Technosoft iPOS4803P Use and care manual

iPOS4803P
Microdrive EtherCAT
iPOS4803PE
Microdrive EtherCAT
iPOS4803S
Microdrive EtherCAT
Intelligent Servo Drive for DC,
Brushless DC and AC Motors
Intelligent Servo Drives
Technical
Reference
©Technosoft 2022 P091.020.iPOS4803.UM.0622

©Technosoft 2022 2 iPOS4803 Microdrive EtherCAT Technical Reference
Table of contents
Table of contents ...................................................................................................................... 2
Read This First .......................................................................................................................... 4
About This Manual ................................................................................................................................... 4
Notational Conventions........................................................................................................................... 4
Trademarks............................................................................................................................................... 5
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 iPOS4803P Microdrive Dimensions .......................................................................................... 12
3.2 iPOS4803PE Microdrive Dimensions ........................................................................................ 12
3.3 iPOS4803S Microdrive Dimensions .......................................................................................... 12
3.4 Mechanical Mounting.................................................................................................................. 13
3.4.1....... iPOS4803P and iPOS4803PE Microdrive.............................................................................................13
3.4.2....... PCB Design .......................................................................................................................................... 14
3.4.2.1 Motherboard PCB Design ............................................................................................................. 15
3.4.2.2 Recommendations for the PCB Design.........................................................................................15
3.4.2.3 EtherCAT signals PCB routing indications ....................................................................................16
3.5 Connectors and Pinouts............................................................................................................. 19
3.5.1....... Pinouts for iPOS4803P Microdrive........................................................................................................19
3.5.2....... Pinouts for iPOS4803PE Microdrive ..................................................................................................... 20
3.5.3....... Pinouts for iPOS4803S Microdrive........................................................................................................21
3.5.4....... Mating Connectors for iPOS4803S Microdrive...................................................................................... 22
3.6 Connection diagrams ................................................................................................................. 23
3.6.1....... iPOS4803P and iPOS4803PE connection diagram .............................................................................. 23
3.6.2....... iPOS4803S connection diagram ........................................................................................................... 24
3.7 24V Digital I/O Connection ......................................................................................................... 25
3.7.1....... NPN inputs............................................................................................................................................ 25
3.7.2....... NPN outputs.......................................................................................................................................... 26
3.7.3....... Solenoid driver connection for motor brake...........................................................................................27
3.8 Analog Inputs Connection ......................................................................................................... 28
3.8.1.1 Recommendation for wiring........................................................................................................... 28

