INGENIA Everest XCR User manual

INGENIA-CAT S.L.
AVILA 124 2-B
08018 BARCELONA
Everest XCR - Product manual
Edition 10/01/2020
For the most up to date information visit the online manual.

1. Table of Contents
1. Table of Contents 2
2. General Information 5
2.1. Manual revision history....................................................................................................................................... 5
2.2. Disclaimers and limitations of liability .............................................................................................................. 5
2.3. Contact ................................................................................................................................................................ 5
3. Safety Information 6
3.1. For your safety..................................................................................................................................................... 6
3.2. Warnings.............................................................................................................................................................. 6
3.3. Precautions ......................................................................................................................................................... 6
4. Product Description 7
4.1. Part Numbering................................................................................................................................................... 7
4.2. Specifications...................................................................................................................................................... 7
4.3. Product Revisions ............................................................................................................................................. 14
4.4. Thermal and Power Specifications .................................................................................................................. 14
4.4.1. Standby power consumption........................................................................................................................... 14
4.4.2. Thermal model.................................................................................................................................................. 15
4.4.3. Current derating................................................................................................................................................ 16
4.4.4. Heat dissipation and heatsink calculation ...................................................................................................... 16
4.4.5. Energy efficiency ............................................................................................................................................... 18
5. EtherCAT Specifications 19
6. CANopen Specifications 20
6.1. Specifications.................................................................................................................................................... 20
7. Connectors Guide 21
7.1. Connector Overview ......................................................................................................................................... 21
7.2. Supply................................................................................................................................................................ 21
7.3. Motor................................................................................................................................................................. 22
7.4. Feedback Connector......................................................................................................................................... 23
7.5. Input / Outputs Connector ............................................................................................................................... 24
7.6. EtherCAT Connectors........................................................................................................................................ 26
7.7. Mating Connectors............................................................................................................................................ 27
7.7.1. Common mating terminals and cables for all signal connectors................................................................... 29
8. Signalling LEDs 32
8.1. Start-up Sequence ............................................................................................................................................ 32
8.2. Driver Status LEDs............................................................................................................................................. 33
8.3. EtherCAT Status LEDs ....................................................................................................................................... 33
8.4. CANopen Status LEDs ....................................................................................................................................... 34
9. Wiring and Connections 36
9.1. Everest XCR Connection Diagram .................................................................................................................... 36

9.2. Protective Earth ................................................................................................................................................ 38
9.3. Power Supply and Motor Power....................................................................................................................... 40
9.3.1. Single Power Supply ......................................................................................................................................... 40
9.3.1.1 Power Supply Requirements............................................................................................................................ 40
9.3.2. Dual Power Supply........................................................................................................................................... 41
9.3.2.1 Logic Supply Requirements.............................................................................................................................. 41
9.3.3. Power Supply EMI Filter.................................................................................................................................... 41
9.3.4. Shunt Braking Resistor Connection ................................................................................................................ 42
9.3.5. Motor Connections............................................................................................................................................ 43
9.3.5.1 3 Phase Brushless.............................................................................................................................................. 43
9.3.5.2 DC Motor............................................................................................................................................................ 44
9.3.5.3 Motor Choke ...................................................................................................................................................... 44
9.3.6. Power Wiring Recommendations..................................................................................................................... 45
9.3.6.1 Cable Selection ................................................................................................................................................. 45
9.3.6.2 Soldering Power Pins........................................................................................................................................ 45
9.4. Safe Torque Off (STO) ....................................................................................................................................... 47
9.4.1. Safety Function Specifications......................................................................................................................... 47
9.4.2. Integration Requirements ................................................................................................................................ 48
9.4.3. STO External Diagnostic Test ........................................................................................................................... 50
9.4.4. STO Operation States ....................................................................................................................................... 52
9.4.5. Interface and Connections ............................................................................................................................... 53
9.4.6. STO bypass (needed when no STO functionality is implemented) ................................................................ 55
9.5. Brake and Motor Temperature......................................................................................................................... 56
9.5.1. Motor electromagnetic / electromechanical brake......................................................................................... 56
9.5.2. External temperature sensor........................................................................................................................... 57
9.6. Feedbacks.......................................................................................................................................................... 59
9.6.1. Digital Halls ....................................................................................................................................................... 59
9.6.2. Absolute Encoder 1 ........................................................................................................................................... 61
9.6.3. Absolute Encoder 2 ........................................................................................................................................... 63
9.6.4. Incremental Encoder........................................................................................................................................ 64
9.6.5. Feedback wiring recommendations ................................................................................................................ 66
9.7. Inputs and Outputs ........................................................................................................................................... 68
9.7.1. Digital Inputs Interface ..................................................................................................................................... 68
9.7.2. Analog Input Interface ...................................................................................................................................... 70
9.7.3. Digital Outputs Interface .................................................................................................................................. 71
9.8. Communications............................................................................................................................................... 73
9.8.1. CANopen Interface............................................................................................................................................ 73
9.8.1.1 CAN wiring recommendations ......................................................................................................................... 74
9.8.2. EtherCAT Interface............................................................................................................................................ 75
9.8.2.1 Recommended EtherCAT cables and connectors........................................................................................... 76

9.8.2.2 Ethernet over EtherCAT (EoE) Protocol - Used by Motion Lab 3..................................................................... 78
10. Dimensions 80
11. Installation 82
11.1. Unboxing ........................................................................................................................................................... 82
11.2. Installation Safety Requirements..................................................................................................................... 82
11.3. Mounting the Drive to a Heatsink or Cooling Plate ......................................................................................... 82
11.3.1. Back Installation ............................................................................................................................................... 82
11.3.2. Front Installation .............................................................................................................................................. 84
12. Commissioning 86
12.1. Safety first.......................................................................................................................................................... 86
12.2. Decommissioning............................................................................................................................................. 87
13. EMC and Environmental Testing Details 88
14. Service 90

