Technosoft iPOS4808 BX-CAT-STO Use and care manual

iPOS4808
BX-CAT-STO
Intelligent Servo Drive
for Step, DC, Brushless
DC and AC Motors
Intelligent Servo Drives
T
echnical
Reference
Technosoft 2017 P091.027.iPOS4808.BX.CAT.STO.UM.0317

Technosoft 2017 2 iPOS4808 BX-CAT-STO 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 ….....................................................................................................5
1Safety information....................................................................................................6
1.1 Warnings.......................................................................................................................6
1.2 Cautions........................................................................................................................6
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
2.4Supported Motor-Sensor Configurations................................................................. 11
2.4.1...... Single loop configurations...................................................................................................... 11
2.4.2...... Dual loop configurations ........................................................................................................ 11
3Hardware Installation.............................................................................................12
3.1 iPOS4808 BX-CAT-STO Board Dimensions..............................................................12
3.2 Mechanical Mounting................................................................................................. 13
3.3 Connectors and Pinouts............................................................................................14
3.3.1...... Pinouts for iPOS4808 BX-CAT-STO ..................................................................................... 14
3.3.2...... Mating Connectors................................................................................................................. 15
3.4 Connection diagrams................................................................................................. 15
3.4.1...... iPOS4808 BX-CAT-STO connection diagram....................................................................... 15
3.4.2...... 24V Digital I/O Connection .................................................................................................... 16
3.4.2.1 PNP inputs...................................................................................................................... 16
3.4.2.2 NPN inputs...................................................................................................................... 16
3.4.2.3 NPN outputs ................................................................................................................... 17
3.4.3...... 5V Digital I/O Connection ...................................................................................................... 17
3.4.4...... Analog Inputs Connection...................................................................................................... 18
3.4.4.1 0-5V Input Range............................................................................................................ 18
3.4.4.2 +/- 10V to 0-5V Input Range Adapter............................................................................. 18
3.4.4.3 Recommendation for wiring............................................................................................ 18
3.4.5...... Motor connections.................................................................................................................. 19
3.4.5.1 Brushless Motor connection........................................................................................... 19
3.4.5.2 2-phase Step Motor connection...................................................................................... 19
3.4.5.3 3-Phase Step Motor connection..................................................................................... 20
3.4.5.4 DC Motor connection...................................................................................................... 20
3.4.5.5 Recommendations for motor wiring................................................................................ 20

Technosoft 2017 3 iPOS4808 BX-CAT-STO Technical Reference
3.4.6...... Feedback connections........................................................................................................... 21
3.4.6.1 Single-ended Incremental Encoder #1 Connection........................................................ 21
3.4.6.2 Differential Incremental Encoder #1 Connection............................................................ 21
3.4.6.3 Single-ended Incremental Encoder #1 Connection........................................................ 22
3.4.6.4 Differential Incremental Encoder #2 Connection............................................................ 22
3.4.6.5 SSI Encoder #2 Connection........................................................................................... 23
3.4.6.6 BiSS Encoder #2 Connection......................................................................................... 23
3.4.6.7 Digital Hall Connection for Motor + Hall + Incremental Encoder.................................... 24
3.4.6.8 Digital Hall Connection for direct motor control without an encoder .............................. 24
3.4.6.9 Sine-Cosine Analog Encoder Connection...................................................................... 25
3.4.6.10 Linear Hall Connection ................................................................................................... 25
3.4.6.11 Recommendations for wiring.......................................................................................... 25
3.4.7...... Power Supply and STO Connection...................................................................................... 26
3.4.7.1 Supply Connection ......................................................................................................... 26
3.4.7.2 Recommendations for Supply Wiring............................................................................. 26
3.4.7.3 Recommendations to limit over-voltage during energy regeneration............................. 26
3.4.8...... Serial RS-232 connection...................................................................................................... 28
3.4.8.1 Serial RS-232 connection............................................................................................... 28
3.4.8.2 Recommendation for wiring............................................................................................ 28
3.4.9...... Recommendations for EtherCAT Wiring................................................................................ 29
3.4.10.... Disabling the setup table at startup ....................................................................................... 30
3.5 Axis ID Selection........................................................................................................30
3.5.1...... LED indicators........................................................................................................................ 31
3.5.2...... EtherCAT® Status indicator................................................................................................... 31
3.6 Electrical Specifications............................................................................................32
3.6.1...... Operating Conditions............................................................................................................. 32
3.6.2...... Storage Conditions ................................................................................................................ 32
3.6.3...... Mechanical Mounting............................................................................................................. 32
3.6.4...... Environmental Characteristics............................................................................................... 32
3.6.5...... Logic Supply Input (+VLOG) .................................................................................................... 32
3.6.6...... Motor Supply Input (+VMOT).................................................................................................... 32
3.6.7...... Motor Outputs (A/A+, B/A-, C/B+, CR/B-).............................................................................. 33
3.6.8...... Digital Inputs (IN0, IN1, IN2/LSP, IN3/LSN, IN5, IN6)........................................................... 33
3.6.9...... Digital Outputs (OUT0, OUT1, OUT2/Error, OUT3/ Ready, OUT4)...................................... 34
3.6.10.... Digital Hall Inputs (Hall1, Hall2, Hall3)................................................................................... 34
3.6.11.... Encoder #1 Inputs (A1+, A1-, B1+, B1-, Z1+, Z1-,)............................................................... 34
3.6.12.... Encoder #2 Inputs (A2+, A2-, B2+, B2-, Z2+, Z2-)................................................................ 35
3.6.13.... Linear Hall Inputs (LH1, LH2, LH3)........................................................................................ 35
3.6.14.... Sin-Cos Encoder Inputs (Sin+, Sin-, Cos+, Cos-) ................................................................. 35
3.6.15.... SSI encoder interface ............................................................................................................ 35
3.6.16.... BiSS Encoder Interface.......................................................................................................... 36
3.6.17.... Analog 0…5V Inputs (REF, FDBK)........................................................................................ 36
3.6.18.... RS-232................................................................................................................................... 36
3.6.21.... Safe Torque OFF (STO1+; STO1-; STO2+; STO2-)............................................................. 37
4Memory Map...........................................................................................................38

