INGENIA Everest CORE User manual

INGENIA-CAT S.L.
AVILA 124
08018 BARCELONA
Everest CORE - Product Manual
Edition 08/01/2019
For the most up to date information visit the online manual.

1. Table of Contents
1. Table of Contents 2
2. General Information 4
2.1. Manual revision history ....................................................................................................................................... 4
2.2. Disclaimers and limitations of liability ............................................................................................................... 4
2.3. Contact ................................................................................................................................................................. 4
3. Safety Information 5
3.1. About this manual................................................................................................................................................ 5
3.2. Warnings............................................................................................................................................................... 5
3.3. Precautions .......................................................................................................................................................... 5
4. Product Description 6
4.1. Part numbering .................................................................................................................................................... 6
4.2. Specifications....................................................................................................................................................... 7
4.3. Thermal specifications ...................................................................................................................................... 10
5. Pinout 12
5.1. Connectors Overview......................................................................................................................................... 12
5.2. P1 and P2 Power pins ........................................................................................................................................ 12
5.3. P3 Feedback connector ..................................................................................................................................... 13
5.4. P4 Everest CORE Interface connector............................................................................................................... 16
6. Dimensions 21
7. Application Guide 22
7.1. Scope and Architecture ..................................................................................................................................... 22
7.1.1. Parts of an Everest CORE integration solution................................................................................................. 22
7.1.2. Single-Axis or Multi-Axis approach.................................................................................................................... 22
7.2. Schematic Design............................................................................................................................................... 22
7.2.1. Input Supplies .................................................................................................................................................... 23
DC Power Supply................................................................................................................................................ 23
DC Bus input stage............................................................................................................................................. 24
Logic supply ....................................................................................................................................................... 27
7.2.2. Protective circuits .............................................................................................................................................. 30
Inverse Polarity Protection................................................................................................................................ 30
Shunt Braking Resistor Transistor .................................................................................................................... 31
Safe Torque Off (STO) ........................................................................................................................................ 33
7.2.3. Inputs and Outputs ............................................................................................................................................ 35
Digital Inputs ...................................................................................................................................................... 35
Digital Outputs ................................................................................................................................................... 37
Mechanical Brake Output .................................................................................................................................. 38
7.2.4. Output Supplies ................................................................................................................................................. 40
3.3 V and 5 V Output Supplies............................................................................................................................ 40

7.2.5. Communications................................................................................................................................................ 42
Motion Control Bus ............................................................................................................................................ 42
Digital Halls ........................................................................................................................................................ 43
Quadrature / Incremental Encoder................................................................................................................... 45
Absolute Encoder............................................................................................................................................... 47
7.2.6. LED Signalling .................................................................................................................................................... 49
Schematic........................................................................................................................................................... 50
Signals description............................................................................................................................................. 50
Design Notes....................................................................................................................................................... 50
Bill of materials .................................................................................................................................................. 50
7.3. Layout Design..................................................................................................................................................... 50
7.3.1. Required files...................................................................................................................................................... 51
7.3.2. The Everest CORE component .......................................................................................................................... 52
Mechanical layer 5: positioning guide .............................................................................................................. 52
Mechanical layer 15: clearances........................................................................................................................ 53
7.3.3. Layout considerations ....................................................................................................................................... 54
Proposed Layer Stack ........................................................................................................................................ 56
Proposed Design Rules ..................................................................................................................................... 57
8. Service 58

Everest CORE - Product Manual|General Information
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2. General Information
2.1. Manual revision history
Revision Release Date Changes PDF
v1 12 Apr 2019 Initial version Export as pdf
For the most up to date information use the onlineProduct Manual. The PDF manual is generated only after major
changes.
2.2. Disclaimers and limitations of liability
The information contained within this document contains proprietary information belonging toINGENIA-CAT S.L.
Such information is supplied solely for the purpose of assisting users of the product in its installation.
INGENIA-CAT S.L.rejects all liability for errors or omissions in the information or the product or in other
documents mentioned in this document.
The text and graphics included in this document are for the purpose of illustration and reference only. The
specifications on which they are based are subject to change without notice.
This document may contain technical or other types of inaccuracies.The information contained within this
document is subject to change without notice and should not be construed as a commitment byINGENIA-CAT S.L.
INGENIA-CAT S.L.assumes no responsibility for any errors that may appear in this document.
Some countries do not allow the limitation or exclusion of liability for accidental or consequential damages,
meaning that the limits or exclusions stated above may not be valid in some cases.
2.3. Contact
INGENIA-CAT S.L.
120-124 Ávila St.
08018 Barcelona
Spain
Telephone: [phone]
E-mail:[email protected]
Web site:www.ingeniamc.com

