maxon motor EPOS4 50/5 Application guide

maxon motor ag Brünigstrasse 220 P.O.Box 263 CH-6072 Sachseln Phone [phone] Fax [phone] www.maxonmotor.com
Edition May 2017
EPOS4 Positioning Controller
Hardware Reference
maxon motor control
Positioning Controller
P/N 546047
Hardware Reference
Document ID: rel6852

maxon motor control
A-2 Document ID: rel6852 EPOS4 Positioning Controller
Edition: May 2017 EPOS4 50/5 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
1 About 5
1.1 About this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 About the Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 About the Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Specifications 9
2.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Thermal Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3Setup 15
3.1 Generally applicable Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3.1 Power Supply (X1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3.2 Logic Supply (X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.3.3 Motor (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3.4 Hall Sensor (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3.5 Encoder (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3.6 Sensor (X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3.7 Digital I/O (X7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.3.8 Analog I/O (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.3.9 STO (X9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.3.10 RS232 (X10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.3.11 CAN 1 (X11) & CAN 2 (X12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3.12 USB (X13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.3.13 Extension NET IN (X14) & Extension NET OUT (X15) . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.3.14 Extension Signal (X16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
TABLE OF CONTENTS
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.
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.
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!

maxon motor control
EPOS4 Positioning Controller Document ID: rel6852 A-3
EPOS4 50/5 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
3.3.15 Extension Slots (EXT1 & EXT2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.3.16 DIP Switch Configuration (SW1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.3.17 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.4 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4Wiring 59
4.1 Possible Combinations to connect a Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.2 Main Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.3 Excerpts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.3.1 Power & Logic Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.3.2 DC Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.3.3 EC (BLDC) Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.3.4 Hall Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.3.5 Digital Incremental Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.3.6 Digital & Digital Incremental Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.3.7 Digital & Analog Incremental Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.3.8 Digital Incremental & SSI Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.3.9 Analog Incremental Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.3.10 SSI Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

maxon motor control
A-4 Document ID: rel6852 EPOS4 Positioning Controller
Edition: May 2017 EPOS4 50/5 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
••page intentionally left blank••

About
About this Document
maxon motor control
EPOS4 Positioning Controller Document ID: rel6852 1-5
EPOS4 50/5 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
1 About
1.1 About this Document
1.1.1 Intended Purpose
Use the document
to…
–stay safe,
–be fast,
–end up with set
up and ready-to-go
equipment.
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
instructions …
• to avoid dangerous situations,
• to keep installation and/or commissioning time at a minimum,
• 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
understand and fulfill the respective work and duties.

About
About this Document
maxon motor control
1-6 Document ID: rel6852 EPOS4 Positioning Controller
Edition: May 2017 EPOS4 50/5 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
1.1.3 How to use
Throughout the document, the following notations and codes will be used.
Table 1-1 Notation used
1.1.4 Symbols & Signs
In the course of the present document, the following symbols and sings will be used.
Table 1-2 Symbols and signs
Notation Meaning
(n) refers to an item (such as part numbers, list items, etc.)
denotes “see”, “see also”, “take note of” or “go to”
Type Symbol Meaning
Safety alert
(typical)
DANGER Indicates an imminent hazardous situation. If not
avoided, it will result in death or serious injury.
WARNING Indicates a potential hazardous situation. If not
avoided, it can result in death or serious injury.
CAUTION
Indicates a probable hazardous situation or calls
the attention to unsafe practices. If not avoided, it
may result in injury.
Prohibited
action
(typical)
Indicates a dangerous action. Hence, you must not!
Mandatory
action
(typical)
Indicates a mandatory action. Hence, you must!
Information
Requirement /
Note / Remark
Indicates an activity you must perform prior
continuing, or gives information on a particular item
you need to observe.
Best practice Indicates an advice or recommendation on the
easiest and best way to further proceed.
Material
Damage
Indicates information particular to possible damage
of the equipment.

