• you must follow the instructions given therein. The EPOS4 Disk 60/12 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............69 LIST OF FIGURES LIST OF TABLES INDEX EPOS4 Disk 60/12 Hardware Reference CCMC | 2022-06 | rel10685...
Page 4
Table of Contents EPOS4 Disk 60/12 Hardware Reference CCMC | 2022-06 | rel10685...
1.1.1 Intended Purpose docu- The purpose of the present document is to familiarize you with the EPOS4 Disk 60/12 positioning controller. ment to… It will highlight the tasks for safe and adequate installation and/or commissioning. Follow the described –stay safe, instructions …...
Page 6
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 EPOS4 Disk 60/12 Hardware Reference CCMC | 2022-06 | rel10685...
About the Device About the Device maxon’s EPOS4 Disk 60/12 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)
– 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 60/12 Hardware Reference 1-10...
Technical Data SPECIFICATIONS Technical Data EPOS4 Disk 60/12 CAN (688775) EPOS4 Disk 60/12 EtherCAT (688777) EPOS4 Disk 60/12 CAN SSC (709859) EPOS4 Disk 60/12 EtherCAT SSC (709862) Nominal power supply voltage +V 12…60 VDC Nominal logic supply voltage +V 12…60 VDC...
Page 12
Specifications Technical Data EPOS4 Disk 60/12 CAN (688775) EPOS4 Disk 60/12 EtherCAT (688777) EPOS4 Disk 60/12 CAN SSC (709859) EPOS4 Disk 60/12 EtherCAT SSC (709862) Sensor signals (choice between multiple Inputs functions) & • SSI absolute encoder signals EIA RS422, 0.4…2 MHz, configurable Outputs •...
Operation within the stated derating specifications is mandatory. Exceeding ambient temperatures beyond the specified limits can lead to thermal overload even at low output currents. Disk CAN Disk EtherCAT Figure 2-2 Derating of output current EPOS4 Disk 60/12 Hardware Reference 2-13 CCMC | 2022-06 | rel10685...
Protection functionality Switch-off threshold Recovery threshold Undervoltage 8.0 V 8.5 V Overvoltage 64 V 63 V Overcurrent ±58 A — Thermal overload 105 °C 90 °C Table 2-7 Limitations EPOS4 Disk 60/12 Hardware Reference 2-14 CCMC | 2022-06 | rel10685...
The device described was successfully tested in the following setup for compliance with the standards listed below: EPOS4 Disk 60/12 EtherCAT (688777) integrated in maxon's Robot Joint 90. 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...
Page 18
Standards • • 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 60/12 Hardware Reference 2-18 CCMC | 2022-06 | rel10685...
SETUP IMPORTANT NOTICE: PREREQUISITES FOR PERMISSION TO COMMENCE INSTALLATION The EPOS4 Disk 60/12 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.
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 21
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 3-51 and Table 3-54).
Molex Mini-Fit Plus (0039012025) Housing Molex Mini-Fit Jr. (0039012020) Suitable plug Contact Molex Mini-Fit Plus (45750311x) Table 3-14 Power supply connector X1 or X1a – Specifications Continued on next page. EPOS4 Disk 60/12 Hardware Reference 3-26 CCMC | 2022-05 | rel10685...
Setup Connections 3.3.3 Motor (X3) The controller is set to drive either a maxon DC motor (brushed DC motor) or maxon EC motor (BLDC, brushless DC motor). Figure 3-14 Motor connector X3 Signal Description Motor (+M) DC motor: Motor + Motor (−M)
Hall sensor 3 Hall sensor 3 input Ground Sensor supply voltage (+5 VDC; I 100 mA) Sensor Table 3-24 Hall sensor connector X4a – Pin assignment Continued on next page. EPOS4 Disk 60/12 Hardware Reference 3-30 CCMC | 2022-05 | rel10685...
Page 31
2.7 k(referenced to +5.45 V - 0.6 V) Table 3-26 Hall sensor specification Figure 3-17 Hall sensor 1 input circuit (analogously valid for Hall sensors 2 & 3 and X4a) EPOS4 Disk 60/12 Hardware Reference 3-31 CCMC | 2022-05 | rel10685...
Suitable cable Encoder Cable on page 3-51 Housing Molex Micro-Lock (05054320801) Suitable plug Contact Molex Micro-Lock (05054311000) AWG26…30 Table 3-31 Encoder connector X5 – Specifications Continued on next page. EPOS4 Disk 60/12 Hardware Reference 3-34 CCMC | 2022-05 | rel10685...
Page 35
Max. input frequency 6.25 MHz Table 3-32 Differential encoder specification Figure 3-21 Encoder input circuit Ch A “differential” (analogously valid for Ch B, Ch I, and X5/X6) Continued on next page. EPOS4 Disk 60/12 Hardware Reference 3-35 CCMC | 2022-05 | rel10685...
Page 36
Open collector 150 kHz (additional external 3k3 pull-up) Table 3-33 Single-ended encoder specification Figure 3-22 Encoder input circuit Ch A “single-ended” (analogously valid for Ch B, Ch I, and X5/X6) EPOS4 Disk 60/12 Hardware Reference 3-36 CCMC | 2022-05 | rel10685...
