Technosoft iPOS4803-SY3 Use and care manual

iPOS4803-SY3
Multi Axis System,
EtherCAT
iPOS4803-SY4
Multi Axis System,
EtherCAT
Intelligent Servo Drive for DC,
Brushless DC and AC Motors
Intelligent Servo Drives
T
echnical
Reference
Technosoft 2021 P091.020.iPOS4803-SY.UM.0921

Technosoft 2021 2 iPOS4803-SY Multi Axis System, EtherCAT Technical Reference
Table of contents
Table of contents ........................................................................................................... 2
Read This First ............................................................................................................... 4
About This Manual................................................................................................................. 4
Notational Conventions......................................................................................................... 4
Trademarks ............................................................................................................................ 4
Related Documentation ......................................................................................................... 5
If you Need Assistance … ..................................................................................................... 6
1Safety information.................................................................................................... 6
1.1 Warnings....................................................................................................................... 6
1.2 Cautions........................................................................................................................ 7
1.3 Quality system, conformance and certifications ....................................................... 7
2Product Overview..................................................................................................... 8
2.1 Introduction .................................................................................................................. 8
2.2 Product Features.......................................................................................................... 9
2.3 Identification Labels................................................................................................... 10
2.4 Supported Motor-Sensor Configurations ................................................................. 11
2.4.1...... Single loop configurations...................................................................................................... 11
2.4.2...... Dual loop configurations ........................................................................................................ 11
3Hardware Installation............................................................................................. 12
3.1 iPOS4803-SY Multi Axis System Dimensions .......................................................... 12
3.2 Mechanical Mounting................................................................................................. 12
3.3 Connectors and Pinouts ............................................................................................ 13
3.3.1...... Pinouts for iPOS4803-SY3 Multi Axis System....................................................................... 13
3.3.2...... Pinouts for iPOS4803-SY4 Multi Axis System....................................................................... 14
3.3.3...... Mating Connectors for iPOS4803-SY Multi-Axis System ...................................................... 15
3.4 Connection diagrams................................................................................................. 16
3.4.1...... iPOS4803-SY Multi Axis System connection diagram .......................................................... 16
3.5 Digital I/O Connection................................................................................................ 17
3.5.1...... NPN inputs............................................................................................................................. 17
3.5.2...... NPN outputs........................................................................................................................... 17
3.6 Analog Inputs Connection......................................................................................... 18
3.6.1.1 Recommendation for wiring............................................................................................ 18
3.7 Motor connections ..................................................................................................... 19
3.7.1...... Brushless Motor connection .................................................................................................. 19
3.7.2...... DC Motor connection ............................................................................................................. 19
3.7.2.1 Recommendations for motor wiring................................................................................ 19
3.8 Feedback connections............................................................................................... 20
3.8.1...... Feedback #1 - Single-ended Incremental Encoder Connection............................................ 20