About
About the Device
maxon motor control
EPOS4 Positioning Controller Document ID: rel6852 1-7
EPOS4 50/5 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
1.1.5 Trademarks and Brand Names
For easier legibility, registered brand names are listed below and will not be further tagged with their
respective trademark. It must be understood that the brands (the list below is not necessarily conclud-
ing) are protected by copyright and/or other intellectual property rights even if their legal trademarks are
omitted in the later course of this document.
Table 1-3 Brand names and trademark owners
1.1.6 Copyright
© 2017 maxon motor. All rights reserved.
The present document – including all parts thereof – is protected by copyright. Any use (including repro-
duction, translation, microfilming, and other means of electronic data processing) beyond the narrow
restrictions of the copyright law without the prior approval of maxon motor ag, is not permitted and sub-
ject to prosecution under the applicable law.
1.2 About the Device
Capabilities of the
device, included fea-
tures, and supported
motors.
maxon motor control’s EPOS4 50/5 is a small-sized, full digital, smart positioning control unit. Its high
power density allows flexible use for brushed DC and brushless EC (BLDC) motors up to approximately
250 Watts with various feedback options, such as Hall sensors, incremental encoders as well as abso-
lute sensors in a multitude of drive applications.
The device is specially designed to be commanded and controlled as a slave node in a CANopen net-
work. In addition, the unit can be operated via any USB or RS232 communication port of a Windows or
Linux workstation. Moreover, the integrated extension interface allows pooling with optionally available
communication interfaces, such as EtherCAT or other additional functionalities.
Latest technology, such as field-oriented control (FOC) and acceleration/velocity feed forward in combi-
nation with highest control cycle rates allow sophisticated, ease-of-use motion control.
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.maxonmotor.com
Brand Name Trademark Owner
Adobe® Reader® © Adobe Systems Incorporated, USA-San Jose, CA
BiSS © iC-Haus GmbH, DE-Bodenheim
CANopen®
CiA® © CiA CAN in Automation e.V, DE-Nuremberg
CLIK-Mate™
Micro-Fit™
Mini-Fit Jr.™
Mega-Fit®
© Molex, USA-Lisle, IL
EnDat © DR. JOHANNES HEIDENHAIN GmbH, DE-Traunreut
EtherCAT® © EtherCAT Technology Group, DE-Nuremberg, licensed by Beckhoff
Automation GmbH, DE-Verl
Linux® © Linus Torvalds (The Linux Foundation, USA-San Francisco CA)
PCI Express®
PCIe® © PCI-SIG, USA-Beaverton, OR
TwinCAT® © Beckhoff Automation GmbH, DE-Verl
Windows® © Microsoft Corporation, USA-Redmond, WA
maxon motor ag
Brünigstrasse 220
P.O.Box 263
CH-6072 Sachseln
Phone
Fax
Web
[phone]
[phone]
www.maxonmotor.com

About
About the Safety Precautions
maxon motor control
1-8 Document ID: rel6852 EPOS4 Positioning Controller
Edition: May 2017 EPOS4 50/5 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
1.3 About the Safety Precautions
Keep in mind:
Safety first! Always! • Make sure that you have read and understood the note “READ THIS FIRST” on page A-2!
• Do not engage with any work unless you possess the stated skills (chapter “1.1.2 Target
Audience” on page 1-5)!
• Refer to chapter “1.1.4 Symbols & Signs” on page 1-6 to understand the subsequently used
indicators!
• 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!
Requirements
• Make sure that all associated devices and components are installed according to local regulations.
• Be aware that, by principle, an electronic apparatus cannot be considered fail-safe. Therefore, you
must make sure that any machine/apparatus has been fitted with independent monitoring and safety
equipment. 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 motor.
Electrostatic sensitive device (ESD)
• Wear working cloth and use equipment in compliance with ESD protective measures.
• Handle device with extra care.
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!

