EPOS4 Positioning Controllers Overview

Modules Ready-to-connect units

Micro Module Compact CAN Compact EtherCAT Encased housing / Disk
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EPOS4 Micro EPOS4 Module EPOS4 Compact EPOS4 Compact EPOS4

24/5 CAN 24/1.5 24/1.5 CAN 24/1.5 EtherCAT 50/5

EPOS4 Micro EPOS4 Module EPOS4 Compact EPOS4 Compact EPOS4

24/5 EtherCAT 50/5 50/5 CAN 50/5 EtherCAT 70/15

EPOS4 Module EPOS4 Compact EPOS4 Compact NEW EPOS4 Disk

50/8 50/8 CAN 50/8 EtherCAT 60/8 CAN


EPOS4 Module EPOS4 Compact EPOS4 Compact NEW EPOS4 Disk

50/15 50/15 CAN 50/15 EtherCAT 60/8 EtherCAT

EPOS4 Compact NEW EPOS4 Disk

24/5 EtherCAT 60/12 CAN
3-axes

NEW EPOS4 Disk

60/12 EtherCAT

maxon EPOS4 products are small, completely wizards that make commissioning easy. It pro- commonly used if a PI position control loop is
digital, intelligent positioning controllers. Their vides a basic overview of the EPOS4 functions closed via the master.
high power density provides high flexibility for and a command option. Analysis tools such as
use with brushed DC and brushless EC (BLDC) the Data Recorder or Command Analyzer sup- Cyclic Synchronuous Torque (CST)
motors up to approx. 1050 W with various feed- plement the features in EPOS Studio. The master executes the path planning and
back options such as Hall sensors, incremental sends the target torque cyclically and synchro-
encoders and absolute encoders, in a variety of CANopen / EtherCAT nously to the EPOS4 via the network. The torque
drive applications. As a standardized motion control slave, EPOS4 (current) control loop runs on the EPOS4. The
can easily be integrated into the system man- EPOS4 sends the measured actual position,
Modules ager tools and motion libraries of various PLC speed and current values to the master. The CST
Robotic, analysis and handing systems require manufacturers. The data exchange and com- mode is commonly used if a PID position control
compact integration of a large number of en- mand functions make use of the CiA® 402 proto- loop is closed via the master.
ergy-efficient drives, combined with highly dy- col (Device Profile for Drives and Motion Control).
namic controllers and a linked bus system. Point-to-point
With the established EPOS4 Module and Micro, Cyclic Synchronuous Position (CSP) The “Profile Position Mode” moves the position
modular multi-axis systems can be set up using The master executes the path planning and of the motor axis from point A to point B. Posi-
CANopen or EtherCAT, without needing high in- sends the target position cyclically and synchro- tioning is in relation to the axis Home position
vestment in development. nously to the EPOS4 via the network. The posi- (absolute) or the actual axis position (relative).
tion control loop runs on the EPOS4. The EPOS4
Ready-to-connect units sends the measured actual position, speed and Position and velocity control with
For prototypes and small batches, the large va- current values to the master. feed forward
riety of ready-to-connect controllers, available The combination of feedback and feed forward
in various power classes and designs, provide Cyclic Synchronuous Velocity (CSV) control provides ideal motion behavior. Feed
attractive, economical options for using EPOS4 The master executes the path planning and forward control reduces control error. EPOS4
products in your application. sends the target speed cyclically and synchro- supports feed forward acceleration and speed
nously to the EPOS4 via the network. The speed control.
EPOS Studio control loop runs on the EPOS4. The EPOS4
The EPOS Studio software, which is available sends the measured actual position, speed and
free of charge, includes intuitive tools and current values to the master. The CSV mode is

506 motor control March 2021 edition / subject to change

 Operating modes/Control
Cyclic Synchronous Position (CSP)