©Technosoft 2022 3 iPOS4803 Microdrive EtherCAT Technical Reference
3.9 Motor connections ...................................................................................................................... 29
3.9.1....... Brushless Motor connection..................................................................................................................29
3.9.2....... DC Motor connection ............................................................................................................................30
3.9.2.1 Recommendations for motor wiring...............................................................................................30
3.10 Feedback connections............................................................................................................ 31
3.10.1..... Feedback #1 - Single-ended Incremental Encoder Connection ............................................................31
3.10.2..... Feedback #1 - Differential Incremental Encoder Connection ................................................................ 32
3.10.3..... Feedback #2 - Single-ended Incremental Encoder Connection ............................................................33
3.10.4..... Feedback #2 - Differential Incremental Encoder Connection ................................................................ 33
3.10.5..... Feedback #1 –Absolute Encoder Connection: SSI, BiSS, Panasonic, Tamagawa, EnDAT, Nikon,
Sanyo Denki..........................................................................................................................................................34
3.10.6..... Feedback #2 –Absolute Encoder Connection: SSI, BiSS, Panasonic, Tamagawa, EnDAT, Nikon,
Sanyo Denki..........................................................................................................................................................35
3.10.7..... Linear Hall Connection.......................................................................................................................... 36
3.10.8..... Digital Hall Connection for Motor + Hall + Incremental Encoder ...........................................................37
3.10.9..... Digital Hall Connection for direct motor control without an encoder...................................................... 38
3.10.9.1 General recommendations for feedback wiring .............................................................................38
3.11 Power Supply Connection ...................................................................................................... 39
3.11.1..... Supply Connection ................................................................................................................................39
3.11.1.1 Recommendations for Supply Wiring ............................................................................................ 40
3.11.1.2 Recommendations to limit over-voltage during braking................................................................. 40
3.12 USB connection....................................................................................................................... 41
3.12.1..... USB connection ....................................................................................................................................41
3.13 EtherCAT Connection ............................................................................................................. 42
3.13.1..... Recommendations for EtherCAT Wiring ............................................................................................... 42
3.13.2..... EtherCAT signals schematic considerations ......................................................................................... 44
3.14 Disabling the setup table at startup ...................................................................................... 45
3.14.1..... Disabling the setup table at startup .......................................................................................................45
3.15 LED Indicators for iPOS4803P ............................................................................................... 46
3.16 Axis ID Selection for CAT drives ........................................................................................... 47
3.16.1..... iPOS4803P and iPOS4803PE ..............................................................................................................47
3.16.2..... iPOS4803S (SW1 settings)................................................................................................................... 48
3.17 Electrical Specifications ......................................................................................................... 49
3.17.1..... 0BOperating Conditions ............................................................................................................................49
3.17.2..... 1BStorage Conditions................................................................................................................................ 49
3.17.3..... 2BMechanical Mounting ............................................................................................................................49
3.17.4..... 3BEnvironmental Characteristics...............................................................................................................49
3.17.5..... 4BLogic Supply Input (+VLOG)....................................................................................................................49
3.17.6..... 5BMotor Supply Input (+VMOT)...................................................................................................................50
3.17.7..... 6BMotor Outputs (A/A+, B/A-, C/B+, CR/B-) .............................................................................................50
3.17.8..... 7BDigital Inputs (IN0, IN1, IN2/LSP, IN3/LSN, IN4, IN5) ...........................................................................50
3.17.1..... 7B RS-232................................................................................................................................................. 50
3.17.1..... USB....................................................................................................................................................... 50
3.17.2..... 8BDigital Outputs (OUT0, OUT1, OUT2/Error, OUT3/ Ready, OUT4, OUT5)...........................................51
3.17.3..... 9BDigital Hall Inputs (Hall1, Hall2, Hall3) ..................................................................................................51
3.17.4..... 11BEncoder Inputs (A1+, A1-, B1+, B1-, Z1+, Z1-, A2+, A2-, B2+, B2-, Z2+, Z2-) .....................................51
3.17.5..... 13BAnalog Input (REF,FDBK)..................................................................................................................... 51
3.17.6..... 14BSSI/BiSS/Panasonic/Tamagawa/EnDAT/Nikon/Sanyo Denki encoder interface ..................................53
4Memory Map...................................................................................................................... 55

©Technosoft 2022 4 iPOS4803 Microdrive 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
iPOS4803P
Microdrive EtherCAT
P020.001.E122
Pins version, 3A nominal, EtherCAT®, hardware AxisID
P020.001.P122
Pins version, 3A nominal, EtherCAT®
iPOS4803PE
Microdrive EtherCAT
P020.001.E322
Enhanced pins version, 3A nominal, EtherCAT®, hardware AxisID
P020.001.P322
Enhanced pins version, 3A nominal, EtherCAT®
iPOS4803S
Microdrive EtherCAT
P020.801.E222
Standalone version, 3A nominal, EtherCAT®, hardware AxisID
P020.801.P222
Standalone version, 3A nominal, EtherCAT®
In order to operate the iPOS4803 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® master0F
1
❑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 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–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®
1
when using and iPOS4803 Microdrive