Technosoft 2017 4 iPOS4808 BX-CAT-STO 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
iPOS4808 BX-CAT-STO
P027.314.E221 Standard version
that can support a differential encoder
on Feedback #1, EtherCAT®, STO input
P027.314.E721
Can support linear halls on Feedback #1, EtherCAT®,
STO input
In order to operate the iPOS4808 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 iPOS4808 hardware including the technical data, the connectors
and the wiring diagrams needed for installation.
For Step 2 and 3, please consult the document iPOS Dual Loop drives Software reference
( 091.027.DL.Software.xxxx). It also includes the scaling factors between the real SI units and the drive internal units.
For detailed information regarding the next steps, refer to the related documentation.
Notational Conventions
This document uses the following conventions:
•iPOS4808– 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.)
•STO – Safe Torque Off
•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 2017 5 iPOS4808 BX-CAT-STO Technical Reference
Related Documentation
iPOS4808 BX-CAT-STO Datasheet ( P027.314.E221.DSH)
– describes the hardware connections of the iPOS4808 BX-CAT-STO intelligent servo drive including
the technical data and connectors.
iPOS family Safe Torque Off (STO) Operating instructions ( 091.099.STO.Operating.Instructions.xxxx)
– describes the principles of STO function, the applied standards, the safety-related data and the
electrical data. It presents the requested information for installation and commissioning of STO function
iPOS Dual Loop drives Software reference (091.027.DL.Software.xxxx)
– describes the compatible software installation, drive software setup commissioning, introduction to TML
motion programming, includes the scaling factors between the real SI units and the drive internal units.
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
CoE Programming (part no. P091.064.UM.xxxx) – explains how to program the Technosoft intelligent drives
using CAN application protocol over EtherCAT® and describes the associated object dictionary.
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
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

Technosoft 2017 6 iPOS4808 BX-CAT-STO Technical Reference
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
1.1 Warnings
WARNING! TO AVOID ELECTRIC ARCING AND HAZARDS, NE
VER CONNECT /
DISCONNECT WIRES FROM THE DRIVE WHILE THE POWER SUPPLIES ARE ON
WARNING! THE DRIVE MAY HAVE HOT SURFACES DURING OPERATION.
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 PERMIT
TED ONLY FOR
PERSONNEL AUTHORISED BY TECHNOSOFT

Technosoft 2017 7 iPOS4808 BX-CAT-STO Technical Reference
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 thatthis product comply with the legal
obligations regarding Article 33 ofthe European REACH Regulation 1907/2006 (Registration,
Evaluation, AuthorizationandRestriction 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.
STO compliance – TUV SUD certifies that this product is SIL 3 / Cat 3 / PL e compatible and
is in conformity with the following safety – related directives:
EN ISO 13849-1:2015 Safety of machinery - Safety-related parts of control systems - Part 1: General principles
for design
EN 61800-5-1:2007 Adjustable speed electrical power drive systems — Safety requirements — Electrical,
thermal and energy
EN 61800-5-2:2007 Adjustable speed electrical power drive systems - Safety requirements –Functional
EN 61508:2010 Functional safety of electrical/electronic/programmable electronic safety-related systems
EN ISO 13849-1:2008 Safety of machinery - Safety-related parts of control systems
EN 61326-3-1:2008 - General industrial applications - EMC - Immunity requirements for functional safety
For other certifications visit: http://technosoftmotion.com/en/quality-system