Everest CORE - Product Manual|Safety Information
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3. Safety Information
3.1. About this manual
Read carefully this chapter to raise your awareness of potential risks and hazards when working with the Everest
CORE Servo Drive.
To ensure maximum safety in operating the Everest CORE Servo Drive, it is essential to follow the procedures
included in this guide. This information is provided to protect users and their working area when using the Everest
CORE Servo Drive, as well as other hardware that may be connected to it. Please read this chapter carefully before
starting the installation process.
3.2. Warnings
The following statements should be considered to avoid serious injury to those individuals performing the
procedures and/or damage to the equipment:
•To prevent the formation of electric arcs, as well as dangers to personnel and electrical contacts, never
connect/disconnect the Everest CORE Servo Drive while the power supply is on.
• Disconnect the EverestServo Drive from all power sources before proceeding with any possible wiring
change.
•After turning off the power and disconnecting the equipment power source, wait at least 10 seconds before
touching any parts of the controller that are electrically charged or hot.
3.3. Precautions
The following statements should be considered to avoid serious injury to those individuals performing the
procedures and/or damage to the equipment:
• The EverestServo CORE Drive components temperature may exceed 100 ºC during operation.
• Some components become electrically charged during and after operation.
•The power supply connected to this controller should comply with the parameters specified in this
document.
• When connecting the EverestServo CORE Drive to an approvedpower source, do so through a line that is
separate from any possible dangerous voltages, using the necessary insulation in accordance with safety
standards.
•High-performance motion control equipment can move rapidly with very high forces. Unexpected motion
may occur especially during product commissioning. Keep clear of any operational machinery and never
touch them while they are working.
•Do not make any connections to any internal circuitry. Only connections to designated connectors are
allowed.
•All service and maintenance must be performed by qualified personnel.
• Before turning on the EverestServo CORE Drive, check that all safety precautions have been followed, as
well as the installation procedures.

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4. Product Description
Everest CORE is a high power, highly-integrated, digital servo drive intended to be plugged or soldered to an
application-specific daughter board. The drive features best-in-class energy efficiency thanks to its state of the art
power stage, and can be easily configured with Ingenia's free-to-download softwareMotionLab 3.
Everest CORE can be interfaced by means of its proprietary Motion Control Bus protocol.
Main features:
•Ultra-small footprint
•80 VDC, 30 ARMS continuous
•Up to 99% efficiency
•Up to 75 kHz current loop, 25 kHz servo loops
•10 kHz ~ 100 kHz PWM frequency
• 16 bit ADC withVGA for current sensing
•Supports Halls, Quadrature encoder, SSI and BiSS-C
•Up to 4 simultaneous feedback sources
•Full voltage, current and temperature protections
Typical applications:
•Collaborative robot joints
•Robotic exoskeletons
•Wearable robots
•AGVs
• UAVs
•Industrial highly integrated servomotors
•Smart motors
•Battery-powered and e-Mobility
•Low inductance motors
4.1. Part numbering
Product Ordering part
number
Status Image
Everest CORE
Pluggable servo drive with
communication through proprietary
Motion Control Bus protocol.
EVE-CORE
For applications requiring a pluggable drive enabled with EtherCAT or CANopen, please see Everest NET.
For applications requiring a ready-to-go product, also enabled enabled with EtherCAT or CANopen, please
seeEverest XCR.
PRE-PROD.

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4.2. Specifications
Part number →EVE-CORE
Electrical and power specifications
Minimum DC bus supply voltage 8 VDC
Maximum DC bus supply voltage 80VDC(continuous)
85VDC(peak 100 ms)
Recommended power supply
voltage range
12 VDC ~ 72 VDC
This voltage range ensures a safety margin including power supply tolerances and regulation
during acceleration and braking.
Internal drive DC bus capacitance 6 µF
Logic supply voltage 4.9 VDC ~ 5.1 VDC
Nominal phase continuous
current (RMS)
30 A
Maximum phase peak current
(RMS)
60 A @ 3 sec
Active current limiting based on power stage and motor temperature.
Efficiency Up to 99% @ 20 kHz, 80 V, 30 A
Bus voltage utilisation > 97% @ 20 kHz, 80 V, voltage mode, no load
Motion control specifications
Standby logic supply
consumption
≤1 W
Measured with commutation turned OFF.
Supported motor types •Rotary brushless (SVPWM and Trapezoidal)
•Rotary brushed (DC)
Power stage PWM frequency
(configurable)
10 kHz, 20 kHz (default), 50 kHz & 100 kHz
Current sensing 16 bit ADC resolution. Accuracy is ±2% full scale.
Current sense resolution
(configurable)
Current gain is configurable in 4 ranges:
•2.475 mA/count
•1.352 mA/count
•0.570 mA/count
•0.379 mA/count