©Technosoft 2022 5 iPOS4803 Microdrive EtherCAT Technical Reference
Trademarks
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH, Germany.
Related Documentation
iPOS4803P Microdrive EtherCAT Datasheet (P020.001.E122.DSH)
iPOS4803P Microdrive EtherCAT Datasheet (P020.001.P122.DSH)
iPOS4803PE Microdrive EtherCAT Datasheet (P020.001.E322.DSH)
iPOS4803PE Microdrive EtherCAT Datasheet (P020.001.P322.DSH)
iPOS4803S Microdrive EtherCAT Datasheet (P020.801.E222.DSH)
iPOS4803S Microdrive EtherCAT Datasheet (P020.801.P222.DSH)
–describes the hardware connections of the iPOS4803 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
iPOS CoE Programming (part no. P091.064.UM.0919) –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.
TML_LIB v2.0 (part no. P091.040.v20.UM.xxxx) –explains how to program in C, C++,C#, Visual Basic or
Delphi Pascal a motion application for the Technosoft intelligent drives using TML_LIB v2.0 motion
control library for PCs. The TML_lib includes ready-to-run examples that can be executed on Windows
or Linux (x86 and x64).
TML_LIB_LabVIEW v2.0 (part no. P091.040.LABVIEW.v20.UM.xxxx) –explains how to program in
LabVIEW a motion application for the Technosoft intelligent drives using TML_LIB_LabVIEW v2.0
motion control library for PCs. The TML_Lib_LabVIEW includes over 40 ready-to-run examples.
TML_LIB_S7 (part no. P091.040.S7.UM.xxxx) –explains how to program in a PLC Siemens series S7-300
or S7-400 a motion application for the Technosoft intelligent drives using TML_LIB_S7 motion control
library. The TML_LIB_S7 library is IEC61131-3 compatible.
TML_LIB_CJ1 (part no. P091.040.CJ1.UM.xxxx) –explains how to program in a PLC Omron series CJ1 a
motion application for the Technosoft intelligent drives using TML_LIB_CJ1 motion control library for
PLCs. The TML_LIB_CJ1 library is IEC61131-3 compatible.
TML_LIB_X20 (part no. P091.040.X20.UM.xxxx) –explains how to program in a PLC B&R series X20 a
motion application for the Technosoft intelligent drives using TML_LIB_X20 motion control library for
PLCs. The TML_LIB_X20 library is IEC61131-3 compatible.

©Technosoft 2022 6 iPOS4803 Microdrive 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: [email protected]
Fax: [phone]
Email: [email protected]
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 2022 7 iPOS4803 Microdrive 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 SENSITIVE 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 2022 8 iPOS4803 Microdrive EtherCAT Technical Reference
2 Product Overview
2.1 Introduction
The iPOS4803 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 drives
accept as position feedback incremental encoders, absolute encoders (SSI, BiSS-C, EnDAT, TAMAGAWA,
Panasonic, Nikon, Sanyo Denki) 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 drives 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 camming1F
1
, 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 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 iPOS481x 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.
1
Available if the master axis sends its position via a communication channel, or by using the secondary encoder input

©Technosoft 2022 9 iPOS4803 Microdrive EtherCAT Technical Reference
2.2 Product Features
•Fully digital servo drive 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
•RS-232 serial
•Dual 100Mbps EtherCAT® interfaces, for use in daisy-chaining topologies;
•Digital and analog I/Os:
•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, I/O1&4 can pull 0.1A , able to drive
inductive loads (such as mechanical brake), with +5V on-board pull-ups
•Feedback devices (dual-loop support)
1st feedback devices supported:
•Incremental A / B (index Z available only for feedback 1): differential or single-ended
•Pulse & direction interface (single-ended or differential) for external (master) digital reference
•Absolute: differential or single-ended encoder. Supported protocols: SSI, BiSS, EnDAT, TAMAGAWA,
Panasonic, Nikon, Sanyo Denki
2nd feedback devices supported:
•Incremental encoder interface differential for iPOS4803S; differential or single-ended for iPOS4803P
and iPOS4803PE
•Pulse & direction interface for external (master) digital reference
•Absolute: differential or single-ended encoder. Supported protocols: SSI, BiSS, EnDAT, TAMAGAWA,
Panasonic, Nikon, Sanyo Denki
Separate feedback devices supported:
•Linear Hall sensors interface (digital or linear)
•1 analogue input: 12-bit 0-5V or ±10V: Reference, Feedback or general purpose
•Feature that detects breakage of Hall wires and/or of incremental/absolute encoder wires
•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
•24K 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 2022 10 iPOS4803 Microdrive EtherCAT Technical Reference
2.3 Identification Labels
Figure 1 iPOS4803P Microdrive identification labels
Figure 2 iPOS4803PE Microdrive identification labels
Figure 3 iPOS4803S Microdrive identification labels
The iPOS4803 can have the following part numbers and names on the identification label:
•P020.001.E122 name iPOS4803P Microdrive EtherCAT–Pins version, 3A nominal, EtherCAT®, hardware
AxisID selection
•P020.001.P122 name iPOS4803P Microdrive EtherCAT–Pins version, 3A nominal, EtherCAT®
•P020.001.E322 name iPOS4803PE Microdrive EtherCAT–Pins version, 3A nominal, EtherCAT®, hardware
AxisID selection
•P020.001.P322 name iPOS4803PE Microdrive EtherCAT–Pins version, 3A nominal, EtherCAT®
•P020.801.P222 name iPOS4803S Microdrive EtherCAT–Standalone version, 3A nominal, EtherCAT®
•P020.801.E222 name iPOS4803S Microdrive EtherCAT–Standalone version, 3A nominal, EtherCAT®,
hardware AxisID selection

