Related Manuals for Maxon EPOS4 50/5
Summary of Contents for Maxon EPOS4 50/5
- Page 1 Hardware Reference EPOS4 50/5 Positioning Controller | P/N 546047 Hardware Reference CCMC | Edition 2023-07 | DocID rel11726...
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Page 2: Table Of Contents
• you must follow the instructions given therein. The EPOS4 50/5 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 com- pleted machinery or equipment. - Page 3 Excerpts............65 LIST OF FIGURES LIST OF TABLES INDEX EPOS4 50/5 Hardware Reference CCMC | 2023-07 | rel11726...
- Page 4 Table of Contents EPOS4 50/5 Hardware Reference CCMC | 2023-07 | rel11726...
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Page 5: About
1.1.1 Intended Purpose docu- The purpose of the present document is to familiarize you with the EPOS4 50/5 positioning controller. It will highlight the tasks for safe and adequate installation and/or commissioning. Follow the described instruc- ment to… –stay safe, tions …... -
Page 6: Table 1-1 Notation Used
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 50/5 Hardware Reference CCMC | 2023-07 | rel11726... -
Page 7: Table 1-3 Brand Names And Trademark Owners
1.1.6 Copyright © 2023 maxon. All rights reserved. Any use, in particular reproduction, editing, translation, and copying, without prior written approval is not permitted (contact: maxon international ltd., Brünigstrasse 220, CH- 6072 Sachseln, +41 41 666 15 00, www.maxongroup.com). Infringements will be prosecuted under civil and criminal law. -
Page 8: About The Device
About the Device About the Device maxon’s EPOS4 50/5 is a small-sized, full digital, smart positioning control unit. Its high power density Capabilities of the allows flexible use for brushed DC and brushless EC (BLDC) motors up to approximately 250 Watts with... -
Page 9: Specifications
Analog Output 2 Digital Hall sensor signals +2.0…+24 VDC (internal pull-up) H1, H2, H3 Digital incremental encoder signals EIA RS422, max. 6.25 MHz A, A\, B, B\, I, I\ Continued on next page. EPOS4 50/5 Hardware Reference CCMC | 2023-07 | rel11726... -
Page 10: Table 2-4 Technical Data
Derating further increases with an inserted extension card. For the actual value, consult Figure 2-2 and shift the graph horizontally to the left by the specified value. Table 2-4 Technical data EPOS4 50/5 Hardware Reference 2-10 CCMC | 2023-07 | rel11726... -
Page 11: Thermal Data
Specifications Thermal Data Thermal Data 2.2.1 Derating of Output Current Figure 2-2 Derating of output current EPOS4 50/5 Hardware Reference 2-11 CCMC | 2023-07 | rel11726... -
Page 12: Limitations
Limitations Protection functionality Switch-off threshold Recovery threshold Undervoltage 8.0 V 8.5 V Overvoltage 58 V 56 V Overcurrent 20 A — Thermal overload 100 °C 90 °C Table 2-5 Limitations EPOS4 50/5 Hardware Reference 2-12 CCMC | 2023-07 | rel11726... -
Page 13: Dimensional Drawing
Specifications Dimensional Drawing Dimensional Drawing Figure 2-4 Dimensional drawing [mm] EPOS4 50/5 Hardware Reference 2-13 CCMC | 2023-07 | rel11726... -
Page 14: Standards
Environment: Ground, benign (GB) Ambient temperature: 298 K (25 °C) Reliability MIL-HDBK-217F Component stress: In accordance with circuit diagram and nominal power Mean Time Between Failures (MTBF): 296'741 hours Table 2-6 Standards EPOS4 50/5 Hardware Reference 2-14 CCMC | 2023-07 | rel11726... -
Page 15: Setup
IMPORTANT NOTICE: PREREQUISITES FOR PERMISSION TO COMMENCE INSTALLATION The EPOS4 50/5 positioning controller is considered as partly completed machinery according to EU Direc- tive 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. -
Page 16: 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 17: Table 3-8 Epos4 Connector Set - Content
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... -