Technosoft 2021 3 iPOS4803-SY Multi Axis System, EtherCAT Technical Reference
3.8.2...... Feedback #1 - Differential Incremental Encoder Connection................................................ 20
3.8.3...... Feedback #2 - Differential Incremental Encoder Connection................................................ 21
3.8.4...... Feedback #1 – Absolute Encoder Connection: SSI, BiSS, Panasonic, Tamagawa, EnDAT,
Nikon, Sanyo Denki.............................................................................................................................. 21
3.8.5...... Feedback #2 – Absolute Encoder Connection: SSI, BiSS, Panasonic, Tamagawa, EnDAT,
Nikon, Sanyo Denki.............................................................................................................................. 22
3.8.6...... Linear(Analog) Hall Connection............................................................................................. 22
3.8.7...... Digital Hall Connection for Motor + Hall + Incremental Encoder ........................................... 23
3.8.8...... Digital Hall Connection for direct motor control without an encoder...................................... 24
3.8.8.1 General recommendations for feedback wiring.............................................................. 24
3.9 Power Supply Connection ......................................................................................... 25
3.9.1...... Supply Connection................................................................................................................. 25
3.9.1.1 Recommendations for Supply Wiring ............................................................................. 25
3.9.1.2 Recommendations to limit over-voltage during braking ................................................. 26
3.10 USB connection ...................................................................................................... 27
3.10.1.... USB connection ..................................................................................................................... 27
3.11 EtherCAT Connection............................................................................................. 28
3.11.1.... Recommendations for EtherCAT Wiring................................................................................ 28
3.12 Disabling the setup table at startup....................................................................... 29
3.12.1.... Disabling the setup table at startup ....................................................................................... 29
3.13 Axis ID Selection for CAT drives............................................................................ 29
3.14 Electrical Specifications......................................................................................... 31
3.14.1.... Operating Conditions ............................................................................................................. 31
3.14.2.... Storage Conditions ................................................................................................................ 31
3.14.3.... Mechanical Mounting ............................................................................................................. 31
3.14.4.... Environmental Characteristics ............................................................................................... 31
3.14.5.... Logic Supply Input (+VLOG) .................................................................................................... 31
3.14.6.... Motor Supply Input (+VMOT).................................................................................................... 31
3.14.7.... Motor Outputs (A/A+, B/A-, C/B+, CR/B-).............................................................................. 32
3.14.8.... Digital Inputs (IN0, IN1, IN2/LSP, IN3/LSN, IN4, IN5) ........................................................... 32
3.14.9.... Digital Outputs (OUT0, OUT1, OUT2/Error, OUT3/ Ready, OUT4, OUT5) .......................... 32
3.14.10.. Digital Hall Inputs (Hall1, Hall2, Hall3)................................................................................... 32
3.14.11.. Linear Hall Inputs (LH1, LH2, LH3)........................................................................................ 32
3.14.12.. Encoder #1 Inputs (A1+, A1-, B1+, B1-, Z1+, Z1-,) ............................................................... 33
3.14.13.. Encoder #2 Inputs (A2+, A2-, B2+, B2-) ................................................................................ 33
3.14.14.. Analog Input (AnalogIN) ........................................................................................................ 33
3.14.15.. Absolute encoder interface: SSI, BISS-C, EnDAT ................................................................ 34
4Memory Map ........................................................................................................... 37

Technosoft 2021 4 iPOS4803-SY Multi Axis System, EtherCAT Technical Reference
Read This First
Whilst Technosoft believes that the information and guidance given in this manual is correct, all parties must rely upon
their own skill and judgment when making use of it. Technosoft does not assume any liability to anyone for any loss or
damage caused by any error or omission in the work, whether such error or omission is the result of negligence or any
other cause. Any and all such liability is disclaimed.
All rights reserved. No part or parts of this document may be reproduced or transmitted in any form or by any means,
electrical or mechanical including photocopying, recording or by any information-retrieval system without permission in
writing from Technosoft S.A.
The information in this document is subject to change without notice.
About This Manual
This book is a technical reference manual for:
Product Name Part Number Description
iPOS4803-SY3
Multi Axis System,
EtherCAT
P020.200.E403 3 Axis Motion System, 3A nominal, EtherCAT®, hardware AxisID
iPOS4803-SY4
Multi Axis System,
EtherCAT
P020.200.E404 4 Axis Motion System, 3A nominal, EtherCAT®, hardware AxisID
P020.200.P404 4 Axis Motion System, 3A nominal, EtherCAT®
In order to operate the iPOS4803-SY drives, you need to pass through 3 steps:
Step 1 Hardware installation
Step 2 Drive setup using Technosoft EasySetUp software for drive commissioning
Step 3 Motion programming using one of the options:
An EtherCAT® master
The drives built-in motion controller executing a Technosoft Motion Language (TML) program
developed using Technosoft EasyMotion Studio software
A distributed control approach which combines the above options, like for example a host calling
motion functions programmed on the drives in TML
This manual covers Step 1 in detail. It describes the iPOS4803-SY hardware including the technical data, the
connectors and the wiring diagrams needed for installation.
For Step 2 and 3, please consult the document EasyMotion Studio – Quick Setup and Programming Guide. For
detailed information regarding the next steps, refer to the related documentation.
Notational Conventions
This document uses the following conventions:
•iPOS4803-SY – all products described in this manual
•IU units –Internal units of the drive
•SI units –International standard units (meter for length, seconds for time, etc.)
•TML – Technosoft Motion Language
•CoE – CAN application protocol over EtherCAT®
Trademarks
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH, Germany.

