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Maxon EPOS4 Disk 60/8 Hardware Reference Manual

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Hardware Reference
EPOS4 Disk 60/8 Positioning Controller | P/Ns 688770 / 688772
Hardware Reference
CCMC | Edition 2021-10 | DocID rel10276

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  • Page 1 Hardware Reference EPOS4 Disk 60/8 Positioning Controller | P/Ns 688770 / 688772 Hardware Reference CCMC | Edition 2021-10 | DocID rel10276...

  • Page 2: Table Of Contents

    • you must follow the instructions given therein. The EPOS4 Disk 60/8 positioning controllers are considered as partly completed machinery according to EU Directive 2006/ 42/EC, Article 2, Clause (g) and are intended to be incorporated into or assembled with other machinery or other partly completed machinery or equipment.
  • Page 3 Excerpts............56 LIST OF FIGURES LIST OF TABLES INDEX EPOS4 Disk 60/8 Hardware Reference CCMC | 2021-10 | rel10276...
  • Page 4 • • 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 Disk 60/8 Hardware Reference CCMC | 2021-10 | rel10276...

  • Page 5: About

    About this Document 1.1.1 Intended Purpose The purpose of the present document is to familiarize you with the EPOS4 Disk 60/8 positioning controller. docu- It will highlight the tasks for safe and adequate installation and/or commissioning. Follow the described ment to…...

  • Page 6: Table 1-1 Notation Used

    Indicates an advice or recommendation on the easiest Best practice Information and best way to further proceed. Material Indicates information particular to possible damage of Damage the equipment. Table 1-2 Symbols and signs EPOS4 Disk 60/8 Hardware Reference CCMC | 2021-10 | rel10276...

  • Page 7: Table 1-3 Brand Names And Trademark Owners

    © 2021 maxon. All rights reserved. Subject to change without prior notice. CCMC | EPOS4 Disk 60/8 Hardware Reference | Edition 2021-10 | DocID rel10276 maxon motor ag Brünigstrasse 220...

  • Page 8: About The Device

    About the Device About the Device maxon’s EPOS4 Disk 60/8 is a round-sized, full digital, smart positioning control unit with a center hole for Capabilities of the cable feed-trough. Its high power density allows flexible use for brushed DC and brushless EC (BLDC)

  • Page 9: About The Safety Precautions

    – 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) •...
  • Page 10 About the Safety Precautions • • 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 Disk 60/8 Hardware Reference 1-10...

  • Page 11: Specifications

    Specifications Technical Data SPECIFICATIONS Technical Data EPOS4 Disk 60/8 CAN (688770) EPOS4 Disk 60/8 EtherCAT (688772) Nominal power supply voltage +V 12…60 VDC Nominal logic supply voltage +V 12…60 VDC Absolute supply voltage +V / +V 10 VDC / 61 VDC 0.9 x +V...
  • Page 12 Specifications Technical Data EPOS4 Disk 60/8 CAN (688770) EPOS4 Disk 60/8 EtherCAT (688772) Sensor signals (choice between multiple Inputs functions) & • SSI absolute encoder signals EIA RS422, 0.4…2 MHz, configurable Outputs • High-speed digital input 4 and EIA RS422, max. 6.25 MHz...

  • Page 13: Thermal Data

    Specifications Thermal Data Thermal Data 2.2.1 Derating of Output Current Disk CAN Disk EtherCAT Figure 2-2 Derating of output current EPOS4 Disk 60/8 Hardware Reference 2-13 CCMC | 2021-10 | rel10276...

  • Page 14: Limitations

    Protection functionality Switch-off threshold Recovery threshold Undervoltage 8.0 V 8.5 V Overvoltage 64 V 63 V Overcurrent ±39 A — Thermal overload 95 °C 90 °C Table 2-6 Limitations EPOS4 Disk 60/8 Hardware Reference 2-14 CCMC | 2021-10 | rel10276...

  • Page 15: Dimensional Drawings

    Specifications Dimensional Drawings Dimensional Drawings Figure 2-4 EPOS4 Disk 60/8 CAN – Dimensional drawing [mm] Figure 2-5 EPOS4 Disk 60/8 EtherCAT – Dimensional drawing [mm] EPOS4 Disk 60/8 Hardware Reference 2-15 CCMC | 2021-10 | rel10276...