Specifications
Technical Data
maxon motor control
EPOS4 Positioning Controller Document ID: rel6852 2-9
EPOS4 50/5 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
2 Specifications
2.1 Technical Data
EPOS4 50/5 (546047)
Electrical
Rating
Nominal power supply voltage +VCC 10…50 VDC
Nominal logic supply voltage +VC10…50 VDC
Absolute supply voltage +Vmin / +Vmax 8 VDC / 56 VDC
Output voltage (max.) 0.9 x +VCC
Output current Icont / Imax (<15 s) 5 A / 15 A
Pulse Width Modulation frequency 50 kHz
Sampling rate PI current controller 25 kHz (40 μs)
Sampling rate PID speed controller 2.5 kHz (400 μs)
Sampling rate PID positioning controller 2.5 kHz (400 μs)
Max. efficiency 98% (Figure 2-3)
Max. speed DC motor limited by max. permissible speed (motor) and
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)
Built-in motor choke 3 x 15 μH; 5 A
Inputs
&
Outputs
Digital Input 1 (general purpose)
Digital Input 2 (general purpose)
Digital Input 3 (general purpose)
Digital Input 4 (general purpose)
DIP switch-selectable levels:
• Logic: +2.0…+30 VDC
• PLC: +9.0…+30 VDC
Digital Output 1 (general purpose)
Digital Output 2 (general purpose)
max. 36 VDC / IL≤500 mA
(open collector with internal pull-up)
STO Input 1
STO Input 2 +4.5…+30 VDC (optically isolated)
STO Output max. 30 VDC / IL≤15 mA (optically isolated with self-resetting
short-circuit protection)
Analog Input 1
Analog Input 2 Resolution 12-bit, −10…+10 V, 10 kHz, differential
Analog Output 1
Analog Output 2 Resolution 12-bit, −4…+4 V, 25 kHz, referenced to GND
Digital Hall sensor signals
H1, H2, H3 +2.0…+24 VDC (internal pull-up)
Digital incremental encoder signals
A, A\, B, B\, I, I\ EIA RS422, max. 6.25 MHz
Sensor signals (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
• SSI absolute encoder configurable, EIA RS422, 5 MHz
• High-speed digital input 1…4 and
High-speed digital output 1 EIA RS422, max. 6.25 MHz
Continued on next page.

Specifications
Technical Data
maxon motor control
2-10 Document ID: rel6852 EPOS4 Positioning Controller
Edition: May 2017 EPOS4 50/5 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
Table 2-4 Technical data
Voltage
Outputs
Sensor supply voltage VSensor +5 VDC / IL≤100 mA
Auxiliary output voltage VAux +5 VDC / IL≤150 mA
Motor
Connections
DC motor + Motor, −Motor
EC motor Motor winding 1, Motor winding 2, Motor winding 3
Interfaces
RS232 max. 115’200 bit/s
USB 2.0 / USB 3.0 Full Speed
CAN max. 1 Mbit/s
EtherCAT 3) Full duplex (100 Mbit/s) as to IEEE 802.3 100 Base T
Status
Indicators
Device Status Operation green LED
Error red LED
NET Status RUN state green LED
Error red LED
NET Port Link activity green LED
Physical
Weight approx. 206 g
Dimensions (L x W x H) 105.0 x 83.0 x 38.7 mm
Mounting mounting holes for M4 screws
Environ-
mental
Conditions
Temperature
Operation −30…+50 °C
Extended range 1)
+50…+80 °C;
Derating: −0.167 A/°C (Figure 2-2)
Additional derating with inserted
extension card: Ambient temperature
less 5 °C (Figure 2-2) 4)
Storage −40…+85 °C
Altitude 2) Operation 0…10’000 m MSL
Humidity 5…90% (condensation not permitted)
EPOS4 50/5 (546047)
Legend
* Available with an upcoming firmware release.
1) Operation within the extended range is permitted. However, a respective derating (declination of output current Icont)
as to the stated values will apply.
2) Operating altitude in meters above Mean Sea Level, MSL.
3) Available with optional EPOS4 EtherCAT Card.
4) 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.