Technosoft 2021 5 iPOS4803-SY Multi Axis System, EtherCAT Technical Reference
Related Documentation
iPOS4803-SY3 Multi Axis System, EtherCAT Datasheet (P020.200.E403.DSH)
iPOS4803-SY4 Multi Axis System, EtherCAT Datasheet (P020.200.E404.DSH)
iPOS4803-SY4 Multi Axis System, EtherCAT Datasheet (P020.200.P404.DSH)
– describes the hardware connections of the iPOS4803-SY family of intelligent servo drives including
the technical data and connectors.
EasyMotion Studio – Quick Setup and Programming Guide (P091.034.ESM-
Quick.Setup.and.Programming.Guide.UM.xxxx) – describes the compatible software installation,
drive software setup commissioning, introduction to TML motion programming and motion evaluation
tools.
Help of the EasySetUp software –describes how to use EasySetUp to quickly setup any Technosoft drive
for your application using only 2 dialogues. The output of EasySetUp is a set of setup data that can be
downloaded into the drive EEPROM or saved on a PC file. At power-on, the drive is initialized with the
setup data read from its EEPROM. With EasySetUp it is also possible to retrieve the complete setup
information from a drive previously programmed. EasySetUp can be downloaded free of charge
from Technosoft web page
Motion Programming using EasyMotion Studio (part no. P091.034.ESM.UM.xxxx) –describes how to
use the EasyMotion Studio to create motion programs using in Technosoft Motion Language (TML).
EasyMotion Studio platform includes EasySetUp for the drive/motor setup, and a Motion Wizard for
the motion programming. The Motion Wizard provides a simple, graphical way of creating motion
programs and automatically generates all the TML instructions. With EasyMotion Studio you can fully
benefit from a key advantage of Technosoft drives – their capability to execute complex motions
without requiring an external motion controller, thanks to their built-in motion controller. A demo
version of EasyMotion Studio (with EasySetUp part fully functional) can be downloaded free of
charge from the Technosoft web page
CoE Programming (part no. P091.064.UM.xxxx) – describes how to program the Technosoft
intelligent drives equipped with EtherCAT® communication interface. These drives support CAN
application protocol over EtherCAT® (CoE) in conformance with CiA 402 device profile. The manual
presents the object dictionary associated with this profile. The manual also explains how to combine
the Technosoft Motion Language and the CoE commands in order to distribute the application between
the EtherCAT® master and the Technosoft drives.
Motion Programming using EasyMotion Studio (part no. P091.034.ESM.UM.xxxx) –describes how to
use the EasyMotion Studio to create motion programs using in Technosoft Motion Language (TML).
EasyMotion Studio platform includes EasySetUp for the drive/motor setup, and a Motion Wizard for
the motion programming. The Motion Wizard provides a simple, graphical way of creating motion
programs and automatically generates all the TML instructions. With EasyMotion Studio you can fully
benefit from a key advantage of Technosoft drives – their capability to execute complex motions
without requiring an external motion controller, thanks to their built-in motion controller. A demo
version of EasyMotion Studio (with EasySetUp part fully functional) can be downloaded free of
charge from the Technosoft web page

Technosoft 2021 6 iPOS4803-SY Multi Axis System, EtherCAT Technical Reference
If you Need Assistance …
If you want to … Contact Technosoft at …
Visit Technosoft online World Wide Web: http://www.technosoftmotion.com/
Receive general information
or assistance (see Note)
Ask questions about product
operation or report suspected
problems (see Note)
Make suggestions about,
or report errors in documentation.
World Wide Web: http://www.technosoftmotion.com/
Email: [e-mail]
Fax: [phone]
Email: [e-mail]
Mail: Technosoft SA
Avenue des Alpes 20
CH-2000 Neuchatel, NE
Switzerland
1 Safety information
Read carefully the information presented in this chapter before carrying out the drive installation and setup! It
is imperative to implement the safety instructions listed hereunder.
This information is intended to protect you, the drive and the accompanying equipment during the product operation.
Incorrect handling of the drive can lead to personal injury or material damage.
The following safety symbols are used in this manual:
WARNING!
SIGNALS A DANGER TO THE OPERATOR WHICH MIGHT CAUSE BODILY
INJURY. MAY INCLUDE INSTRUCTIONS TO PREVENT THIS SITUATION
CAUTION!
SIGNALS A DANGER FOR THE DRIVE WHICH MIGHT DAMAGE THE PRODUCT
OR OTHER EQUIPMENT. MAY INCLUDE INSTRUCTIONS
TO AVOID THIS
SITUATION
CAUTION! Indicates areas SENSITIVE TO electrostatic discharges (ESD) WHICH REQUIRE
HANDLING IN AN ESD PROTECTED ENVIRONMENT
1.1 Warnings
WARNING! THE VOLTAGE USED IN THE DRIVE MIGHT CAUSE ELECTRICAL SHOCKS. DO
NOT TOUCH LIVE PARTS WHILE THE POWER SUPPLIES ARE ON
WARNING!
TO AVOID ELECTRIC ARCING AND HAZARDS, NEVER CONNECT /
DISCONNECT WIRES FROM THE DRIVE WHILE THE POWER SUPPLIES ARE
ON
WARNING! THE DRIVE MAY HAVE HOT SURFACES DURING OPERATION.