  • Page 16: Standards

    The device described was successfully tested in the following setup for compliance with the standards listed below: EPOS4 Disk 60/8 EtherCAT (688772) integrated into maxon's Robot Joint 60. In practical terms, only the complete system (the fully operational equipment comprising all individual com- ponents, such as motor, servo controller, power supply unit, EMC filter, cabling etc.) can undergo an EMC...

  • Page 17: Setup

    SETUP IMPORTANT NOTICE: PREREQUISITES FOR PERMISSION TO COMMENCE INSTALLATION The EPOS4 Disk 60/8 positioning controllers are considered as partly completed machinery according to EU Directive 2006/42/EC, Article 2, Clause (g) and are intended to be incorporated into or assembled with other machinery or other partly completed machinery or equipment.

  • Page 18: Cabling

    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.

  • Page 19: Table 3-9 Epos4 Disk Connector Set - Content

    Cabling MAKE&BAKE YOUR OWN If you decide not to employ maxon’s prefab cable assemblies, you might wish to use the prepackaged kit. It contains the connectors required to make up your own cabling (connectors for CAN/EtherCAT communi- cation not included, for details see Table 3-43 and Table 3-46).

  • Page 20: Connections

    X6 SSI page 3-28 X16 Brake page 3-39 X7 Digital I/O page 3-30 Figure 3-6 EPOS4 Disk 60/8 CAN – Connectors X1/X2 Power & Logic Supply page 3-21 X8 Analog I/O page 3-33 X3 Motor page 3-23 X13 USB page 3-35 X4 Hall Sensor page 3-24...

  • Page 21: Power & Logic Supply (X1/X2)

    Power & Motor Cable on page 3-40 Housing Molex Micro-Fit (0436450300) Suitable plug Contact Molex Micro-Fit (0430300038) Table 3-13 Power and logic supply combo connector X1/X2 – Specifications Continued on next page. EPOS4 Disk 60/8 Hardware Reference 3-21 CCMC | 2021-10 | rel10276...

  • Page 22: Table 3-14 Power Supply Requirements

    SOUGHT VALUE: • Supply voltage +V [Volt] SOLUTION: Δn   ≥ ⋅ ⋅ ⋅ 1 V [ ] ------ - -------- - M ------ -   ΔM EPOS4 Disk 60/8 Hardware Reference 3-22 CCMC | 2021-10 | rel10276...

  • Page 23: Motor (X3)

    Connections 3.3.2 Motor (X3) The controller is set to drive either a maxon DC motor (brushed DC motor) or maxon EC motor (BLDC, brushless DC motor). Danger of confusion Note that both connectors X3 (Motor) and X1/X2 (Power & Logic Supply) are of identical type. Make sure not to interchange them.

  • Page 24: Hall Sensor (X4)

    2.7 kΩ (referenced to +5.45 V - 0.6 V) Table 3-21 Hall sensor specification Figure 3-11 Hall sensor 1 input circuit (analogously valid for Hall sensors 2 & 3) EPOS4 Disk 60/8 Hardware Reference 3-24 CCMC | 2021-10 | rel10276...

  • Page 25: Encoder (X5)

    Suitable cable Encoder Cable on page 3-41 Housing Molex Micro-Lock (05054320801) Suitable plug Contact Molex Micro-Lock (05054311000) AWG26…30 Table 3-23 Encoder connector X5 – Specifications Continued on next page. EPOS4 Disk 60/8 Hardware Reference 3-25 CCMC | 2021-10 | rel10276...

  • Page 26: Figure 3-13 Digital Incremental Encoder Input Circuit Ch A "Differential" (Analogously Valid For Ch B & Ch I)

    Table 3-24 Differential digital incremental encoder specification Figure 3-13 Digital incremental encoder input circuit Ch A “differential” (analogously valid for Ch B & Ch I) Continued on next page. EPOS4 Disk 60/8 Hardware Reference 3-26 CCMC | 2021-10 | rel10276...

  • Page 27: Figure 3-14 Digital Incremental Encoder Input Circuit Ch A "Single-Ended" (Analogously Valid For Ch B & Ch I)

    150 kHz (additional external 3k3 pull-up) Table 3-25 Single-ended digital incremental encoder specification Figure 3-14 Digital incremental encoder input circuit Ch A “single-ended” (analogously valid for Ch B & Ch I) EPOS4 Disk 60/8 Hardware Reference 3-27 CCMC | 2021-10 | rel10276...