©Technosoft 2022 11 iPOS4803 Microdrive 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 (single ended2F
1or diff.)
Incr. encoder +
Digital Hall
FDBK #1 (single ended or diff.)
Digital
Halls
interface
Yes
Yes
-
FDBK #2 (single ended1or diff.)
Digital halls only
Digital halls interface
Yes
-
-
Linear halls
(analogue)
Linear halls interface
Yes
-
-
SSI
FDBK #1
(single ended or diff.)
FDBK #2
(single ended3or diff.)
Yes
Yes
Yes
EnDAT
FDBK #1
(single ended or diff.)
FDBK #2
(single ended3or diff.)
Yes
Yes
Yes
BiSS-C
FDBK #1
(single ended or diff.)
FDBK #2
(single ended3or diff.)
Yes
Yes
Yes
TAMAGAWA
FDBK #1
(single ended or diff.)
FDBK #2
(single ended3or diff.)
Yes
Yes
Yes
Panasonic
FDBK #1
(single ended or diff.)
FDBK #2
(single ended3or diff.)
Yes
Yes
Yes
Nikon
FDBK #1
(single ended or diff.)
FDBK #2
(single ended3or diff.)
Yes
Yes
Yes
Sanyo Denki
FDBK #1
(single ended or diff.)
FDBK #2
(single ended3or 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
(single-ended1or 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 (single-ended1or
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
(single-ended1or 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
1
Single-Ended encoder compatible with iPOS4803P and iPOS4803PE drives.

©Technosoft 2022 12 iPOS4803 Microdrive EtherCAT Technical Reference
3 Hardware Installation
3.1 iPOS4803P Microdrive Dimensions
Figure 4 iPOS4803P Microdrive dimensions
3.2 iPOS4803PE Microdrive Dimensions
Figure 5 iPOS4803PE Microdrive dimensions
3.3 iPOS4803S Microdrive Dimensions
Figure 6 iPOS4803S Microdrive dimensions

©Technosoft 2022 13 iPOS4803 Microdrive EtherCAT Technical Reference
3.4 Mechanical Mounting
The iPOS4803P and iPOS4803PE Microdrives are intended to be mounted horizontally on a motherboard equipped
with the recommended mating connectors, as specified in chapter 3.3.2.1.Motherboard PCB Design. Several drives
can be hosted by a single motherboard.
The iPOS4803S Microdrive 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 Microdrives 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.
3.4.1 iPOS4803P and iPOS4803PE Microdrive
Figure 7 Recommended spacing - horizontal mounting, worst case: non-metallic, closed box
(All dimension are expressed in mm)
The figures above shows the minimum spacing to assure proper airflow by natural convection.
If closed completely in a box, ventilation openings shall be foreseen on the top and bottom sides.
If ventilation driven by natural convection is not enough to maintain the temperature surrounding the drives, then
alternate forced cooling methods must be applied.
Remark: In case of using a metallic box, with ventilation openings, all spacing values may be reduced substantially.
With proper ventilation, keeping the air surrounding the iPOS4803P or iPOS4803PE inside the limits indicated, the
spacing values may be reduced down to zero.

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3.4.2 PCB Design
For iPOS4803P Microdrive motherboard PCB design, use the dimensional drawing from Figure 8 iPOS4803P Microdrive
PCB Footprint below.
Figure 8 iPOS4803P Microdrive PCB Footprint
For iPOS4803PE Microdrive motherboard PCB design, use the dimensional drawing from Figure 9 iPOS4803PE
Microdrive PCB Footprint below.
Figure 9 iPOS4803PE Microdrive PCB Footprint