Technosoft 2021 7 iPOS4803-SY Multi Axis System, EtherCAT Technical Reference
WARNING! DURING DRIVE OPERATION, THE CONTROLLED MOTOR WILL MOVE. KEEP
AWAY FROM ALL MOVING PARTS TO AVOID INJURY
1.2 Cautions
CAUTION! THE POWER SUPPLIES CONNECTED TO THE DRIVE MUST COMPLY WITH
THE PARAMETERS SPECIFIED IN THIS DOCUMENT
CAUTION!
TROUBLESHOOTING AND SERVICING ARE PERMITTED ONLY FOR
PERSONNEL AUTHORISED BY TECHNOSOFT
CAUTION!
THE DRIVE CONTAINS ELECTROSTATICALLY SENS
ITIVE COMPONENTS
WHICH MAY BE DAMAGED BY
INCORRECT HANDLING. THEREFORE THE
DRIVE SHALL BE REMOVED FROM ITS ORIGINAL PACKAGE ONLY IN AN ESD
PROTECTED ENVIRONMENT
To prevent electrostatic damage, avoid contact with insulating materials, such as synthetic fabrics or plastic surfaces.
In order to discharge static electricity build-up, place the drive on a grounded conductive surface and also ground
yourself.
1.3 Quality system, conformance and certifications
IQNet and Quality Austria certification about the implementation and maintenance of the
Quality Management System which fulfills the requirements of Standard ISO 9001:2015.
Quality Austria Certificate about the application and further development of an effective
Quality Management System complying with the requirements of Standard ISO 9001:2015
REACH Compliance - TECHNOSOFT hereby confirms that this product comply with the
legal obligations regarding Article 33 of the European REACH Regulation 1907/2006
(Registration, Evaluation, Authorization
and Restriction of Chemicals), which came into
force on 01.06.2007.
RoHS Compliance - Technosoft SA here with declares that this product is manufactured in
compliance with the RoHS directive 2002/95/EC on the restriction of the use of certain
hazardous substances in electrical and electronic equipment (RoHS)
Technosoft SA hereby declares that this product conforms to the following European
applicable directives:
2014/30/EU Electromagnetic Compatibility (EMC) Directive
2014/35/EU Low Voltage Directive (LVD)
93/68/EEC CE Marking Directive
Conflict minerals statement - Technosoft declares that the company does not purchase
3T&G (tin, tantalum, tungsten & gold) directly from mines or smelters...
We have no indication that Technosoft products contain minerals from conflict mines or
smelters in and around the DRC.
For other certifications visit: http://technosoftmotion.com/en/quality-system

Technosoft 2021 8 iPOS4803-SY Multi Axis System, EtherCAT Technical Reference
2 Product Overview
2.1 Introduction
The iPOS4803-SY is a family of fully digital intelligent servo drives, based on the latest DSP technology and they offer
unprecedented drive performance combined with an embedded motion controller.
Suitable for control of brushless DC, brushless AC (vector control) and DC brushed motors the iPOS4803-SY Multi
Axis System accept as position feedback incremental encoders, absolute encoders (SSI, BiSS-C, EnDAT,
TAMAGAWA, Panasonic, Nikon, Sanyo Denki), digital and linear Hall signals.
All drives perform position, speed or torque control and work in single, multi-axis or stand-alone configurations.
Thanks to the embedded motion controller, the iPOS4803-SY Multi Axis System combine controller, drive and PLC
functionality in a single compact unit and are capable to execute complex motions without requiring intervention of an
external motion controller. Using the high-level Technosoft Motion Language (TML) the following operations can be
executed directly at drive level:
Setting various motion modes (profiles, PVT, PT, electronic gearing1or camming1, etc.)
Changing the motion modes and/or the motion parameters
Executing homing sequences
Controlling the program flow through:
Conditional jumps and calls of TML functions
TML interrupts generated on pre-defined or programmable conditions (protections triggered,
transitions on limit switch or capture inputs, etc.)
Waits for programmed events to occur
Handling of digital I/O and analogue input signals
Executing arithmetic and logic operations
Performing data transfers between axes
Synchronizing all the axes from a network
By implementing motion sequences directly at drive level you can really distribute the intelligence between the master
and the drives in complex multi-axis applications, reducing both the development time and the overall communication
requirements. For example, instead of trying to command each movement of an axis, you can program the drives
using TML to execute complex motion tasks and inform the master when these tasks are done. Thus, for each axis
control the master job may be reduced at: calling TML functions stored in the drive EEPROM and waiting for a
message, which confirms the TML functions execution completion.
For iPOS4803-SY commissioning EasySetUp or EasyMotion Studio PC applications may be used.
EasySetUp is a subset of EasyMotion Studio, including only the drive setup part. The output of EasySetUp is a set of
setup data that can be downloaded into the drive EEPROM or saved on a PC file. At power-on, the drive is initialized
with the setup data read from its EEPROM. With EasySetUp it is also possible to retrieve the complete setup
information from a drive previously programmed. EasySetUp shall be used for drive setup in all cases where the
motion commands are sent exclusively from a master. Hence neither the iPOS4803-SY TML programming capability
nor the drive camming mode are used. EasySetUp can be downloaded free of charge from Technosoft web
page.
EasyMotion Studio platform includes EasySetUp for the drive setup, and a Motion Wizard for the motion
programming. The Motion Wizard provides a simple, graphical way of creating motion programs and automatically
generates all the TML instructions. With EasyMotion Studio you can execute complex motions, thanks to their built-in
motion controllers. EasyMotion Studio, may be used to program motion sequences in TML.
A demo version of EasyMotion Studio (with EasySetUp part fully functional) can be downloaded free of
charge from Technosoft web page.
1Available if the master axis sends its position via a communication channel, or by using the secondary encoder input