Technosoft 2017 8 iPOS4808 BX-CAT-STO Technical Reference
2 Product Overview
2.1 Introduction
The iPOS4808 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), DC brushed motors and step motors, the iPOS4808
drives accept as position feedback incremental encoders (quadrature or sine/cosine), absolute encoders (SSI and
BiSS-C) and linear Hall signals1.
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 iPOS4808 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 gearing or camming, 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
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 iPOS4808 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 itis also possible to retrieve thecomplete 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 iPOS4808 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. Thisis the iPOS4808 typical
CAN operation mode when TMLCAN protocol is selected. EasyMotion Studio can also be used with the CANopen
protocol,if the user wants tocall TML functions stored in the drive EEPROM or to use the camming mode. With camming
mode, EasyMotion Studio offers the possibility to quickly download and test a cam profile and also to create a .sw file
with the cam data. The .sw file can be afterwards stored in a master and downloaded to the drive, wherever needed. A
demo version of EasyMotion Studio (with EasySetUp part fully functional) can be downloaded free of charge
from Technosoft web page.
1Available only with P027.314.E721

Technosoft 2017 9 iPOS4808 BX-CAT-STO Technical Reference
2.2 Product Features
•Fully digital servo drive suitable for the control of rotary or linear brushless, DC brush, and step motors
•Very compact design
•Sinusoidal (FOC) or trapezoidal (Hall-based) control of brushless motors
•Open or closed-loop control of 2 and 3-phase steppers
•STO: 2 safe torque-off inputs, safety integrity level (SIL3/Cat3/PLe) acc. to EN61800-5-1;-2/ EN61508-3;-4/
EN ISO 13849-1. When left not connected will disable the motor outputs. This provides a dual redundant
hardware protection that cannot be overdriven by the software or other hardware components.
•Various modes of operation, including: cyclic synchronous torque, velocity or position control(CST, CSV or
CSP); position or velocity profiles, external analogue reference or sent via a communication bus
•Technosoft Motion Language (TML) instruction set for the definition and execution of motion sequences
•Standalone operation with stored motion sequences
•Communication:
•RS-232 serial up to 115kbits/s
•Dual 100Mbps EtherCAT® interfaces, for use in daisy-chaining topologies
•Digital and analog I/Os:
•6 digital inputs: 5-36 V, programmable polarity: sourcing/NPN or sinking/PNP: 2 Limit switches and 4
general-purpose
•5 digital outputs: 5-36 V, with 0.5 A, sinking/NPN open-collector (Ready, Error and 3 general-purpose)
•NTC/PTC analogue Motor Temperature sensor input
•Electro-Mechanical brake support: software configurable digital output to control motor brake
•Feedback devices (dual-loop support)
1st feedback devices supported:
•Incremental encoder interface (single ended or differential1)
•Analog sin/cos encoder interface (differential 1VPP)
•Linear Hall sensors interface2
•Pulse & direction interface (single ended) for external (master) digital reference
2nd feedback devices supported:
•Incremental encoder interface (differential only)
•Pulse & direction interface (differential only) for external (master) digital reference
•BiSS-C / SSI encoder interface
Separate feedback devices supported:
•Digital Hall sensor interface (single-ended and open collector)
•2 analogue inputs: 12 bit, 0-5V: Reference and Feedback (for Tacho) 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)
•Cyclic Synchronous Velocity (CSV)
•Cyclic Synchronous Torque (CST)
•Electronic gearing and camming
•35 Homing modes
•127 h/w selectable addresses
•EtherCAT® with CAN application protocol over EtherCAT (CoE) for CAT drives
•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: 12-50V
•Logic supply: 9-36V.
•STO supply: 18-40V
1Available only on P027.314.E221
2Available only on P027.314.E721

Technosoft 2017 10 iPOS4808 BX-CAT-STO Technical Reference
•Output current: 81continuous; 20A peak
•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
•Feedback sensor error
2.3 Identification Labels
Figure 2.3.1. iPOS4808 BX-CAT-STO identification labels
The iPOS4808 BX-CAT can have the following part numbers and names on the identification label:
p.n. P027.314.E221name iPOS4808 BX-CAT-STO – standard EtherCAT® execution
p.n. P027.324.E721name iPOS4808 BX-CAT-STO – Linear Hall EtherCAT® execution
120A cont. with DC, step and BLDC motors (trapezoidal), 20A amplitude (14.2ARMS) for PMSM (sinusoidal)