©Technosoft 2022 15 iPOS4803 Microdrive EtherCAT Technical Reference
3.4.2.1 Motherboard PCB Design
It is recommended to use a multi-layer PCB for the motherboard, in order to have enough room for routing all the pins
of the iPOS4803P / iPOS4803PE drives. Using a 2-layer PCB is possible when some of the pins remain unconnected.
The iPOS4803P / iPOS4803PE drives are intended to be mounted on a mainboard. The recommended method of
electrical connection is to use sockets on the mainboard. It is also possible to directly solder the module into the
mainboard.
To secure the modules to the mainboard, it is recommended to have the mainboard equipped with 3 self-clinching nut
inserts, with internal thread M2. The inserts will allow to use 3 screws M2x10, which will pull the module into the
mainboard.
The recommended socket type, inserts and screws are:
Image
Connector
Description
Manufacturer
Part Number
J1
2x11, 2.0mm pass-through SMD socket
Lanbo electronics
PSDSM20-22G-24-PCH
J2
2x8, 2.0mm pass-through SMD socket
PSDSM20-16G-24-PCH
-
Self-clinching nuts M2
PennEngineering®
(PEM®)
KF2-M2-ET
-
Screws M2x10
Bossard
BN610-M2x10
The 3 fixing holes shall provide a means to pull the iPOS drive against the PCB. For example, use self-clinching nuts
pressed onto the PCB on the bottom side. The iPOS drive shall be pressed against the PCB using 3 screws M2x10,
with head diameter not larger than 5mm (such as hexsocket head cap screws, colloquially also called “Inbus”).
The fixing hardware shall be connected to system ground (GND), to improve thermal dissipation and EMC emissions.
3.4.2.2 Recommendations for the PCB Design
Below is a list of recommendations for the PCB design of the motherboard:
•Motor supply and motor outputs: use islands / areas of copper to escape connector area; this will maximize
current capability. When using simple tracks, use at least 100mil cross section (75mil track width for 1oz/ft2
copper thickness) –for iPOS4803P / iPOS4803PE drives.
•Motor supply and ground return tracks between iPOS4803P / iPOS4803PE drive and the nearby VMOT
decoupling capacitor are to be considered as EMI sources, and kept to a minimum length.
•Place the decoupling capacitors on VMOT and VLOG (see also 3.10 Power Supply Connection) as close as
physically possible to the drive, to minimize EM radiated emissions. For un-shielded applications (no metallic
box) and typical EMC regulations, the spacing between drive and capacitors must be less than 3
centimeters.
•In multi-axis applications (multiple iPOS4803P / iPOS4803PE drives on the same motherboard), it is
preferable to have a separate decoupling capacitor for each drive’s VMOT. For VLOG it is acceptable to share
one decoupling capacitor for two drives.
•For stringent EMI requirements, it may be necessary to add common-mode filtering on the motor and/or logic
supply inputs. Be sure to use 3-phase EMC filters, not 2-phase filters, in order to fulfill the basic requirement
of zero common-mode current through the filter. This is necessary because the ground negative return is
shared between VMOT and VLOG.
•Motor outputs shall be routed with parallel traces, and minimizing the loop area between these tracks. Avoid
placing components above or below the motor output tracks, as these components may become effective
antennas radiating EMI. If possible, route all 3 motor outputs in strip-line configuration (above or below a
ground plane).
•For stringent EMI requirements, it may be necessary to add common-mode inductors on the motor outputs.
Place these filters near the iPOS4803P / iPOS4803PE drive, not near the external connector, to reduce
radiation from the PCB tracks.
•Motor outputs must be separated from any nearby track (on the same layer) by a guard ring / track / area
connected to ground. It is recommended to use the same guarding precaution also for tracks on nearby
layers, i.e. use intermediate guard layer(s) connected to ground. The motor outputs must be treated as first
source of noise on the motherboard. Second source of noise is the current flow between each drive and it’s
decoupling VMOT capacitor.