  • Page 28: Ssi (X6)

    Suitable cable Sensor Cable 3x2core on page 3-41 Housing Molex Micro-Lock (05055650601) Suitable plug Contact Molex Micro-Lock (05054311000) AWG26…30 Table 3-27 Sensor connector X6 – Specifications Continued on next page. EPOS4 Disk 60/8 Hardware Reference 3-28 CCMC | 2021-10 | rel10276...

  • Page 29: Figure 3-16 Ssi Absolute Encoder Data Input (Analogously Valid For Hsdigin4)

    0.4… 2 MHz Table 3-28 SSI absolute encoder specification Figure 3-16 SSI absolute encoder data input (analogously valid for HsDigIn4) Figure 3-17 SSI absolute encoder clock output (analogously valid for HsDigOut1) EPOS4 Disk 60/8 Hardware Reference 3-29 CCMC | 2021-10 | rel10276...

  • Page 30: Digital I/O (X7)

    Signal Cable 8core on page 3-41 Housing Molex Micro-Lock (05055650801) Suitable plug Contact Molex Micro-Lock (05054311000) AWG26…30 Table 3-30 Digital I/O connector X7 – Specifications Continued on next page. EPOS4 Disk 60/8 Hardware Reference 3-30 CCMC | 2021-10 | rel10276...

  • Page 31: Figure 3-19 Digin1 Circuit (Analogously Valid For Digin2

    Open drain (internal pull-up resistor 2k2 and diode Circuit to +5.45 VDC Table 3-32 Digital output specification Figure 3-20 DigOUT1 circuit (analogously valid for DigOUT2) Continued on next page. EPOS4 Disk 60/8 Hardware Reference 3-31 CCMC | 2021-10 | rel10276...

  • Page 32: Figure 3-21 Digout1 "Sinks" (Analogously Valid For Digout2)

    = 5.45 V − 0.75 V − (I Load ≤2 mA Max. load current Load Table 3-34 Digital output 1 & 2 specification – Source Figure 3-22 DigOUT1 “source” (analogously valid for DigOUT2) EPOS4 Disk 60/8 Hardware Reference 3-32 CCMC | 2021-10 | rel10276...

  • Page 33: Analog I/O (X8)

    Signal Cable 7core on page 3-42 Housing Molex Micro-Lock (05055650701) Suitable plug Contact Molex Micro-Lock (05054311000) AWG26…30 Table 3-36 Analog I/O connector X8 – Specifications Continued on next page. EPOS4 Disk 60/8 Hardware Reference 3-33 CCMC | 2021-10 | rel10276...

  • Page 34: Figure 3-24 Anin1 Circuit (Analogously Valid For Anin2)

    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 3-38 Analog output specification Figure 3-25 AnOUT1 circuit EPOS4 Disk 60/8 Hardware Reference 3-34 CCMC | 2021-10 | rel10276...

  • Page 35: Usb (X13)

    USB connector X13 – Specifications 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 3-41 USB interface specification EPOS4 Disk 60/8 Hardware Reference 3-35 CCMC | 2021-10 | rel10276...

  • Page 36: Can In (X14) & Can Out (X15)

    (751388) (Table 3-10) or Suitable plugs HARTING (09 45 181 9002 XL) or Hirose (IX30G-B-10S-CV(7.0)) Table 3-43 CAN 1 connector X14 / CAN 2 connector X15 – Specifications Continued on next page. EPOS4 Disk 60/8 Hardware Reference 3-36 CCMC | 2021-10 | rel10276...

  • Page 37: Table 3-44 Can Interface Specification

    • The standard bit rate setting (factory setting) is 1 Mbit/s, automatic bit rate detection is set. Ω • Use 120 termination resistor at both ends of the CAN bus.  • For detailed CAN information see separate document «EPOS4 Communication Guide». EPOS4 Disk 60/8 Hardware Reference 3-37 CCMC | 2021-10 | rel10276...

  • Page 38: Ethercat In (X14) & Ethercat Out (X15)

    (748166) (Table 3-10) or Suitable plug HARTING (09 45 181 2562 XL) or Hirose (IX30G-A-10S-CV(7.0)) Table 3-46 EtherCAT IN connector X14 / EtherCAT OUT connector X15 – Specifications EPOS4 Disk 60/8 Hardware Reference 3-38 CCMC | 2021-10 | rel10276...