Page 18: Connections
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. -
Page 19: Power Supply (X1)
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 3-11 Power Cable Continued on next page. EPOS4 50/5 Hardware Reference 3-19 CCMC | 2023-07 | rel11726... -
Page 20: Table 3-12 Power Supply Requirements
Speed/torque gradient of the motor n/M [rpm/mNm] SOUGHT VALUE: • Supply voltage +V [Volt] SOLUTION: n ------ - -------- - M ------ - 1 V M EPOS4 50/5 Hardware Reference 3-20 CCMC | 2023-07 | rel11726... -
Page 21: Logic Supply (X2)
For the matching prefab cable assembly Table 3-11. Power supply requirements 10…50 VDC Output voltage Absolute supply voltage min. 8 VDC; max. 56 VDC min. 3.5 W Min. output power Table 3-14 Logic supply requirements EPOS4 50/5 Hardware Reference 3-21 CCMC | 2023-07 | rel11726... -
Page 22: Motor (X3)
Setup Connections 3.3.3 Motor (X3) The controller is set to drive either maxon DC motors (brushed DC motor) or maxon EC motors (BLDC, brushless DC motor). Figure 3-8 Motor connectors X3 Prefab Head B Head A Cable Signal Description Color... -
Page 23: Hall Sensor (X4)
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 mm Table 3-19 Hall Sensor Cable Continued on next page. EPOS4 50/5 Hardware Reference 3-23 CCMC | 2023-07 | rel11726... -
Page 24: Figure 3-10 Hall Sensor 1 Input Circuit (Analogously Valid For Hall Sensors 2 & 3)
Internal pull-up resistor 2.7 k(referenced to +5.45 V - 0.6 V) Table 3-20 Hall sensor specification Figure 3-10 Hall sensor 1 input circuit (analogously valid for Hall sensors 2 & 3) EPOS4 50/5 Hardware Reference 3-24 CCMC | 2023-07 | rel11726... -
Page 25: Encoder (X5)
1 retainer clip, height 7.9 mm, 3M (3505-8010) Latch For sockets with strain relief: 2 pieces, 3M (3505-33B) Table 3-22 Encoder connector X5 – Accessories Continued on next page. EPOS4 50/5 Hardware Reference 3-25 CCMC | 2023-07 | rel11726... -
Page 26: Figure 3-12 Encoder Input Circuit Ch A "Differential" (Analogously Valid For Ch B & Ch I)
Max. input frequency 6.25 MHz Table 3-24 Differential encoder specification Figure 3-12 Encoder input circuit Ch A “differential” (analogously valid for Ch B & Ch I) Continued on next page. EPOS4 50/5 Hardware Reference 3-26 CCMC | 2023-07 | rel11726... -
Page 27: Figure 3-13 Encoder Input Circuit Ch A "Single-Ended" (Analogously Valid For Ch B & Ch I)
40 kHz (internal pull-up only) Open collector 150 kHz (additional external 3k3 pull-up) Table 3-25 Single-ended encoder specification Figure 3-13 Encoder input circuit Ch A “single-ended” (analogously valid for Ch B & Ch I) EPOS4 50/5 Hardware Reference 3-27 CCMC | 2023-07 | rel11726... -
Page 28: Sensor (X6)
Data (SSI) complement HsDigIN4\ High-speed digital input 4 complement black Ground Auxiliary output voltage (+5 VDC; I 145 mA) violet Table 3-26 Sensor connector X6 – Pin assignment Continued on next page. EPOS4 50/5 Hardware Reference 3-28 CCMC | 2023-07 | rel11726... -
Page 29: Incremental Encoder
Max. input frequency 6.25 MHz Table 3-28 Differential digital incremental encoder specification Figure 3-15 Digital incremental encoder input circuit Ch A “differential” (analogously valid for Ch B) Continued on next page. EPOS4 50/5 Hardware Reference 3-29 CCMC | 2023-07 | rel11726... -
Page 30: Figure 3-16 Digital Incremental Encoder Input Circuit Ch I
Setup Connections Figure 3-16 Digital incremental encoder input circuit Ch I Continued on next page. EPOS4 50/5 Hardware Reference 3-30 CCMC | 2023-07 | rel11726... -
Page 31: Figure 3-17 Digital Incremental Encoder Input Circuit Ch A "Single-Ended" (Analogously Valid For Ch B)
100 kHz (additional external 3k3 pull-up) Table 3-29 Single-ended digital incremental encoder specification Figure 3-17 Digital incremental encoder input circuit Ch A “single-ended” (analogously valid for Ch B) Continued on next page. EPOS4 50/5 Hardware Reference 3-31 CCMC | 2023-07 | rel11726... -