Technosoft 2021 9 iPOS4803-SY Multi Axis System, EtherCAT Technical Reference
2.2 Product Features
•Fully digital servo multi axis system suitable for the control of rotary or linear brushless and DC brush
•Very compact design
•Sinusoidal (FOC) or trapezoidal (Hall-based) control of brushless motors
•Technosoft Motion Language (TML) instruction set for the definition and execution of motion sequences
•Standalone operation with stored motion sequences
•Communication:
•USB port for each axis
•RS-232 serial for each axis
•Dual 100Mbps EtherCAT® interfaces, for use in daisy-chaining topologies;
•Digital and analog I/Os per axis:
•3 digital inputs: 5-60V, 2 x limit switches + 1 x Enable input, NPN, pull-to-GND to activate
•3 x individually configurable input/output pins:
•Digital input, 5-60V, NPN, pull-to-GND to activate, with pull-up on-board to +5V
•Digital output, 5-60V, NPN (open-collector),I/O0 able to pull 1.5A able to drive inductive loads (such
as mechanical brake), I/O1&4 can pull 0.1A , with +5V on-board pull-ups
•Feedback devices per axis (dual-loop support)
1st feedback devices supported:
•Incremental A / B (index Z available only for 1 encoder): differential or single-ended
•Pulse & direction interface (single-ended or differential) for external (master) digital reference
•BISS / SSI / EnDAT / TAMAGAWA / Panasonic/ Nikon/ Sanyo Denki encoder interface
2nd feedback devices supported:
•Incremental encoder interface (differential)
•Pulse & direction interface (differential) for external (master) digital reference
•BISS / SSI / EnDAT / TAMAGAWA / Panasonic/ Nikon/ Sanyo Denki encoder interface
Separate feedback devices supported:
•Hall sensors interface (digital or linear)
•1 analogue input: 16bit ±10V or 12-bit 0-5V: Reference, Feedback or general purpose
•Various motion programming modes:
•Position profiles with trapezoidal or S-curve speed shape
•Position, Velocity, Time (PVT) 3rd order interpolation
•Position, Time (PT) 1st order interpolation
•Cyclic Synchronous Position (CSP) for CANopen mode and EtherCAT® drives.
•Cyclic Synchronous Velocity (CSV) only for EtherCAT® drives.
•Cyclic Synchronous Torque (CST) only for EtherCAT® drives.
•Electronic gearing and camming
•35 Homing modes
•EtherCAT® supported protocols for CAT drives:
•FoE – File over EtherCAT – for setup/TML functions and firmware update
•EoE – Ethernet over EtherCAT – for Easy Motion studio communication over EtherCAT
•16K ×16 internal SRAM memory for data acquisition
•16K ×16 E2ROM to store TML motion programs, cam tables and other user data
•PWM switching frequency up to 100kHz
•Motor supply: 7-48VDC
•Logic supply: 6-48VDC
•Operating ambient temperature: 0-40°C (over 40°C with derating)
•Protections:
•Short-circuit between motor phases
•Short-circuit from motor phases to ground
•Over-voltage
•Under-voltage
•Over-current
•Over-temperature
•Communication error
•Control error