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Current sense ranges
(configurable)
Current ranges for the 4 configurable current gains:
•±81.1 A
•±44.3 A
•±18.7 A
•±12.4 A
Max. Current loop frequency 75 kHz
Max. servo loops frequency
(position & velocity)
25 kHz @ 75 kHz current loop
Feedbacks •Digital Halls
•Quadrature / Incremental encoder
•Absolute Encoder: up to 2 at the same time, combining any of the
following:
•BiSS-C (up to 2 in daisy chain topology)
•SSI
*Only a specific subset of absolute encoders are supported. Contact Ingenia for further
information.
Supported target sources Network communication (Motion Control Bus)
Control modes •Cyclic Synchronous Position
•Cyclic Synchronous Velocity
•Cyclic Synchronous Current
•Profile Position (trapezoidal & s-curves)
•Profile Velocity
•Interpolated Position (P, PT, PVT)
•Homing
Inputs/outputs and protections
General purpose Inputs and
outputs
4 x non-isolated single-ended digital inputs - 3.3 V logic level. Can be
configured as:
•General purpose
•Positive or negative homing switch
•Positive or negative limit switch
•Quick stop input
4 xnon-isolated single-endeddigital outputs - 3.3 V logic level, 3 mA max.
sink / source current. Can be configured as:
•General purpose
•Operation enabled event flag
•External shunt braking resistor driving signal
1 x ±3.3 V ,16-bit, differential analog input for load cells or torque sensors.
Can be read by the Master to close a torque loop.
Shunt braking resistor output Configurable over any of the digital outputs (see above).
Enabling this function would require an external transistor or power driver.

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Motor brake output Dedicated, PWM capable, 3.3 V digital output for driving a mechanical
brake. Turn-on and turn-off times are configurable.
Enabling this function would require an external transistor or power driver.
Safe Torque OFF inputs 2 x dedicated, non-isolated STO digital inputs (3.3 V and 5 V tolerant).
Motor temperature input 1 x dedicated, 5 V, 12-bit, single-ended analog input for measuring motor
temperature.
Protections •Hardcoded / hardwired Drive protections:
•Automatic current derating on voltage, current and
temperature
•Short-circuit Phase to DC bus
•Short-circuit Phase to Phase
•Short-circuit Phase to GND
•Configurable protections:
•DC bus over-voltage
•DC bus under-voltage
•Drive over-temperature
•Drive under-temperature
•Motor over-temperature (requires external sensor)
•Current overload (I2t). Configurable up to Drive limits
•Voltage mode over-current (with a closed current loop,
protection effectiveness depends on the PID).
•Motion Control protections:
•Halls sequence / combination error (Pending
implementation)
•Limit switches
•Position following error
•Velocity / Position out of limits
Communications
MCB Proprietary Motion Control Bus protocol based on SPI.
Environmental conditions
Aluminium case Yes (connectors side open)
PE isolation > 300 MΩ@ 1000 V
Case temperature Operation:
•-40 ºC to +60 ºC at full current
•+60 ºC to +85 ºC with derated current
For further information, see Thermal Specifications below.
Storage:
•-40 ºC to +100 ºC
Maximum humidity 5% ~ 85% non-condensing

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Mechanical specifications
Horizontal dimensions 34.5 mm x 26 mm
Height 10.4 mm (case)
17 mm (including full length of the power pins)
Weight 16 gr
Certifications
Certifications CE, RoHS
STO SIL3 (certification pending)
4.3. Thermal specifications
Thermal performance of Everest CORE is specified as function of thetemperature measured in its aluminium
case, theDC bus voltageand thePWM commutation frequency. This 3 parameters could ultimately determine
the maximum continuous current the Everest CORE can output, provided that anactive deratingalgorithm will be
continuously protecting it from thermal over-stress. Notice that PWM commutation frequency cannot be changed
dynamically, but pre-selected to match the application needs: most probably 10 kHz will be selected for
highestcurrentat a given temperature (be aware that selecting this frequency may cause audible noise), but 100
kHz will be preferred to control a low inductance motor.
The following figure show the maximum phase current at different case temperatures and DC bus voltages.
Herecurrent is expressed in RMS.To obtain the equivalent current in amplitude just multiply it by√2.
To ensure a proper performance of Everest CORE, thecase temperature must be held always below 85 ºC (Tc-
max=85 ºC).