Technosoft 2017 11 iPOS4808 BX-CAT-STO 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 Stepper 2 phase Stepper 3 phase
Sensor type Sensor location
Incr. encoder FDBK #1 (single ended or diff.) Yes - Yes Yes -
FDBK #2 (diff.)
Incr. encoder + Digital Hall
FDBK #1 (single
ended or diff1.) Digital
halls
interface Yes Yes - - -
FDBK #2 (diff.)
Digital halls only Digital halls interface Yes - - - -
Linear halls2(analogue) Linear halls interface Yes - - - -
SSI FDBK #2 (diff.) Yes - Yes Yes -
BiSS-C FDBK #2 (diff.) Yes - Yes Yes -
Analogue Sin/Cos encoder FDBK #1 (diff.) Yes - Yes Yes -
Tacho Analogue input: Feedback - - Yes - -
Open-loop (no sensor) - - - - Yes Yes
Open-loop (with step loss detection
using
Incr. Encoder/SinCos/SSI/BiSS)
FDBK #1 (single ended or diff.) - - - Yes Yes
FDBK #2 (diff.)
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 differential1)
•
Analogue Sin/Cos encoder
•Linear Halls
2
(only on motor)
•Incremental encoder
(differential)
•
SSI/BiSS C encoder
BLDC
•Incremental encoder
(single-ended or differential) +
Digital halls
•Incremental encoder
(differential) + Digital Halls
•SSI/BiSS C encoder (only on load)
Stepper
2ph
•Incremental encoder
(single-ended or differential)
•Analogue Sin/Cos encoder
•Incremental encoder
(differential)
•SSI/BiSS C encoder
DC Brush
•Incremental encoder
(single-ended or differential)
•
Analogue Sin/Cos encoder
•Analogue Tacho (only on motor)
•Incremental encoder
(differential)
•
SSI/BiSS C encoder
Each defined motor type can have any combination of the supported feedbacks either on motor or on load.
Examples: -PMSM motor with Incremental encoder (from feedback #1) on motor and Incremental encoder (from
feedback#2) on load; -DC brush motor with SSI encoder (from feedback #2) on motor and Sin/Cos encoder (from
feedback #1) on load.
1A differential encoder on Feedback #1 is available only with P027.314.E221
2Linear hall sensors are compatible only with P027.314.E721

Technosoft 2017 12 iPOS4808 BX-CAT-STO Technical Reference
3 Hardware Installation
3.1 iPOS4808 BX-CAT-STO Board Dimensions
Figure 3.1.1. iPOS4808 BX-CAT-STO drive dimensions
All dimensions are in mm. The drawings are not to scale.

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3.2 Mechanical Mounting
The iPOS4808 drive is intended to be mounted vertically on a on a metallic support using the provided mounting holes
and the recommended mating connectors, as specified in chapter 3.3.2 Mating Connectors.
For thermal calculations, the iPOS4808 BX-CAT-STO drive can be assumed to generate 3.7 Watt (= 8 BTU/hour) at
idle, and up to 7.2 Watt (= 25 BTU/hour) worst case while driving a motor.
When the iPOS4808 BX-CAT is mounted vertically, its overall envelope (size) including the recommended mating
connectors is shown in Figure 3.1. Fixing the iPOS4808 BX-CAT onto a support using the provided mounting holes is
strongly recommended to avoid vibration and shock problems.
Figure 3.2.1. iPOS4808 BX-CAT-STO dimensions with mating connectors
and minimum spacing for vertical mounting
The iPOS4808 BX-CAT drive(s) can be cooled by natural convection. The support shall be thermally conductive
(metallic), and shall be mounted vertically.
Figure 3.2.1 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 bynatural convection is not enough to maintain the temperature surrounding the iPOS4808 BX-CAT
drive(s), then alternate forced cooling methods must be applied.