Page 32: Figure 3-18 Digital Incremental Encoder Input Circuit Ch I
Setup Connections Figure 3-18 Digital incremental encoder input circuit Ch I Continued on next page. EPOS4 50/5 Hardware Reference 3-32 CCMC | 2023-07 | rel11726... -
Page 33: Figure 3-19 Analog Incremental Encoder Input Circuit Ch A "Differential" (Analogously Valid For Ch B)
0.88 mV Bandwidth 10 kHz Table 3-30 Differential analog incremental encoder specification Figure 3-19 Analog incremental encoder input circuit Ch A “differential” (analogously valid for Ch B) Continued on next page. EPOS4 50/5 Hardware Reference 3-33 CCMC | 2023-07 | rel11726... -
Page 34: Figure 3-20 Analog Incremental Encoder Input Circuit Ch I (Digital Evaluation)
Setup Connections Figure 3-20 Analog incremental encoder input circuit Ch I (digital evaluation) Continued on next page. EPOS4 50/5 Hardware Reference 3-34 CCMC | 2023-07 | rel11726... -
Page 35: Ssi Absolute Encoder
Line receiver (internal) EIA RS422 standard Encoder input/output frequency 0.4… 2 MHz Table 3-31 SSI absolute encoder specification Figure 3-21 SSI absolute encoder data input Figure 3-22 SSI absolute encoder clock output EPOS4 50/5 Hardware Reference 3-35 CCMC | 2023-07 | rel11726... -
Page 36: High-Speed Digital I/Os
Line receiver (internal) EIA RS422 standard Max. input frequency 6.25 MHz Table 3-32 Differential high-speed digital input specification Figure 3-23 HsDigIN1 circuit “differential” (analogously valid for HsDigIN2…4) Continued on next page. EPOS4 50/5 Hardware Reference 3-36 CCMC | 2023-07 | rel11726... -
Page 37: Figure 3-24 Hsdigin1 Circuit "Single-Ended" (Analogously Valid For Hsdigin2
−7 A @ 0 VDC (HsDigIN3, 4) Max. input frequency 6.25 MHz Table 3-33 Single-ended high-speed digital input specification Figure 3-24 HsDigIN1 circuit “single-ended” (analogously valid for HsDigIN2…4) Continued on next page. EPOS4 50/5 Hardware Reference 3-37 CCMC | 2023-07 | rel11726... -
Page 38: Figure 3-25 Hsdigout1 Output Circuit
±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 3-34 High-speed digital output specification Figure 3-25 HsDigOUT1 output circuit EPOS4 50/5 Hardware Reference 3-38 CCMC | 2023-07 | rel11726... -
Page 39: Digital I/O (X7)
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 mm Table 3-36 Signal Cable 8core Continued on next page. EPOS4 50/5 Hardware Reference 3-39 CCMC | 2023-07 | rel11726... -
Page 40: Figure 3-27 Digin1 Circuit (Analogously Valid For Digin2
<300 s @ 24 VDC Table 3-38 Digital input specification – PLC level setting Figure 3-28 DigIN1 circuit (analogously valid for DigIN2…4) – PLC level setting Continued on next page. EPOS4 50/5 Hardware Reference 3-40 CCMC | 2023-07 | rel11726... -
Page 41: Figure 3-29 Digout1 Circuit (Analogously Valid For Digout2)
Digital outputs 1…2 Open drain (internal pull-up resistor 2k2 and diode Circuit to +5.45 VDC Table 3-39 Digital output specification Figure 3-29 DigOUT1 circuit (analogously valid for DigOUT2) Continued on next page. EPOS4 50/5 Hardware Reference 3-41 CCMC | 2023-07 | rel11726... -
Page 42: Figure 3-30 Digout1 "Sinks" (Analogously Valid For Digout2)
= 5.45 V − 0.75 V − (I x 2200 ) Output voltage Load 2 mA Max. load current Load Table 3-41 Digital output – Source Figure 3-31 DigOUT1 “source” (analogously valid for DigOUT2) EPOS4 50/5 Hardware Reference 3-42 CCMC | 2023-07 | rel11726... -
Page 43: Analog I/O (X8)
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 mm Table 3-43 Signal Cable 7core Continued on next page. EPOS4 50/5 Hardware Reference 3-43 CCMC | 2023-07 | rel11726... -
Page 44: Figure 3-33 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 3-45 Analog output specification Figure 3-34 AnOUT1 circuit (analogously valid for AnOUT2) EPOS4 50/5 Hardware Reference 3-44 CCMC | 2023-07 | rel11726... -