Technosoft 2021 10 iPOS4803-SY Multi Axis System, EtherCAT Technical Reference
2.3 Identification Labels
Figure 1 iPOS4803-SY Multi Axis System, EtherCAT identification labels1
The iPOS4803 can have the following part numbers and names on the identification label:
•P020.200.E403 – iPOS4803-SY3 – 3 Axis Motion System, 3A nominal, EtherCAT®, hardware AxisID
•P020.200.E404 – iPOS4803-SY4 – 4 Axis Motion System, 3A nominal, EtherCAT®, hardware AxisID
•P020.200.P404 – iPOS4803-SY4 – 4 Axis Motion System, 3A nominal, EtherCAT®
1Where “x” can be 1, 2 or 3 for iPOS4803-SY3 or 1, 2, 3 or 4 for iPOS4803-SY4

Technosoft 2021 11 iPOS4803-SY Multi Axis System, EtherCAT Technical Reference
2.4 Supported Motor-Sensor Configurations
2.4.1 Single loop configurations
The position and/or speed are controlled using one feedback sensor. The other available feedback sensor input can
be used for External reference Position or Velocity, Pulse and Direction, Electronic Gearing or Camming.
Motor
Sensor Brushless
PMSM
Brushless
BLDC DC Brush
Sensor type Sensor location
Incr. encoder
FDBK #1 (single ended or diff.)
Yes - Yes
FDBK #2 (diff.)
Incr. encoder +
Digital Hall
FDBK #1 (single ended or diff.)
Digital
Halls
interface
Yes Yes -
FDBK #2 (diff.)
Digital halls only
Digital halls interface
Yes
-
-
Linear halls
(analogue)
Linear halls interface Yes - -
SSI
FDBK #1
(single ended or diff.)
FDBK #2
(diff.)
Yes Yes Yes
EnDAT
FDBK #1
(single ended or diff.)
FDBK #2
(diff.)
Yes Yes Yes
BiSS-C
FDBK #1
(single ended or diff.)
FDBK #2
(diff.)
Yes Yes Yes
TAMAGAWA
FDBK #1
(single ended or diff.)
FDBK #2
(diff.)
Yes Yes Yes
Panasonic
FDBK #1
(single ended or diff.)
FDBK #2
(diff.)
Yes Yes Yes
Nikon
FDBK #1
(single ended or diff.)
FDBK #2
(diff.)
Yes Yes Yes
Sanyo Denki
FDBK #1
(single ended or diff.)
FDBK #2
(diff.)
Yes Yes Yes
Tacho
Analogue input: Feedback
-
-
Yes
2.4.2 Dual loop configurations
The motor speed control loop is closed on one feedback connected on the motor while the motor position control loop
is closed on the other available feedback which is placed on the load. There is usually a transmission between the
load and the motor.
Motor type Feedback #1 Feedback #2
PMSM
Incremental encoder
(single-ended or differential)
Incremental encoder
(differential)
Linear Halls (only on motor)
SSI/ BiSS C/ EnDat/ TAMAGAWA/
Panasonic/ Nikon/ Sanyo Denki encoder
SSI/ BiSS C/ EnDat/ TAMAGAWA/
Panasonic/ Nikon/ Sanyo Denki encoder
BLDC
Incremental encoder
(single-ended or differential) + Digital halls
Incremental encoder (differential) + Digital
Halls
SSI/ BiSS C/ EnDat/ TAMAGAWA/
Panasonic/ Nikon/ Sanyo Denki encoder
SSI/ BiSS C/ EnDat/ TAMAGAWA/
Panasonic/ Nikon/ Sanyo Denki encoder
DC Brush
Incremental encoder
(single-ended or differential)
Incremental encoder
(differential)
Analogue Tacho (only on motor)
SSI/ BiSS C/ EnDat/ TAMAGAWA/
Panasonic/ Nikon/ Sanyo Denki encoder
SSI/ BiSS C/ EnDat/ TAMAGAWA/
Panasonic/ Nikon/ Sanyo Denki encoder
Each defined motor type can have any combination of the supported feedbacks either on motor or on load.
Example: PMSM motor with Incremental encoder (from feedback #1) on motor and Incremental encoder (from
feedback#2) on load