Everest XCR - Product manual|General Information
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2. General Information
2.1. Manual revision history
Revisio
n
Release Date Changes
v1 01 Apr 2019 Initial version
v2 21 Feb 2020 Added safety-related indications, expanded STO information,
added commissioning guide. Reordered manual structure.
v3 14 Sep 2020 Cahnges according to Safe Torque Off (STO) certification. Export as PDF
For the most up to date information use the onlineProduct manual.
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.
C/ Avila 124, 2-B
08018 Barcelona
Spain
Telephone: [phone]
E-mail:[email protected]
Web site:www.ingeniamc.com

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3. Safety Information
3.1. For your safety
The instructions set out below must be read carefully prior to initial commissioning or installation in order to
raise awareness of potential risks and hazards, and to prevent injury to personnel and/or damage to property.
To ensure safety when operating this servo drive, it is mandatory to follow the procedures included in this manual.
The information provided is intended to protect users and their working area when using the device, as well as
other hardware that may be connected to it.
3.2. Warnings
Electric servo drives are dangerous:The following statements should be considered to avoid serious injury to
individuals and/or damage to the equipment:
Do not touch the power terminals of the device (supply and phases) as they can carry dangerously high
voltages > 50 V.
Never connect or disconnect the device while the power supply is ON to prevent danger to personnel, the
formation of electric arcs, or unwanted electrical contacts.
Disconnect the drive from all power sources before proceeding with any wiring change.
The surface of the device may exceed 100 ºC during operationand may cause severe burns to direct touch.
After turning OFF and disconnecting all power sources from the equipment, wait at least 10 seconds before
touching any parts of the controller, as it can remain 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:
Always comply with the connection conditions and technical specifications. Especially regarding wire cross-
section and grounding.
Some components become electrically charged during and after operation.
The power supply connected to this controller should comply with the parameters specified in this manual.
When connecting this 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 drive, check that all safety precautions have been followed, as well as the installation
procedures.

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4. Product Description
Main features:
Ultra-small footprint
80 VDC, 30 A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
Safety Torque Off (STO SIL3 Ple) inputs
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 Label
Everest XCR
Ready-to-use servo
drive featuring
EtherCAT and
CANopen
communications.
EVE-XCR
For applications requiring a pluggable drive enabled with EtherCAT or CANopen, please seeEverest NET.
For applications not requiring CANopen or EtherCAT, please seeEverest CORE.
4.2. Specifications
Part number →EVE-XCR
Electrical and power specifications
Minimum power supply voltage 8 VDC
PRODUCTIO
N

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Maximum absolute power
supply voltage
80 VDC (continuous)
85 VDC (peak 100 ms)
Recommended power supply
voltage
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
30 μF
Logic power supply voltage
(optional)
8 to 50 VDC
Providing the logic supply is optional, as the drive is supplied from the DC bus (single supply) on its
full operating voltage range. When supplied from logic, an intelligent switch will stop consuming
from the DC bus.
Nominal phase continuous
current
> 30 A @ 50ºC
Typically, 30 A(RMS) can be obtained with appropriatecooling and keeping heatsink at 50ºC. SeeTh
ermal and Power Specifications below. For disambiguation on current definitions please
seeDisambiguation on current values and naming for Ingenia Drives.
Maximum phase peak current 60 A @ 3 sec
Active current limiting based on power stage and motor temperature.
Short circuit protection By active hardware detection. Short circuit detection level: 100 A ~ 250 A
max. < 10 µs.
Maximum continuous output
power
2800 W
Efficiency Up to 98% @ 20 kHz, 80 V, 30 A
Bus voltage > 97% @ 20 kHz, 80 V, voltage mode, no load
Standby power 2.4 W ~ 3.2 W with power stage disabled.
*See detailed standby power consumption below.
Motion control specifications
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

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Current sensing 3 phase, shunt based 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
Current sense ranges (configura
ble)
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 (Single ended)
Quadrature Incremental encoder (RS-422 or Single ended)
Absolute Encoder (RS-422 or Single ended): up to 2 at the same time,
combining any of the following:
BiSS-C (up to 2 in daisy chain topology)
SSI
Supported target sources Network communication (EtherCAT or CANopen*)
*CANopen is the communication enabled by default. In order to use EtherCAT, the FW must be
updated.
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

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General purpose Inputs and
outputs
4 x non-isolated single-ended digital inputs - 5 V logic level & 3.3 V
compatible. 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 - 5 V logic level (continuous
short circuit capable with 470 Ωseries resistance) - 8 mA max. current. Can
be configured as:
General purpose
Operation enabled event flag
External shunt braking resistor driving signal
1 x ±10 V, 16 bit, fully 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.
Motor brake output 1 A, 50 V, dedicated brake output. Open drain with re-circulation diode.
Brake enable and disable timing can be configured accurately.
PWM modulation available to reduce brake voltage and power consumption.
Safe Torque OFF inputs 2 x dedicated, isolated (> 4 GΩ, 1 kV) STO inputs (from 3.3 V to 30 V).
The STO inputs include a current limiter at ~ 5 mA to minimize losses.Details:
Safe Torque Off (STO).
Motor temperature input 1 x dedicated, 5 V, 12-bit, single-ended analog input for motor temperature
(1.65 kΩpull-up to 5 V included).
NTC, PTC, RTD, Linear Voltage Sensors , Silicon Based Sensors and Switches
are supported.