Technosoft 2017 14 iPOS4808 BX-CAT-STO Technical Reference
3.3 Connectors and Pinouts
3.3.1 Pinouts for iPOS4808 BX-CAT-STO

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3.3.2 Mating Connectors
Image
Connector
Description
Manufacturer
Part Number Image
J1
MINIFIT JR. receptacle housing, 2x2 way
MOLEX 39-03-9042
J2
MINIFIT JR. receptacle housing, 2x5 way
MOLEX 39-03-9102
J1,J2
CRIMP PIN, MINIFIT JR., 13A
MOLEX
45750-1111
J3, J4
C
-Grid III™ Crimp Housing Dual Row, 10 Circuits, with retention MOLEX 90142-0010
C-Grid III™ Crimp Housing Dual Row, 10 Circuits, without
ention
90143-0010
J3, J4
C-Grid III™ Crimp Terminal
MOLEX
90119-0109
J7
MICROFIT RECEPTACLE HOUSING, 2x9 WAY
MOLEX 43025-1800
J8, J9
MICROFIT RECEPTACLE HOUSING, 2x2 WAY
MOLEX
43025-0400
J7, J8, J9
CRIMP
PIN, MICROFIT, 5A MOLEX 43030-0007
J5, J6
Standard 8P8C modular jack (RJ
-45) male - -
3.4 Connection diagrams
3.4.1 iPOS4808 BX-CAT-STO connection diagram
Figure 3.2. iPOS4808 BX-CAT-STO Connection diagram
* For other available feedback / motor options, check the detailed connection diagrams below

Technosoft 2017 16 iPOS4808 BX-CAT-STO Technical Reference
3.4.2 24V Digital I/O Connection
3.4.2.1 PNP inputs
Figure 3.3. 24V Digital PNP Inputs connection
Remarks:
1. The inputs are selectable as PNP/ NPN by software.
2. The inputs arecompatible with PNP type outputs (input must receive a positive voltage value (5-36V)to change
its default state)
3. The length of the cables must be up to 30m, reducing the exposure to voltage surge in industrial environment.
3.4.2.2 NPN inputs
Figure 3.4. 24V Digital NPN Inputs connection
Remarks:
1. The inputs are selectable as PNP/ NPN by software.
2. The inputs are compatible with NPN type outputs (input must be pulled to GND to change its default state)
3. The lengthof the cables must be up to 30m, reducing the exposure to voltage surges in industrial environment.

Technosoft 2017 17 iPOS4808 BX-CAT-STO Technical Reference
3.4.2.3 NPN outputs
1
18
23456789
1011
12
13
1415
16
17
J7
J8
J6 J5 J4J3 J2J1
Figure 3.5. 24V Digital NPN Outputs connection
Remark:
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)
3.4.3 5V Digital I/O Connection
1
18
23456789
1011
12
13
1415
16
17
J7
J8
J6 J5 J4J3 J2J1
Figure 3.6. 5V Digital I/O connection
Remarks:
1. The inputs are selectable as PNP/ NPN by software. For the 5V connection they are selected as PNP. NPN
is not compatible on a 5V connection.
2. The inputs are compatible with TTL(5V), LVTTL(3.3V), CMOS (3.3V-24V) outputs
3. The outputs are compatible with TTL (5V) and CMOS (5V) inputs
4. The lengthof the cables must be up to 30m, reducing the exposureto voltage surges in industrial environment.
The output loads can be individually and independently connected to +5V or to GND.

Technosoft 2017 18 iPOS4808 BX-CAT-STO Technical Reference
3.4.4 Analog Inputs Connection
3.4.4.1 0-5V Input Range
1
18
23456789
1011
12
13
1415
16
17
J7
J8
J6 J5 J4J3 J2J1
Figure 3.7. 0-5V Analog inputs connection
Remarks:
1. Default input range for analog inputs is 0÷5 V for REF and FBDK. For a +/-10 V range, see Figure 3.8.
2. The lengthof the cables must be up to 30m, reducing the exposure to voltage surges inindustrial environment.
3.4.4.2 +/- 10V to 0-5V Input Range Adapter
Figure 3.8. +/-10V to 0-5V adapter
Remark: The length of thecables must be up to 30m, reducing the exposure to voltage surges inindustrial environment.
3.4.4.3 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 GND, 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 GND, and is left unconnected at the source side. The source minus (negative, out-of-phase)
output remains unconnected.

Technosoft 2017 19 iPOS4808 BX-CAT-STO Technical Reference
3.4.5 Motor connections
3.4.5.1 Brushless Motor connection
Figure 3.9. Brushless motor connection
3.4.5.2 2-phase Step Motor connection
Figure 3.10.2-phase step motor connection, one coil per phase
Figure 3.11.2-phase step motor connection, two coils per phase

Technosoft 2017 20 iPOS4808 BX-CAT-STO Technical Reference
3.4.5.3 3-Phase Step Motor connection
Figure 3.12.3-phase step motor connection
3.4.5.4 DC Motor connection
Figure 3.13.DC Motor connection
3.4.5.5 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. Connect the cable shield to the iPOS4808 GND
pin. Leave the other end disconnected.
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 iPOS4808 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.
A good shielding can be obtained if the motor wires are running inside a metallic cable guide.