections 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 3-42 Digital output – Sinks Figure 3-30 DigOUT1 “sinks”...
Setup Connections 3.3.8 Analog I/O (X8) Figure 3-32 Analog I/O connector X8 Prefab Head B Head A Cable Signal Description Color white AnIN1+ Analog input 1, positive signal brown AnIN1− Analog input 1, negative signal green AnIN2+ Analog input 2, positive signal yellow AnIN2−...
Setup Connections 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.
Setup Connections 3.3.9 STO (X9) The STO (Safe Torque Off) function can be utilized to bring the drive to a torque-free, safe condition via two independent inputs. The drive output power stage is switched off if either one of the inputs is not powered. For in-depth details on the STO functionality separate document «EPOS4 Application Notes».
Setup Connections 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 3-50...
Setup Connections STO Logic State STO-IN1 STO-IN2 STO-OUT Power Stage open inactive closed inactive closed inactive closed active Table 3-52 STO logic state EPOS4 70/15 Hardware Reference 3-49 CCMC | 2019-11 | rel8611...
Setup Connections 3.3.10 RS232 (X10) Figure 3-38 RS232 connector X10 Prefab Head B Head A Cable Signal Description Color white EPOS_RxD EPOS RS232 receive brown Ground green EPOS_TxD EPOS RS232 transmit yellow Ground Shield Housing Shield Cable shield Table 3-53 RS232 connector X10 –...
Setup Connections 3.3.11 CAN 1 (X11) & CAN 2 (X12) 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.
Setup Connections CAN-CAN Cable (520858) Cross-section 2 x 2 x 0.14 mm , twisted pair, shielded Length 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)
Setup Connections 3.3.12 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. •...
Even though both NET 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 IN (X14) as «Input».
Setup Connections 3.3.14 Extension Signal (X16) The connector provides direct access to the signal extension slot EXT2 (chapter “3.3.15 Extension Slots (EXT1 & EXT2)” on page 3-57) thus allowing the use of signal extension cards (such as for additional abso- lute sensors or customized signal extensions).
Setup Connections 3.3.15 Extension Slots (EXT1 & EXT2) The controller provides two extension slots (Figure 3-43) located underneath the plastic lid at the control- ler housing’s top face. They host optionally available extension cards (Table 3-66) and thereby expand the controller’s comprehensive motion control functionality even further. •...
Setup Connections Switch off the controller’s power supply. Comply with ESD protective measures. Open plastic lid Unlock the two latches (A) on the plastic lid. Lift the plastic lid upward (B) and remove. Remove extension card, if necessary Turn the plastic lid over and look for the molded catch in one of its corners.
Setup Connections Extension Cards Slot Description Part number EXT1 EPOS4 EtherCAT Card 581245 EXT2 — — Table 3-66 Extension cards (optional) 3.3.16 DIP Switch Configuration (SW1) Figure 3-45 DIP switch SW1 3.3.16.1 CAN ID (Node-ID) / DEV ID NOTE: 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.
Setup Connections The set ID can be observed by adding the valence of all activated switches. Use the following table as a (non-concluding) guide: Switch Setting – 0 = Switch “OFF” 1 = Switch “ON” Table 3-68 DIP switch SW1 – Examples 3.3.16.2 CAN automatic Bit Rate Detection Switch...
Setup Connections 3.3.16.4 Digital Input Level For details chapter “3.3.7 Digital I/O (X7)” on page 3-40. Switch Logic level PLC level (factory setting) Table 3-71 DIP switch SW1 – Digital input level 3.3.17 Spare Parts Order number Description 520860 STO Idle Connector X9 Table 3-72 Spare parts list EPOS4 70/15 Hardware Reference...
Setup Status Indicators Status Indicators The EPOS4 features three sets of LED indicators to display the device condition. NET Status; the LEDs display communication RUN states and errors conditions Device Status; the LEDs display the device’s operation status and error conditions NET Port;...
Setup Status Indicators 3.4.2 Device Status The LEDs (Figure 3-46; B) display the actual status and possible errors of the EPOS4: • Green LED shows the status • Red LED indicates errors Description Green Power stage is disabled. The EPOS4 is in status… •...
Page 64
Setup Status Indicators • • p a g e i n t e n t i o n a l l y l e f t b l a n k • • EPOS4 70/15 Hardware Reference 3-64 CCMC | 2019-11 | rel8611...
Wiring WIRING In this section you will find the wiring information for the setup you are using. You can either use the consol- idated wiring diagram (Figure 4-48) 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.
Wiring Possible Combinations to connect a Motor Possible Combinations to connect a Motor The following tables show feasible ways on how to connect the motor with its respective feedback sig- nals or possible combinations thereof. To find the wiring that best suits your setup, proceed as follows: Decide on the type of motor you are using;...
Page 72
Wiring Excerpts • • p a g e i n t e n t i o n a l l y l e f t b l a n k • • EPOS4 70/15 Hardware Reference 4-72 CCMC | 2019-11 | rel8611...
Page 73
List of Figures LIST OF FIGURES Figure 1-1 Documentation structure ..............5 Figure 2-2 Derating of output current .
Page 74
List of Figures Figure 3-42 Extension Signal connector X16............56 Figure 3-43 Extension slots .
Page 75
Motor connector X3a / X3b – Pin assignment for maxon DC motor ......
Page 76
List of Tables Table 3-42 Digital output – Sinks ..............43 Table 3-43 Digital output –...
Page 77
Index INDEX X7 40 X8 44 X9 47 alerts 6 country-specific regulations 8 analog incremental encoder (differential) 34 analog inputs 45 analog outputs 46 applicable EU directive 15 DEV ID (see “ID”) applicable regulations 8 device condition, display of 62 digital high-speed inputs (differential) 37 digital high-speed inputs (single-ended) 38 digital high-speed output 39...
Page 78
Index ID (of the device) 59 part numbers 275829 21 incorporation into surrounding system 15 275851 23 informatory signs 6 275878 24 inputs 275934 27 analog 45 403968 53 high-speed digital 37 422827 55 STO 48 520850 19 interfaces 520851 23 CAN 51 520852 30 location and designation 65...
Page 79
Index USB port 53 wiring examples analog incremental encoder 70 DC motor 69 digital & digital incremental encoder 70 digital incremental encoder 70 DigOUT 43 EC (BLDC) motor 69 Hall sensors 69 power & logic supply 69 SSI encoder 71 EPOS4 70/15 Hardware Reference Z-79 CCMC | 2019-11 | rel8611...
Need help?
Do you have a question about the EPOS4 70/115 and is the answer not in the manual?
Questions and answers