Page 45: Sto (X9)
For the matching prefab cable assembly Table 3-36 on page 3-39. STO Idle Connector (520860) —included with every delivery— Plug Molex CLIK-Mate, single row, 8 poles (502578-0800) with cable bridges Table 3-47 STO Idle Connector Continued on next page. EPOS4 50/5 Hardware Reference 3-45 CCMC | 2023-07 | rel11726... -
Page 46: Figure 3-36 Sto-In1 Circuit (Analogously Valid For Sto-In2)
<10 A @ +30 VDC 1.3 V @ 2 mA Max. voltage drop 2.5 V @ 15 mA Table 3-49 STO output specification Figure 3-37 STO-OUT circuit Continued on next page. EPOS4 50/5 Hardware Reference 3-46 CCMC | 2023-07 | rel11726... -
Page 47: Table 3-50 Sto Logic State
Setup Connections STO Logic State STO-IN1 STO-IN2 STO-OUT Power Stage open inactive closed inactive closed inactive closed active Table 3-50 STO logic state EPOS4 50/5 Hardware Reference 3-47 CCMC | 2023-07 | rel11726... -
Page 48: Rs232 (X10)
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 3-53 RS232 interface specification EPOS4 50/5 Hardware Reference 3-48 CCMC | 2023-07 | rel11726... -
Page 49: Can 1 (X11) & Can 2 (X12)
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 3-55 CAN-COM Cable Continued on next page. EPOS4 50/5 Hardware Reference 3-49 CCMC | 2023-07 | rel11726... -
Page 50: Table 3-56 Can-Can Cable
• 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 50/5 Hardware Reference 3-50 CCMC | 2023-07 | rel11726... -
Page 51: Usb (X13)
USB Type A - micro B Cable 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 3-60 USB interface specification EPOS4 50/5 Hardware Reference 3-51 CCMC | 2023-07 | rel11726... -
Page 52: Extension In (X14) & Extension Out (X15)
3.3.13 Extension IN (X14) & Extension OUT (X15) The EPOS4 50/5 features two NET connectors for extension communication interfaces, such as EtherCAT. One serves for NET input, the other for NET output. Both sockets are identical in respect to their external wiring. -
Page 53: Extension Signal (X16)
EXT2 (Table 3-64) pink EXT-6 blue EXT-7 EXT-8 black EXT-9 violet EXT-10 Table 3-63 Extension Signal connector X16 – Pin assignment For the matching prefab cable assembly Table 3-27 on page 3-29. EPOS4 50/5 Hardware Reference 3-53 CCMC | 2023-07 | rel11726... -
Page 54: Extension Slots (Ext1 & Ext2)
Switch off the controller’s power supply before removing or inserting an extension card. Electrostatic sensitive device (ESD) • Wear working cloth and use equipment in compliance with ESD protective measures. • Handle device with extra care. Continued on next page. EPOS4 50/5 Hardware Reference 3-54 CCMC | 2023-07 | rel11726... -
Page 55: Figure 3-44 Installation & Removal Of An Extension Card
Fold down the plastic lid (H), press it down firmly, and let the two latches snap into place. Figure 3-44 Installation & removal of an extension card Continued on next page. EPOS4 50/5 Hardware Reference 3-55 CCMC | 2023-07 | rel11726... -
Page 56: Dip Switch Configuration (Sw1)
• DIP switches 6…8 do not have any impact on the ID. Switch Binary Code Valence Setting (factory setting) Table 3-65 DIP switch SW1 – Binary code values Continued on next page. EPOS4 50/5 Hardware Reference 3-56 CCMC | 2023-07 | rel11726... -
Page 57: Can Automatic Bit Rate Detection
DIP switch SW1 – CAN automatic bit rate detection 3.3.16.3 CAN Bus Termination Switch Without bus termination Bus termination with 120 Ω (factory setting) Table 3-68 DIP switch SW1 – CAN bus termination EPOS4 50/5 Hardware Reference 3-57 CCMC | 2023-07 | rel11726... -
Page 58: Digital Input Level
Logic level PLC level (factory setting) Table 3-69 DIP switch SW1 – Digital input level 3.3.17 Spare Parts Order number Description 520860 STO Idle Connector X9 Table 3-70 Spare parts list EPOS4 50/5 Hardware Reference 3-58 CCMC | 2023-07 | rel11726... -
