Maxon EPOS4 Application guide

EPOS4 EtherCAT Card Positioning Controller | P/N 581245
Hardware Reference
CCMC | Edition 2019-11 | DocID rel8613
Hardware Reference

Table of Contents
EPOS4 EtherCAT Card Hardware Reference
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1 ABOUT 3
1.1 About this Document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 About the Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 About the Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 SPECIFICATIONS 7
2.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 SETUP 11
3.1 Generally applicable Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3.1 EPOS4 Controllers with encased Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3.2 EPOS4 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 MOTHERBOARD DESIGN GUIDE 17
4.1 Schematic Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Requirements for Components of Third-party Suppliers. . . . . . . . . . . . . . . . . . . 18
4.2.1 Card Edge Connector & Socket Headers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2.2 Supply Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.3 EtherCAT Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2.4 EtherCAT Port LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.5 EtherCAT Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2.6 Recommended Components and Manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3 THT Footprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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.

About
About this Document
EPOS4 EtherCAT Card Hardware Reference
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1 ABOUT
1.1 About this Document
1.1.1 Intended Purpose
Use the docu-
ment 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 EtherCAT Card. 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 under-
stand and fulfill the respective work and duties.

About
About this Document
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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 signs will be used.
Table 1-2 Symbols and signs
Notation Meaning
Module refers to an EPOS4 Module (such as «EPOS4 Module 24/1.5», «EPOS4 Module
50/15»,and others)
(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
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1.1.5 Trademarks and Brand Names
For easier legibility, registered brand names are listed below and will not be further tagged with their respec-
tive trademark. It must be understood that the brands (the list below is not necessarily concluding) are pro-
tected 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
This document is protected by copyright. Any further use (including reproduction, translation, microfilming,
and other means of electronic data processing) without prior written approval is not permitted. The men-
tioned trademarks belong to their respective owners and are protected under intellectual property rights.
© 2019 maxon. All rights reserved. Subject to change without prior notice.
CCMC | EPOS4 EtherCAT Card Hardware Reference | Edition 2019-11 | DocID rel8613
1.2 About the Device
Capabilities of the
device, included
features, and sup-
ported controllers.
maxon's «EPOS4 EtherCAT Card» is a plug-in extension card to provide complete EtherCAT communica-
tion capability for an EPOS4 positioning controller. It is optionally available to equip either an EPOS4
encased housing variant or an EPOS4 Module with full EtherCAT functionality. For the latter, development
of an own motherboard as to particular guidelines is needed (for details chapter “4 Motherboard Design
Guide” on page 4-17).
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.maxongroup.com
In addition, you may wish to browse the EPOS video library. It features video tutorials that provide easy to
follow instructions on how to get started with «EPOS Studio» and shows you tips and tricks on how to setup
communication interfaces, and so on. Explore on Vimeo: https://vimeo.com/album/4646388
Brand name Trademark owner
Adobe® Reader® © Adobe Systems Incorporated, USA-San Jose, CA
EtherCAT® © EtherCAT Technology Group, DE-Nuremberg, licensed by Beckhoff Automation
GmbH, DE-Verl
PCI Express®
PCIe® © PCI-SIG, USA-Beaverton, OR
Windows® © Microsoft Corporation, USA-Redmond, WA
maxon motor ag
Brünigstrasse 220
CH-6072 Sachseln
[phone]
www.maxongroup.com

About
About the Safety Precautions
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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 Audi-
ence” on page 1-3)!
• Refer to chapter “1.1.4 Symbols & Signs” on page 1-4 to understand the subsequently used indi-
cators!
• 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 equip-
ment. 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.
Electrostatic sensitive device (ESD)
• Wear working cloth and use equipment in compliance with ESD protective measures.
• Handle device with extra care.
Hot plugging/hot swapping the card may cause hardware damage
Switch off the controller’s power supply before removing or inserting an extension card.
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
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2 SPECIFICATIONS
2.1 Technical Data
Table 2-4 Technical data
EPOS4 EtherCAT Card (581245)
Electrical
Rating
Nominal power supply voltage +VCC 10…70 VDC
Absolute supply voltage +Vmin / +Vmax 8 VDC / 76 VDC
Interface
EtherCAT input
EtherCAT output As to IEEE 802.3 100 Base T
Max. bit rate 100 Mbit/s (full duplex)
Physical
Weight approx. 7 g
Dimensions (L x W x H) 41 x 25 x 9.2 mm
Mounting Card edge connector, PCIe; 2x18 position
Environment
Temperature
Operation −30…+60 °C
Extended range (1) For details consult Hardware Reference of
respective EPOS4 controller
Storage −40…+85 °C
Altitude (2) Operation 0…10’000 m MSL
Humidity 5…90% (condensation not permitted)
(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.

Specifications
Dimensional Drawings
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2.2 Dimensional Drawings
Figure 2-2 EPOS4 EtherCAT Card with card edge connector & retainer – Dimensional drawing [mm]

Specifications
Standards
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2.3 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.
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 2-5 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: E207844
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) 544’021 hours

Specifications
Standards
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