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3 Hardware Installation
3.1 iPOS4803-SY Multi Axis System Dimensions
Figure 2iPOS4803-SY Multi Axis System dimensions
All dimensions are in mm. The drawings are not to scale.
3.2 Mechanical Mounting
The iPOS4803-SY Multi Axis System is intended to be mounted vertically or horizontally on a metallic support using
the provided mounting holes and the recommended mating connectors.
For thermal calculations: the iPOS4803-SY Multi Axis System can be assumed to generate 1 Watt (= 3.4 BTU/hour) at
idle, and up to 2.2 Watt (=7.5 BTU/hour) worst case while driving a motor.
The recommended inserts and screws are:
Image Connector Description Manufacturer Part Number
- Self-clinching nuts M2
PennEngineering®
(PEM®) KF2-M2-ET
- Screws M2x10 Bossard BN610-M2x10

Technosoft 2021 13 iPOS4803-SY Multi Axis System, EtherCAT Technical Reference
3.3 Connectors and Pinouts
3.3.1 Pinouts for iPOS4803-SY3 Multi Axis System
•Where “x” can be 1, 2 or 3

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3.3.2 Pinouts for iPOS4803-SY4 Multi Axis System
•Where “x” can be 1, 2, 3 or 4

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3.3.3 Mating Connectors for iPOS4803-SY Multi-Axis System
Image Connector Description Manufacturer Part Number Image
J1
Nano-Fit Receptacle Housing, TPA Capable,
2.50mm Pitch, Dual Row, 8
Circuits, Black,
Glow-Wire Capable
Molex 1053081208
J2#x
1x4 Nano-Fit, 2.50mm Pitch Nano-Fit Wire-to-
Board Housing, 4 circuits
Molex 1053071204
J3#x
2x10 Pico-Clasp, 1.00mm Pitch Pico-Clasp
Wire-to-Board Housing, 20 Circuits
Molex 5011892010
J4#x
1x13 Pico
-Clasp, 1.00mm Pitch Pico-Clasp
Wire
-to-Board Housing, 13 Circuits Molex 5013301300
J9
1x3 Nano
-Fit, 2.50mm Pitch Nano-Fit Wire-to-
Board Housing, 3 circuits
Molex 1053071203
J7#x
USB cable, Cable USB A Male - Micro B
Male, 1m, shielded, black, 9.6mm plastic
width
Tensility
International
Corp
1002333
J8#x
Pico
-Clasp Receptacle Crimp Housing,
1.00mm Pitch, Single Row,
Friction Lock, 5
Circuits, White
Molex 5013300500
J1, J9, J2#x
Pre
-
Crimped
wires for
Nano
-Fit
Cable Assembly, Nano-Fit
Crimp Terminal Socket to
Nano-Fit Crimp Terminal
Socket, 300mm
Molex 0797582140
J3#x, J4#x,
J8#x
Pre
-
Crimped
wires for
Pico
-Clasp
Cable Assembly, Pico-Clasp
Crimp Terminal Socket to
Pico-Clasp Crimp Terminal
Socket, 300mm
Molex 0797581019
J1, J9, J2#x
Pins for
Nano
-Fit
Nano-Fit Crimp Terminal,
Female, 2.54μm Matte Tin
(Sn) Plating, 20-22 AWG
Molex 1053002100
J3, J4,
J8#x
Pins for
Pico
-Clasp
1.00mm Pitch, Pico-Clasp
Female Crimp Terminal, Gold
Plating 0.10μm, 28-32 AWG,
Reel
Molex 5011937000
J1, J9, J2#x
Crimp tool
Pico
-Clasp
Crimp Tool, Ratchet, Molex
Pico-Clasp 501193 & 501334
Series 32-28AWG Contacts
Molex 638191500
J3#x, J4#x,
J8#x
Crimp tool
Nano Fit
Crimp Tool, Ratchet, Molex
Nano-Fit 105300 Series 26-
24AWG Socket Contacts,
207129 Series
Molex 638276000
•Where “x” can be 1, 2 or 3 for iPOS4803-SY3 or 1, 2, 3 or 4 for iPOS4803-SY4

Technosoft 2021 16 iPOS4803-SY Multi Axis System, EtherCAT Technical Reference
3.4 Connection diagrams
3.4.1 iPOS4803-SY Multi Axis System connection diagram
Figure 3iPOS4803-SY Multi Axis System Connection diagram
*Where “x” can be 1, 2 or 3 for iPOS4803-SY3 or 1, 2, 3 or 4 for iPOS4803-SY4
**For other available feedback / motor options, check the detailed diagrams below
***Pins are software selectable individually as NPN inputs/outputs