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•For best EMC performance, it is strongly recommended to provide an un-interrupted ground plane on one of
the inner layers.
•All GND pins of the iPOS4803P / iPOS4803PE drive are galvanically connected together on-board. If the
motherboard provides an uninterrupted ground plane, it is recommended to connect all GND pins to the
ground plane, and use the ground plane to distribute GND wherever needed. If the motherboard does not
provide an uninterrupted ground plane, it is best to use each GND pin for its intended purpose. This will
create local “star point” ground connection on-board each drive.
•For a multi-axis motherboard with one common power supply for all motors, each motor power supply return
track shall be routed separately for each iPOS4803P / iPOS4803PE drive, and star-point connected at the
power supply terminal.
•The following signal pairs must be routed differentially, i.e. using parallel tracks with minimal loop area:
A1+/DAT1+, A1-/DAT1- ; B1+/CLK1+, B1-/CLK1- ; Z1+, Z1- ; A2+/DAT2+, A2-/DAT2- ; B2+/CLK2+,
B2 /CLK2-; CAN-Hi, CAN-Lo.
•When using +5VOUT as supply for external devices (like encoders, Hall sensors, etc.) provide extra filtering
and protection: use series resettable (PTC) fuses to add short-circuit protection; use transient absorbers to
protect against ESD and over-voltage; add high-frequency filtering to protect against external noise injected
on +5VOUT.
•The outer box / case / cabinet must be connected to the motherboard ground either galvanically (directly) or
through high-frequency decoupling capacitors, rated at an appropriate voltage.
3.4.2.3 EtherCAT signals PCB routing indications
3.4.2.3.1 PCB electrical Wiring calculations
 
󰇛󰇜󰇧 󰇨 
W = Width of the trace
H = Height of dielectric above the return plane
T = Trace thickness
S = Space between traces
Er= Relative permittivity of the dielectric
Figure 10 Microstrip Differential Impedance
For example:







󰇛󰇜

  

©Technosoft 2022 17 iPOS4803 Microdrive EtherCAT Technical Reference
 
󰇛󰇜󰇧 󰇨󰇛󰇜  
Figure 11 Stripline Differential Impedance
For example:







󰇛󰇜

  
Figure 12 Stripline Differential Impedance
3.4.2.3.2 PCB EtherCAT routing indications
•High-speed signals (Tx/Rx 0/1 +/-) must be routed as differential pairs, with controlled impedance, microstrip
or stripline.
•Microstrip and stripline pairs shall be guarded on the same layer as the differential pair, with outer traces
connected to the return plane by vias. The guarding traces shall form preferably a closed ring, wherever
possible.
•Use above formulae (or other method) to calculate microstrip or stripline differential impedance
•Avoid stubs, crossovers and vias on high-speed signals. Vias present impedance discontinuities and should
be avoided. Route an entire differential pair trace on a single layer if possible.
•High-speed signals should not be run such that they cross a plane split. A signal crossing a plane split may
cause unpredictable return path currents and would likely impact signal quality, also potentially creating EMI
problems.
•The center tap of the magnetics isolated winding has a "Bob Smith" termination to chassis ground. "Bob
Smith" termination is used to reduce noise resulting from common-mode current flows, as well as reduce
susceptibility to any noise from unused wire pairs on the RJ45.
•"Bob Smith" termination is different depending on Power Over Ethernet (PoE) compliance. PoE carries up to
57V between pairs, which would destroy the 75ohm terminating resistors if DC blocking capacitors of 10nF
are not in place.
•Capacitor 1nF 2KV must sustain 1.5KVrms for 1 minute as per IEEE802.3. The 1Meg discharge resistor may
be destroyed during this hi-pot testing.
•For enhanced EMC immunity it is possible to add surge protectors on the high-speed signals, on the isolated
side of the magnetics (not across pins, there is DC current flowing through windings). Check that signals are
not affected by the added parasitic capacitance.
•Use magnetics with integrated common-mode choking devices. Use magnetics compatible with Auto
MDI/MDI-X (with symmetrical windings). Use metal shielded connectors, and connect the shield to device
chassis / PE.
•Do not run any signals under the magnetics - this could cause unwanted noise crosstalk. Likewise void the
planes under magnetics, this will help prevent common-mode noise coupling.
•To save board space and reduce component count, RJ45 connectors with integrated magnetics may be
used. Check the PoE compliance where applicable.

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3.4.2.3.3 EtherCAT Bus connection
Figure 13 EtherCAT bus to RJ45 connection PoE compliant
Figure 14 EtherCAT bus to RJ45 connection non-compliant with PoE
•For additional details regarding signal swapping, please check the
EtherCAT signals schematic considerations chapter.

©Technosoft 2022 19 iPOS4803 Microdrive EtherCAT Technical Reference
3.5 Connectors and Pinouts
3.5.1 Pinouts for iPOS4803P Microdrive

©Technosoft 2022 20 iPOS4803 Microdrive EtherCAT Technical Reference
3.5.2 Pinouts for iPOS4803PE Microdrive
4