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Cyclic Synchronous Velocity (CSV)
Cyclic Synchronous Torque (CST)
Profile Position, Profile Velocity and Homing
Mode
Speed and Acceleration Feed Forward
Sinusoidal or Block Commutation for EC
motors
Alternative set value input via analog
commands
Easy-to-use High functionality Dual-loop Position and Speed Control
and performance Communication/Configuration
Communication via CANopen and/or USB
Speed control Safe Torque Off (STO) 2.0/3.0 and/or RS232
In the Profile Velocity Mode, the motor axis is With this safety feature based on IEC61800-5-2 EtherCAT (CoE)
moved with a defined set speed. The motor axis (not certified), the drive can be brought to a safe USB to CAN and RS232 to CAN gateway
keeps the speed constant until a new speed set state at any time from two independent digital Inputs/Outputs
value is given. inputs. The supply of torque-generating power STO (Safe Torque Off) inputs and outputs,


is interrupted. optically isolated, not certified
Homing The state can be monitored via an additional Free digital inputs, configurable e.g. for limit/
The Homing Mode is used for referencing to a digital output. The inputs and outputs are opti- reference switches
specific mechanical position. There is a wide cally isolated. Free digital outputs, configurable e.g. for brake
variety of methods available. Free analog inputs, configurable
Capture Inputs (Touch Probe) Free analog ouputs, configurable
Feedback options and dual loop The digital inputs can be configured so that the
Available software
Two different encoder signals can be evaluated actual position value is stored whenever a posi-
simultaneously. This allows dual-loop control, tive or negative edge occurs at an input. EPOS Studio
which can be tuned automatically to compen- Windows DLL (32-/64-bit) with programming
sate for mechanical backlash and elasticity. A Trigger Output (Position Compare) examples
wide range of sensors is permitted: digital incre- The digital outputs can be configured to that Linux shared object library (X86 32-/64-
mental encoders, analog incremental encoders a digital signal is sent at a selectable position bit, ARMv6/v7/v8 32-bit, ARMv8 64-bit
(sin/cos), and SSI absolute encoders. value (on request). for Raspberry Pi and BeagleBone) with
programming examples
Protection Control of Holding Brakes Firmware
The positioning controller has protective circuits Control of holding brakes can be integrated in Available documentation
against overcurrent, excess temperature, un- the device status management. The delay times Feature Chart
der- and overvoltage, voltage transients, short- can be individually configured for switching on Hardware Reference
circuits in the motor cable, and against feed- and off. Firmware Specification
back signal loss. An adjustable current limitation Communication Guide
protects the motor and load. Supplementary information for technical data Application Notes
page 509–515.

EPOS4 performance characteristics

− Maximum power density.
− Convincing control performance even with highly dynamic mo-
tors.
− Comprehensive feedback options.
− Diverse I/O connection options for peripherals.
− Uncompromising protective features for controller and drive.
− Configuration and communication via CANopen (CiA 301, 402,
305), RS232, USB, or EtherCAT. IEC 61158 type 12 EtherCAT
slave: CoE (CAN application layer over EtherCAT) compliant with
IEC 61800-7 profile type 1 (CiA 402). Easy integration into exist-
ing EtherCAT systems. Can be connected to a network of other
EtherCAT units.
− Easy commissioning via EPOS studio GUI and intuitive tools.
− Libraries and programming examples for efficient integration in a
wide variety of systems.
− All software components are freely available at any time.
− Full documentation and outstanding support.

The complete package for your motion control solution with

added value.