Specifications
Thermal Data
maxon motor control
EPOS4 Positioning Controller Document ID: rel6852 2-11
EPOS4 50/5 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
2.2 Thermal Data
2.2.1 Derating of Output Current
Figure 2-2 Derating of output current

Specifications
Limitations
maxon motor control
2-12 Document ID: rel6852 EPOS4 Positioning Controller
Edition: May 2017 EPOS4 50/5 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
2.2.2 Power Dissipation and Efficiency
Figure 2-3 Power dissipation and efficiency
2.3 Limitations
Table 2-5 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

Specifications
Dimensional Drawing
maxon motor control
EPOS4 Positioning Controller Document ID: rel6852 2-13
EPOS4 50/5 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
2.4 Dimensional Drawing
Figure 2-4 Dimensional drawing [mm]

Specifications
Standards
maxon motor control
2-14 Document ID: rel6852 EPOS4 Positioning Controller
Edition: May 2017 EPOS4 50/5 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
2.5 Standards
The described device has been successfully tested for compliance with the below listed standards. 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 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.
Table 2-6 Standards
Electromagnetic Compatibility
Generic
IEC/EN 61000-6-2 Immunity for industrial environments
IEC/EN 61000-6-3 Emission standard for residential, commercial and light-
industrial environments
Applied
IEC/EN 55022
(CISPR22) Radio disturbance characteristics / radio interference
IEC/EN 61000-4-3 Radiated, radio-frequency, electromagnetic field immunity test
>10 V/m
IEC/EN 61000-4-4 Electrical fast transient/burst immunity test ±2 kV
IEC/EN 61000-4-6 Immunity to conducted disturbances, induced by radio-
frequency fields 10 Vrms
Others
Environment IEC/EN 60068-2-6 Environmental testing – Test Fc: Vibration (sinusoidal,
10…500 Hz, 20 m/s2)
MIL-STD-810F Random transport (10…500 Hz up to 2.53 grms)
Safety UL File Number Unassembled printed circuit board: E229342
Reliability MIL-HDBK-217F
Reliability prediction of electronic equipment
Environment: Ground, benign (GB)
Ambient temperature: 298 K (25 °C)
Component stress: In accordance with circuit diagram and
nominal power
Mean Time Between Failures (MTBF): 296'741 hours

Setup
Generally applicable Rules
maxon motor control
EPOS4 Positioning Controller Document ID: rel6852 3-15
EPOS4 50/5 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
3Setup
IMPORTANT NOTICE: PREREQUISITES FOR PERMISSION TO COMMENCE INSTALLATION
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 completed machinery or equipment.
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. 5 A
– short-time (acceleration) max. 15 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
potential 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,
balance them.
• Insert the USB connector first, then switch on the power supply of the controller.
Hot plugging/hot swapping the extension slots may cause hardware damage
Switch off the controller’s power supply before removing or inserting an extension card.
WARNING
Risk of injury
Operating the device without the full compliance of the surrounding system with the EU Direc-
tive 2006/42/EC may cause serious injuries!
• Do not operate the device, unless you have made completely sure that the other machinery fully
complies 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!

Setup
Cabling
maxon motor control
3-16 Document ID: rel6852 EPOS4 Positioning Controller
Edition: May 2017 EPOS4 50/5 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
3.2 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.
Table 3-7 Prefab maxon cables
Connector Prefab Cable Assembly
Designation Part
Number Page
X1 Power Cable 275829 3-19
X2 Power Cable 275829 3-19
X3 Motor Cable 275851 3-22
X4 Hall Sensor Cable 275878 3-23
X5 Encoder Cable 275934 3-26
X6 Sensor Cable 5x2core 520852 3-29
X7 Signal Cable 8core 520853 3-38
X8 Signal Cable 7core 520854 3-42
X9 Signal Cable 8core 520853 3-38
X10 RS232-COM Cable 520856 3-46
X11 CAN-COM Cable
CAN-CAN Cable
520857
520858
3-47
3-48
X12 CAN-COM Cable
CAN-CAN Cable
520857
520858
3-47
3-48
X13 USB Type A - micro B Cable 403968 3-49
X14 Ethernet Cable 422827 3-51
X15 Ethernet Cable 422827 3-51
X16 Sensor Cable 5x2core 520852 3-29