  • Page 39: Brake (X16)

    Brake current ≤700 mA Brake Max. voltage drop (Brake− to GND) 0.15 V @ 700 mA Table 3-49 Brake output specification Figure 3-30 HsDigOut 2 (Holding Brake only) circuit EPOS4 Disk 60/8 Hardware Reference 3-39 CCMC | 2021-10 | rel10276...

  • Page 40: Prefab Cable Assemblies

    Colors white ¦¦ brown ¦¦ green ¦¦ yellow ¦¦ grey Plug Molex Micro-Lock (05055650501) Head A Contacts Molex Micro-Lock (05054311000) Head B Wire end sleeves 0.14 mm Table 3-51 Hall Sensor Cable EPOS4 Disk 60/8 Hardware Reference 3-40 CCMC | 2021-10 | rel10276...

  • Page 41: Table 3-52 Encoder Cable

    Colors white ¦¦ brown ¦¦ green ¦¦ yellow ¦¦ grey ¦¦ pink ¦¦ blue ¦¦ red Plug Molex Micro-Lock (05055650801) Head A Contacts Molex Micro-Lock (05054311000) Head B Wire end sleeves 0.14 mm Table 3-54 Signal Cable 8core EPOS4 Disk 60/8 Hardware Reference 3-41 CCMC | 2021-10 | rel10276...

  • Page 42: Table 3-55 Signal Cable 7Core

    HARTING ix Industrial, Type B (09 45 181 9002 XL) [d] Alternative lengths are available from HARTING: 0.5 m (33 48 111 1A20 005); 1 m (33 48 111 1A20 010) Table 3-57 CAN-CAN Cable EPOS4 Disk 60/8 Hardware Reference 3-42 CCMC | 2021-10 | rel10276...

  • Page 43: Table 3-58 Can-Com Cable

    HARTING ix Industrial, Type A (09 45 181 2562 XL) [e] Alternative lengths are available from HARTING: 0.5 m (09 48 262 6749 005); 1 m (09 48 262 6749 010) Table 3-59 EtherCAT-EtherCAT Cable EPOS4 Disk 60/8 Hardware Reference 3-43 CCMC | 2021-10 | rel10276...

  • Page 44: Table 3-60 Ethercat-Com Cable

    , shielded, grey / 3 m Wire identifier Numbers 1 ¦¦ 2 Plug Molex Micro-Fit (0436450200) Head A Contacts Molex Micro-Fit (0430300001) (0430300007) Head B Wire end sleeves 0.5 mm Table 3-61 Brake Cable EPOS4 Disk 60/8 Hardware Reference 3-44 CCMC | 2021-10 | rel10276...

  • Page 45: Dip Switch Configuration (Sw1)

    JP301 closed JP302 closed * the default setting for the solder pads JP301, JP302 is “open” Table 3-62 DIP switch SW1 – Binary code values Continued on next page. EPOS4 Disk 60/8 Hardware Reference 3-45 CCMC | 2021-10 | rel10276...

  • Page 46: Table 3-63 Dip Switch Sw1 - Examples

    JP301 JP302 closed JP301 JP302 closed 0 = Switch “OFF” / solder pad “open” 1 = Switch “ON” / solder pad “shorted” Table 3-63 DIP switch SW1 – Examples EPOS4 Disk 60/8 Hardware Reference 3-46 CCMC | 2021-10 | rel10276...

  • Page 47: Can Automatic Bit Rate Detection

    DIP switch SW1 – CAN automatic bit rate detection 3.5.3 CAN Bus Termination Switch Without bus termination Bus termination with 120 Ω (factory setting) Table 3-65 DIP switch SW1 – CAN bus termination EPOS4 Disk 60/8 Hardware Reference 3-47 CCMC | 2021-10 | rel10276...

  • Page 48: Status Indicators

    Device Status; the LEDs display the device’s operation status and error conditions NET Port; the LED displays the NET link activity For detailed information see separate document «EPOS4 Firmware Specification». Figure 3-32 LEDs – Location EPOS4 Disk 60/8 Hardware Reference 3-48 CCMC | 2021-10 | rel10276...

  • Page 49: Table 3-66 Net Status Leds

    • “Fault Reaction Active” Flash No valid firmware or firmware download in progress Flash = flashing (≈0.9 s OFF/≈0.1 s ON) Slow = slow blinking (≈1 Hz) Table 3-67 Device Status LEDs EPOS4 Disk 60/8 Hardware Reference 3-49 CCMC | 2021-10 | rel10276...