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 EPOS4 Positioning Controllers Overview

Module + Connector Board = Compact

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USB RS232 GUI

Accessories EPOS4 Module & Micro (not included in delivery)

403968 USB Type A - micro B Cable    

638328 Micro 24/5 CAN

654731 Micro 24/5 EtherCAT

536630 Module 24/1.5

534130 Module 50/5

504384 Module 50/8

504383 Module 50/15

536997 EPOS4 CB 24/1.5 CAN 
620048 EPOS4 CB 24/1.5 EtherCAT 
534133 EPOS4 CB 50/5 CAN 


620044 EPOS4 CB 50/5 EtherCAT 

520884 EPOS4 CB Power CAN  
604594 EPOS4 CB Power EtherCAT  
581245 EPOS4 EtherCAT Card  (a)  (a)  (a)  (a)
638677 EPOS4 EB Micro  
659508 EPOS4 MB Micro EtherCAT 3-axes 
590738 EPOS4 Module SMT socket 2 x 23 poles  
677324 EPOS4 Micro SMT socket 2 x 40 poles  
(a) with matching motherboard
Accessories EPOS4 Compact & Encased housing (not included in delivery)
520858 CAN-CAN Cable      
628094 Compact 50/5 EtherCAT

605298 Compact 50/8 EtherCAT

520886 Compact 50/15 CAN

605299 Compact 50/15 EtherCAT

684519 Compact 24/5 EtherCAT 3-axes

546714 Compact 24/1.5 CAN

628092 Compact 24/1.5 EtherCAT

541718 Compact 50/5 CAN

520885 Compact 50/8 CAN

546047 50/5

594385 70/15
520857 CAN-COM Cable      
275934 Encoder Cable          
520859 EPOS4 Connector Set          
581245 EPOS4 EtherCAT Card  
691408 EPOS4 MB 3-axes Conn. Set 
422827 Ethernet Cable       
275878 Hall Sensor Cable         
275851 Motor Cable         
520851 Motor Cable High Current   
275829 Power Cable  (b)  (b)  (b)  (b)  (b)   (b)
520850 Power Cable High Current  (c)  (c)  (c)  (c)  (c)  (c)
520856 RS232-COM Cable      
520852 Sensor Cable 5 x 2core           
520854 Signal Cable 7core           
520853 Signal Cable 8core           
520860 STO Idle Connector X9  (i)  (i)  (i)  (i)  (i)  (i)  (i)  (i)  (i)  (i)
403968 USB Type A - micro B Cable           
(b) optional for separate logic supply (c) mandatory for supply of power stage (i) included Additional accessories from page 529
Accessories EPOS4 Disk (not included in delivery)
710928 Brake Cable      
688770 Disk 60/8 CAN

688772 Disk 60/8 EtherCAT

688775 Disk 60/12 CAN

709859 Disk 60/12 CAN SSC

688777 Disk 60/12 EtherCAT

709862 Disk 60/12 EtherCAT SSC

710931 CAN-CAN Cable   

710932 CAN-COM Cable   
696285 Encoder Cable      
710926 EPOS4 Disk Connector Set      
710934 EtherCAT-COM Cable   
710933 EtherCAT-EtherCAT Cable   
275878 Hall Sensor Cable    
696284 Hall Sensor Cable      
710930 Motor Cable High Current    
696283 Power & Motor Cable  
710929 Power Cable High Current    
696286 Sensor Cable 3x2core      
520852 Sensor Cable 5x2core    
696288 Signal Cable 7core      
696287 Signal Cable 8core      
696289 USB Type A - Micro-Lock Cable      

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EPOS4 Positioning Controllers Data

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EPOS4 Compact 50/15 EtherCAT EPOS4 50/5 EPOS4 70/15
Ready-to-install compact solution, designed Positioning controller in a robust housing, Positioning controller in a robust housing,
for use with brushed DC motors with encoders designed for use with brushed DC motors with designed for use with brushed DC motors with
or brushless EC motors with Hall sensors and encoders or brushless EC motors with Hall sen- encoders or brushless EC motors with Hall sen-
encoders up to 750/1500 Watt. sors and encoders up to 250/750 Watt. sors and encoders up to 1050/2100 Watt.
Controller version
EtherCAT Slave CANopen Slave with EtherCAT option CANopen Slave with EtherCAT option
Electrical data