Signal Cable 8core on page 3-52 Housing Molex Micro-Lock (05055650801) Suitable plug Contact Molex Micro-Lock (05054311000) AWG26…30 Table 3-38 Digital I/O connector X7 or X7a – Specifications Continued on next page. EPOS4 Disk 60/12 Hardware Reference 3-39 CCMC | 2022-05 | rel10685...
Page 40
Open drain (internal pull-up resistor 2k2 and diode Circuit to +5.45 VDC Table 3-40 Digital output specification Figure 3-28 DigOUT1 circuit (analogously valid for DigOUT2 and X7a) Continued on next page. EPOS4 Disk 60/12 Hardware Reference 3-40 CCMC | 2022-05 | rel10685...
Page 41
2200 ) Load Max. load current 2 mA Load Table 3-42 Digital output 1 & 2 specification – Source Figure 3-30 DigOUT1 “source” (analogously valid for DigOUT2 and X7a) EPOS4 Disk 60/12 Hardware Reference 3-41 CCMC | 2022-05 | rel10685...
Signal Cable 7core on page 3-52 Housing Molex Micro-Lock (05055650701) Suitable plug Contact Molex Micro-Lock (05054311000) AWG26…30 Table 3-44 Analog I/O connector X8 or X8a – Specifications Continued on next page. EPOS4 Disk 60/12 Hardware Reference 3-42 CCMC | 2022-05 | rel10685...
Page 43
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 3-46 Analog output specification Figure 3-33 AnOUT1 circuit (analogously valid for X8a) EPOS4 Disk 60/12 Hardware Reference 3-43 CCMC | 2022-05 | rel10685...
USB connector X13 or X13a – 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 3-49 USB interface specification EPOS4 Disk 60/12 Hardware Reference 3-44 CCMC | 2022-05 | rel10685...
HARTING (09 45 181 9002 XL) or Hirose (IX31G-B-10S-CV(7.0)) Table 3-51 CAN 1 connector X14 or X14a / CAN 2 connector X15 or X15a – Specifications Continued on next page. EPOS4 Disk 60/12 Hardware Reference 3-45 CCMC | 2022-05 | rel10685...
Page 46
• The standard bit rate setting (factory setting) is 1 Mbit/s, automatic bit rate detection is set. • Use 120 termination resistor at both ends of the CAN bus. • For detailed CAN information see separate document «EPOS4 Communication Guide». EPOS4 Disk 60/12 Hardware Reference 3-46 CCMC | 2022-05 | rel10685...
Brake current 700 mA Brake Max. voltage drop (Brake− to GND) 0.15 V @ 700 mA Table 3-57 Brake output specification Figure 3-38 HsDigOut 2 (Holding Brake only) circuit EPOS4 Disk 60/12 Hardware Reference 3-48 CCMC | 2022-05 | rel10685...
Characters “+” ¦¦ “−” 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 mm Table 3-59 Power Cable EPOS4 Disk 60/12 Hardware Reference 3-49 CCMC | 2022-05 | rel10685...
Page 50
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 3-62 Hall Sensor Cable EPOS4 Disk 60/12 Hardware Reference 3-50 CCMC | 2022-05 | rel10685...
Page 51
Colors white ¦¦ brown ¦¦ green ¦¦ yellow ¦¦ grey ¦¦ pink Plug Molex Micro-Lock (05055650601) Head A Contacts Molex Micro-Lock (05054311000) Head B Wire end sleeves 0.14 mm Table 3-65 Sensor Cable 3x2core EPOS4 Disk 60/12 Hardware Reference 3-51 CCMC | 2022-05 | rel10685...
Page 52
USB 2.0 / USB3.0 (full speed), black / 1.5 m Wire identifier — Plug Molex Micro-Lock (05055650401) Head A Contacts Molex Micro-Lock (05054311000) Head B Plug Male USB A, straight Table 3-68 USB Type A-Micro-Lock Cable EPOS4 Disk 60/12 Hardware Reference 3-52 CCMC | 2022-05 | rel10685...
Page 53
Colors white ¦¦ brown ¦¦ green ¦¦ yellow ¦¦ grey ¦¦ pink ¦¦ blue ¦¦ red ¦¦ black ¦¦ violet Head A HARTING ix Industrial, Type B (09 45 181 9002 XL) Head B D-SUB socket 9, female Table 3-70 CAN-COM Cable EPOS4 Disk 60/12 Hardware Reference 3-53 CCMC | 2022-05 | rel10685...
Page 54
HARTING ix Industrial, Type A (09 45 181 2562 XL) Head B RJ45 [f] Alternative lengths are available from HARTING: 0.5 m (33 48 06 5383 0005); 1 m (33 48 06 5383 0010) Table 3-72 EtherCAT-COM Cable EPOS4 Disk 60/12 Hardware Reference 3-54 CCMC | 2022-05 | rel10685...