  • Page 50: Table 3-68 Net Port Led

    Port is closed Flicker Port is open / activity is present Port is open — Data rate is 100 Mbit/s Flicker = continuous flickering (≈10 Hz) Table 3-68 NET Port LED EPOS4 Disk 60/8 Hardware Reference 3-50 CCMC | 2021-10 | rel10276...

  • Page 51: Wiring

    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). EPOS4 Disk 60/8 Hardware Reference 4-51 CCMC | 2021-10 | rel10276...

  • Page 52: Possible Combinations To Connect A Motor

    Encoder Figure(s) (Sensor 1) (Sensor 2) 4-37 4-37  4-40 4-37  4-41 4-37   4-40 / 4-41 Table 4-69 Possible combinations of feedback signals for DC motor EPOS4 Disk 60/8 Hardware Reference 4-52 CCMC | 2021-10 | rel10276...

  • Page 53: Table 4-70 Possible Combinations Of Feedback Signals For Ec (Bldc) Motor

    4-38   4-39 / 4-41 4-38    4-39 / 4-40 / 4-41 4-38  4-41 Table 4-70 Possible combinations of feedback signals for EC (BLDC) motor EPOS4 Disk 60/8 Hardware Reference 4-53 CCMC | 2021-10 | rel10276...

  • Page 54: Main Wiring Diagrams

    Wiring Main Wiring Diagrams Main Wiring Diagrams EPOS4 Disk 60/8 CAN Figure 4-34 EPOS4 Disk 60/8 CAN – Main wiring diagram EPOS4 Disk 60/8 Hardware Reference 4-54 CCMC | 2021-10 | rel10276...

  • Page 55: Figure 4-35 Epos4 Disk 60/8 Ethercat - Main Wiring Diagram

    Wiring Main Wiring Diagrams EPOS4 Disk 60/8 EtherCAT Figure 4-35 EPOS4 Disk 60/8 EtherCAT – Main wiring diagram EPOS4 Disk 60/8 Hardware Reference 4-55 CCMC | 2021-10 | rel10276...

  • Page 56: Excerpts

    Power & logic supply 4.3.2 DC Motor Figure 4-37 DC motor 4.3.3 EC (BLDC) Motor Figure 4-38 EC (BLDC) motor 4.3.4 Hall Sensors (Sensor 3) Figure 4-39 Hall sensors (Sensor 3) EPOS4 Disk 60/8 Hardware Reference 4-56 CCMC | 2021-10 | rel10276...

  • Page 57: Figure 4-40 Digital Incremental Encoder (Sensor 1)

    Wiring Excerpts 4.3.5 Digital Incremental Encoder (Sensor 1) Figure 4-40 Digital incremental encoder (Sensor 1) 4.3.6 SSI Encoder (Sensor 2) Figure 4-41 SSI encoder (Sensor 2) EPOS4 Disk 60/8 Hardware Reference 4-57 CCMC | 2021-10 | rel10276...
  • Page 58 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 Disk 60/8 Hardware Reference 4-58 CCMC | 2021-10 | rel10276...

  • Page 59: List Of Figures

    EPOS4 Disk 60/8 EtherCAT – Dimensional drawing [mm] ....... . .

  • Page 60: List Of Tables

    Motor connector X3 – Pin assignment for maxon DC motor .......
  • Page 61 Possible combinations of feedback signals for EC (BLDC) motor ....... . . 53 EPOS4 Disk 60/8 Hardware Reference...

  • Page 62: Index

    X14 (EtherCAT) 38 JP301, JP302 45 X15 (CAN) 36 X15 (EtherCAT) 38 X16 39 country-specific regulations 9 LEDs, interpretation of 48 mandatory action signs 6 motor types, supported 8 EPOS4 Disk 60/8 Hardware Reference Z-62 CCMC | 2021-10 | rel10276...
  • Page 63 751388 19 performance data 11 precautions 9 prerequisites prior installation 17 prohibitive signs 6 protective measures (ESD) 9 purpose of the device 8 of the document 5 regulations, applicable 9 EPOS4 Disk 60/8 Hardware Reference Z-63 CCMC | 2021-10 | rel10276...
  • Page 64 The mentioned trademarks belong to their respective owners and are protected under intellectual property rights. © 2021 maxon. All rights reserved. Subject to change without prior notice. CCMC | EPOS4 Disk 60/8 Hardware Reference | Edition 2021-10 | DocID rel10276 maxon motor ag Brünigstrasse 220...

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