Technosoft 2021 17 iPOS4803-SY Multi Axis System, EtherCAT Technical Reference
3.5 Digital I/O Connection
3.5.1 NPN inputs
Figure 4Digital NPN Inputs connection for iPOS4803-SY
Remarks:
1. The inputs are compatible with NPN type outputs (input must be pulled to GND to change its default state).
2. The I/O pins are individually software selectable as either NPN inputs or outputs.
3. The length of the cables must be up to 30m, reducing the exposure to voltage surges in industrial
environment.
3.5.2 NPN outputs
Figure 5Digital NPN Outputs connection for iPOS4803-SY
Remarks:
1. The outputs are compatible with NPN type inputs (load is tied to common +VLOG, output pulls to GND when
active and is floating when inactive).
2. The I/O pins are individually software selectable as either NPN inputs or outputs.

Technosoft 2021 18 iPOS4803-SY Multi Axis System, EtherCAT Technical Reference
3.6 Analog Inputs Connection
+5VOUT
iPOS4803-SY
Analog Inputs
Connection
+3.3V
AnalogIN
Controller
100Ω Ω÷1K
13
11
12
GND
+5V
0÷5V
20K
Low-Pass
& ESD
J4#x
Figure 60-5V Analog inputs connection for iPOS4803-SY
Remarks:
1. The analog input range is configurable by software: 16bit ±10V or 12-bit 0-5V: Reference, Feedback or
general purpose input.
2. The length of the cables must be up to 30m, reducing the exposure to voltage surges in industrial
environment.
3.6.1.1 Recommendation for wiring
a) If the analogue signal source is single-ended, use a 2-wire twisted shielded cable as follows: 1st wire
connects the live signal to the drive input; 2nd wire connects the source ground to the drive ground; shield will
be connected to the drive ground terminal.
b) If the analogue signal source is differential and the signal source ground is isolated from the drive GND, use
a 2-wire twisted shielded cable as follows: 1st wire connects the source plus (positive, in-phase) to the drive
analogue input; 2nd wire connects the source minus (negative, out-of-phase) to the drive ground (GND).
Shield is connected only at the drive side, to the drive PE, and is left unconnected at the source side.
c) If the analogue signal source is differential and the signal source ground is common with the drive GND, use
a 2-wire shielded cable as follows: 1st wire connects the source plus (positive, in-phase) to the drive
analogue input; 2nd wire connects the source ground to the drive ground (GND); shield is connected only at
the drive side, to the drive PE, and is left unconnected at the source side. The source minus (negative, out-
of-phase) output remains unconnected.

Technosoft 2021 19 iPOS4803-SY Multi Axis System, EtherCAT Technical Reference
3.7 Motor connections
3.7.1 Brushless Motor connection
Figure 7Brushless motor connection for iPOS4803-SY
3.7.2 DC Motor connection
Figure 8DC Motor connection for iPOS4803-SY
3.7.2.1 Recommendations for motor wiring
a) Avoid running the motor wires in parallel with other wires for a distance longer than 2 meters. If this situation
cannot be avoided, use a shielded cable for the motor wires.
b) The parasitic capacitance between the motor wires must not bypass 10nF. If very long cables (tens of
meters) are used, this condition may not be met. In this case, add series inductors between the iPOS4803-
SY Multi Axis System outputs and the cable. The inductors must be magnetically shielded (toroidal, for
example), and must be rated for the motor surge current. Typically the necessary values are around 100 μH.
c) A good shielding can be obtained if the motor wires are running inside a metallic cable guide.

Technosoft 2021 20 iPOS4803-SY Multi Axis System, EtherCAT Technical Reference
3.8 Feedback connections
3.8.1 Feedback #1 - Single-ended Incremental Encoder Connection
Figure 9Feedback #1 - Single-ended Incremental Encoder Connection for iPOS4803-SY
CAUTION!
DO NOT CONNECT UNTERMINATED WIRES TO PINS J3#x.9, J3#x.13 AND
J3#x.17
. THEY MIGHT PICK UP UNWANTED NOISE AND GIVE FALSE
ENCODER READINGS.
3.8.2 Feedback #1 - Differential Incremental Encoder Connection
Figure 10 Feedback #1 - Differential Incremental Encoder Connection for iPOS4803-SY
Remarks:
1. For iPOS4803-SY Multi Axis System Feedback #1 differential connection, 120Ω (0.25W) termination resistors
are internally added by putting the SW1#x pins 1,2 and 3 on “ON” position.
2. Length of the cables must be up to 30m, reducing the exposure to voltage surges in industrial environment.