Page 55
, 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 3-73 Brake Cable EPOS4 Disk 60/12 Hardware Reference 3-55 CCMC | 2022-05 | rel10685...
JP301 closed JP302 closed * the default setting for the solder pads JP301, JP302 is “open” Table 3-74 DIP switch SW1 – Binary code values Continued on next page. EPOS4 Disk 60/12 Hardware Reference 3-56 CCMC | 2022-05 | rel10685...
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 3-77 DIP switch SW1 – CAN bus termination EPOS4 Disk 60/12 Hardware Reference 3-58 CCMC | 2022-05 | rel10685...
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 3-40 LEDs – Location EPOS4 Disk 60/12 Hardware Reference 3-59 CCMC | 2022-05 | rel10685...
Page 60
• “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 3-79 Device Status LEDs EPOS4 Disk 60/12 Hardware Reference 3-60 CCMC | 2022-05 | rel10685...
Page 61
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 3-80 NET Port LED EPOS4 Disk 60/12 Hardware Reference 3-61 CCMC | 2022-05 | rel10685...
Page 62
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 Disk 60/12 Hardware Reference 3-62 CCMC | 2022-05 | rel10685...
Page 63
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 4-41 Interfaces – Designations and locations on Disk CAN EPOS4 Disk 60/12 Hardware Reference 4-63 CCMC | 2022-06 | rel10685...
Page 64
Wiring Figure 4-42 Interfaces – Designations and locations on Disk EtherCAT EPOS4 Disk 60/12 Hardware Reference 4-64 CCMC | 2022-06 | rel10685...
X5 or X5/X6 X6 or X5/X6 4-46 4-46 4-49 4-46 4-50 4-46 4-49 / 4-50 Table 4-81 Possible combinations of feedback signals for DC motor EPOS4 Disk 60/12 Hardware Reference 4-65 CCMC | 2022-06 | rel10685...
Page 66
4-48 / 4-50 (or 4-52) 4-47 4-48 / 4-49 / 4-50 (or 4-52) 4-47 4-50 (or 4-52) Table 4-82 Possible combinations of feedback signals for EC (BLDC) motor EPOS4 Disk 60/12 Hardware Reference 4-66 CCMC | 2022-06 | rel10685...
Wiring Main Wiring Diagrams Main Wiring Diagrams EPOS4 Disk 60/12 CAN Figure 4-43 EPOS4 Disk 60/12 CAN – Main wiring diagram EPOS4 Disk 60/12 Hardware Reference 4-67 CCMC | 2022-06 | rel10685...
Page 68
Wiring Main Wiring Diagrams EPOS4 Disk 60/12 EtherCAT Figure 4-44 EPOS4 Disk 60/12 EtherCAT – Main wiring diagram EPOS4 Disk 60/12 Hardware Reference 4-68 CCMC | 2022-06 | rel10685...
Excerpts Excerpts 4.3.1 Power & Logic Supply Figure 4-45 Power & logic supply 4.3.2 DC Motor Figure 4-46 DC motor 4.3.3 EC (BLDC) Motor Figure 4-47 EC (BLDC) motor EPOS4 Disk 60/12 Hardware Reference 4-69 CCMC | 2022-06 | rel10685...
Page 70
Digital Incremental Encoder (Sensor 1) on X5 Figure 4-49 Digital incremental encoder (Sensor 1) on X5 4.3.6 SSI Encoder (Sensor 2) on X6 Figure 4-50 SSI encoder (Sensor 2) on X6 EPOS4 Disk 60/12 Hardware Reference 4-70 CCMC | 2022-06 | rel10685...
Page 71
3-32). For this setup, leave open both solder pads JP701 and JP702 (default factory setting). Figure 4-52 Digital incremental encoder (Sensor 1) and SSI encoder (Sensor 2) on X5/X6 EPOS4 Disk 60/12 Hardware Reference 4-71 CCMC | 2022-06 | rel10685...
Page 72
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 60/12 Hardware Reference 4-72 CCMC | 2022-06 | rel10685...
Page 74
EPOS4 Disk 60/12 EtherCAT – Main wiring diagram........
Page 75
Motor connector X3 – Pin assignment for maxon DC motor .......
Page 76
Possible combinations of feedback signals for EC (BLDC) motor ........66 EPOS4 Disk 60/12 Hardware Reference...
Page 77
19 outputs analog 43 DEV ID (see “ID”) digital 40, 41 device condition, display of 59 digital outputs 40 DIP switch SW1 56 part numbers 275829 49 EPOS4 Disk 60/12 Hardware Reference Z-77 CCMC | 2022-06 | rel10685...
Page 78
LEDs 59 supply voltage, required 27 SW1 56 switch SW1 56 symbols used 6 technical data 11 termination (CAN bus) 46, 58 USB port 44 versions and variants 8 EPOS4 Disk 60/12 Hardware Reference Z-78 CCMC | 2022-06 | rel10685...
Page 79
Index EPOS4 Disk 60/12 Hardware Reference Z-79 CCMC | 2022-06 | rel10685...
Need help?
Do you have a question about the EPOS4 Disk 60/12 and is the answer not in the manual?
Questions and answers