Page 59: Status Indicators
(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 3-71 NET Status LEDs EPOS4 50/5 Hardware Reference 3-59 CCMC | 2023-07 | rel11726... -
Page 60: Table 3-72 Device Status Leds
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 3-73 NET Port LED EPOS4 50/5 Hardware Reference 3-60 CCMC | 2023-07 | rel11726... -
Page 61: 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 50/5 Hardware Reference 4-61 CCMC | 2022-04 | rel10445... -
Page 62: Possible Combinations To Connect A Motor
4-56 4-50 4-53 / 4-54 4-50 4-53 / 4-55 4-50 4-53 / 4-56 Table 4-74 Possible combinations of feedback signals for DC motor EPOS4 50/5 Hardware Reference 4-62 CCMC | 2022-04 | rel10445... -
Page 63: Figure 4-51 Ec (Bldc) Motor
4-51 4-52 / 4-53 / 4-56 4-51 4-53 / 4-56 4-51 EC10 4-56 Table 4-75 Possible combinations of feedback signals for EC (BLDC) motor EPOS4 50/5 Hardware Reference 4-63 CCMC | 2022-04 | rel10445... -
Page 64: Main Wiring Diagram
Wiring Main Wiring Diagram Main Wiring Diagram Figure 4-54 Figure 4-55 Figure 4-56 Figure 4-48 Main wiring diagram EPOS4 50/5 Hardware Reference 4-64 CCMC | 2022-04 | rel10445... -
Page 65: Excerpts
Power & logic supply 4.3.2 DC Motor Figure 4-50 DC motor 4.3.3 EC (BLDC) Motor Figure 4-51 EC (BLDC) motor 4.3.4 Hall Sensors (Sensor 3) Figure 4-52 Hall sensors (Sensor 3) EPOS4 50/5 Hardware Reference 4-65 CCMC | 2022-04 | rel10445... -
Page 66: Figure 4-53 Digital Incremental Encoder 1 (Sensor 1)
Digital incremental encoder 1 (Sensor 1) 4.3.6 Digital Incremental Encoder 2 (Sensor 2) Figure 4-54 Digital incremental encoder 2 (Sensor 2) 4.3.7 Analog incremental encoder SinCos (Sensor 2) Figure 4-55 Analog incremental encoder (Sensor 2) EPOS4 50/5 Hardware Reference 4-66 CCMC | 2022-04 | rel10445... -
Page 67: Figure 4-56 Ssi Encoder (Sensor 2)
Wiring Excerpts 4.3.8 SSI Encoder (Sensor 2) Figure 4-56 SSI encoder (Sensor 2) EPOS4 50/5 Hardware Reference 4-67 CCMC | 2022-04 | rel10445... - Page 68 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 50/5 Hardware Reference 4-68 CCMC | 2022-04 | rel10445...
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Page 69: List Of Figures
Extension IN & OUT connectors X14 & X15 ..........52 EPOS4 50/5 Hardware Reference... - Page 70 SSI encoder (Sensor 2) ..............67 EPOS4 50/5 Hardware Reference...
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Page 71: List Of Tables
Motor connector X3– Pin assignment for maxon EC motor ....... . - Page 72 Possible combinations of feedback signals for EC (BLDC) motor ........63 EPOS4 50/5 Hardware Reference...
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Page 73: Index
(and signs) used in this document unplug an extension card ID (of the device) incorporation into surrounding system informatory signs inputs analog high-speed digital interfaces location and designation RS232 LEDs, interpretation of country-specific regulations EPOS4 50/5 Hardware Reference Z-73 CCMC | 2023-07 | rel11726... - Page 74 Requirements of power supply safety alerts safety first! signs used SSI encoder specification wiring standards, fulfilled status LEDs supply voltage, required EPOS4 50/5 Hardware Reference Z-74 CCMC | 2023-07 | rel11726...
- Page 75 Index EPOS4 50/5 Hardware Reference Z-75 CCMC | 2023-07 | rel11726...
- Page 76 EtherCAT® is a registered trademark and patented technology, licensed by Beckhoff Automation GmbH, Germany © 2023 maxon. All rights reserved. Any use, in particular reproduction, editing, translation, and copying, without prior written approval is not permitted (contact: maxon international ltd., Brünigstrasse 220, CH-6072 Sachseln, +41 41 666 15 00, www.max- ongroup.com).
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