10 - 50 VDC 10 - 50 VDC 10 - 70 VDC
10 - 50 VDC 10 - 50 VDC 10 - 70 VDC
0.9 x VCC 0.9 x VCC 0.9 x VCC
30 A (<60 s) 15 A (<15 s) 30 A (<60 s)
15 A 5A 15 A
50 kHz 50 kHz 50 kHz
25 kHz (40 µs) 25 kHz (40 µs) 25 kHz (40 µs)
2.5 kHz (400 µs) 2.5 kHz (400 µs) 2.5 kHz (400 µs)
2.5 kHz (400 µs) 2.5 kHz (400 µs) 2.5 kHz (400 µs)
50 000 rpm (sinusoidal), 100 000 rpm (block) 50 000 rpm (sinusoidal), 100 000 rpm (block) 50 000 rpm (sinusoidal), 100 000 rpm (block)
2.2 μH / 15 A 15 μH / 5 A 15 μH / 15 A
Inputs
H1, H2, H3 H1, H2, H3 H1, H2, H3
A, A\, B, B\, I, I\ (max. 6.25 MHz) A, A\, B, B\, I, I\ (max. 6.25 MHz) A, A\, B, B\, I, I\ (max. 6.25 MHz)
A, A\, B, B\, I, I\, Clock, Clock\, Data, Data\ A, A\, B, B\, I, I\, Clock, Clock\, Data, Data\ A, A\, B, B\, I, I\, Clock, Clock\, Data, Data\
4 (level switchable: logic/PLC) 4 (level switchable: logic/PLC) 4 (level switchable: logic/PLC)
4, differential 4, differential 4, differential
2 (12-bit resolution, -10…+10 V) 2 (12-bit resolution, -10…+10 V) 2 (12-bit resolution, -10…+10 V)
configurable with DIP switch 1…5 configurable with DIP switch 1…5 configurable with DIP switch 1…5
Outputs
2 2 2
1, differential 1, differential 1, differential
2 (12-bit resolution, -4…+4 V, max. 1 mA) 2 (12-bit resolution, -4…+4 V, max. 1 mA) 2 (12-bit resolution, -4…+4 V, max. 1 mA)
+5 VDC, max. 70 mA +5 VDC, max. 70 mA +5 VDC, max. 70 mA
+5 VDC, max. 30 mA +5 VDC, max. 30 mA +5 VDC, max. 30 mA
+5 VDC, max. 150 mA +5 VDC, max. 150 mA +5 VDC, max. 150 mA
Interfaces
– RxD; TxD (max. 115 200 bit/s) RxD; TxD (max. 115 200 bit/s)
– high; low (max. 1 Mbit/s) high; low (max. 1 Mbit/s)
Data+; Data- (Full Speed) Data+; Data- (Full Speed) Data+; Data- (Full Speed)
100 Mbit/s (Full Duplex) Optional 581245 EPOS4 EtherCAT Card available Optional 581245 EPOS4 EtherCAT Card available
Indicator
Green LED, red LED Green LED, red LED Green LED, red LED
Environmental conditions
-30…+25°C -30…+50°C -30…+50°C
+25...+77°C; Derating: -0.288 A/°C +50...+80°C; Derating: -0.167 A/°C +50...+85°C; Derating: -0.429 A/°C
-40…+85°C -40…+85°C -40…+85°C
5…90% 5…90% 5…90%
Mechanical data
approx. 140 g approx. 206 g approx. 372 g
59.5 x 79.5 x 37.8 mm 105.0 x 83.0 x 38.7 mm 125.0 x 94.5 x 38.7 mm
M3 screws Flange for M4-screws Flange for M4-screws
Part numbers
605299 EPOS4 Compact 50/15 EtherCAT 546047 EPOS4 50/5 594385 EPOS4 70/15
Accessories
235811 DSR 70/30 Shunt regulator 309687 DSR 50/5 Shunt regulator 235811 DSR 70/30 Shunt regulator
Order accessories separately, see page 529 Order accessories separately, see page 529 Order accessories separately, see page 529

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