Setup
Cabling
maxon motor control
EPOS4 Positioning Controller Document ID: rel6852 3-17
EPOS4 50/5 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
MAKE&BAKE YOUR OWN
If you decide not to employ maxon motor’s prefab cable assemblies, you might wish to use the prepack-
aged kit that contains all connectors required to make up your own cabling.
Table 3-8 EPOS4 Connector Set – Content
TOOLS
Table 3-9 Recommended tools
EPOS4 Connector Set (520859)
Connector Specification Quantity
Connectors
Molex Mega-Fit, 2 poles (171692-0102) 1
X1 / X2 Molex Mini-Fit Jr., 2 poles (39-01-2020) 2
X3 Molex Mini-Fit Jr., 4 poles (39-01-2040) 1
Molex Mega-Fit, 4 poles (171692-0104) 1
X4 Molex Micro-Fit 3.0, 6 poles (430-25-0600) 1
X6 / X16 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
Molex Mega-Fit, female crimp terminal (172063-0311) 7
X1 / X2 / X3 Molex Mini-Fit Jr. female crimp terminal (45750-1111) 9
X4 Molex Micro-Fit 3.0 female crimp terminal (43030-0010) 7
X6…X12 /
X16 Molex CLIK-Mate crimp terminal (502579-0100) 44
Accessories
X5 3M Retainer Clip with strain relief, height 13.5 mm (3505-8110) 1
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 Mini-Fit crimp terminals Molex 63819-0900

Setup
Connections
maxon motor control
3-18 Document ID: rel6852 EPOS4 Positioning Controller
Edition: May 2017 EPOS4 50/5 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
3.3 Connections
The actual connection will depend on the overall configuration of your drive system and the type of
motor you will be using.
For each connector you will find detailed information on the pin assignment, the available accessories
and prefab cable assemblies, the requirements that must be met, if any, and the circuitry.
How to read pin assignment tables
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.
• 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.
Follow the description in given order and choose the wiring diagram (as of page 4-59) that best suits
the components you are using.
Figure 3-5 Connectors
X1
X2
X3
X4
X5
X6
X7
X8
X9
X10
X11
X12
X13
X14 5)
X15 5)
X16 5)
Power Supply page 3-19
Logic Supply page 3-21
Motor page 3-22
Hall Sensor page 3-23
Encoder page 3-25
Sensor page 3-28
Digital I/O page 3-38
Analog I/O page 3-42
STO page 3-44
RS232 page 3-46
CAN 1 page 3-47
CAN 2 page 3-47
USB page 3-49
Extension NET IN page 3-50
Extension NET OUT page 3-50
Extension Signal page 3-52
5) Requires an optionally available maxon Extension Card

Setup
Connections
maxon motor control
EPOS4 Positioning Controller Document ID: rel6852 3-19
EPOS4 50/5 Hardware Reference Edition: May 2017
© 2017 maxon motor. Subject to change without prior notice.
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
Table 3-10 Power supply connector X1 – Pin assignment
Table 3-11 Power Cable
Continued on next page.
X1
Head A Prefab Cable Head B Signal Description
Pin Color Pin
1black−GND Ground
2 black + +VCC Nominal power supply voltage (+10…+50 VDC)
Power Cable (275829)
Cross-section 2 x 0.75 mm2, grey
Length 3 m
Head A Plug Molex Mini-Fit Jr., 2 poles (39-01-2020)
Contacts Molex Mini-Fit Jr. female crimp terminals (45750)
Head B Wire end sleeves 0.75 mm2
Power supply requirements
Output voltage +VCC 10…50 VDC
Absolute output voltage min. 8 VDC; max. 56 VDC
Output current
Depending on load
• continuous max. 5 A
• short-time (acceleration, <15 s) max. 15 A

Setup
Connections
maxon motor control
3-20 Document ID: rel6852 EPOS4 Positioning Controller
Edition: May 2017 EPOS4 50/5 Hardware Reference
© 2017 maxon motor. Subject to change without prior notice.
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
protection circuit is configured inoperative within the operating range.
The formula already takes the following into account:
• Maximum PWM duty cycle of 90%
• Controller’s max. voltage drop of 1 V @ 5 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:
VCC UN
nO
------- nΔn
ΔM
---------M⋅+


1
0.9
-------
⋅⋅1V[]+≥