INGENIA Capitan XCR User manual

INGENIA-CAT S.L.
AVILA 124 2-B
08018 BARCELONA
Capitan XCR - Product Manual
Edition 07/30/2021
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
3.4. Pour votre sécurité............................................................................................................................................... 6
3.4.1. Avertissements..................................................................................................................................................... 7
3.4.2. Précautions .......................................................................................................................................................... 7
4. Product Description 8
4.1. Part Numbering.................................................................................................................................................... 8
4.2. Specifications....................................................................................................................................................... 9
4.2.1. Electrical and Power Specifications....................................................................................................................9
4.2.2. Motion Control Specifications........................................................................................................................... 10
4.2.3. Inputs/Outputs and Protections .......................................................................................................................11
4.2.4. Communication for Operation .......................................................................................................................... 12
4.2.5. Environmental Conditions................................................................................................................................. 12
4.2.6. Reliability Specifications ................................................................................................................................... 13
4.2.7. Mechanical Specifications ................................................................................................................................. 13
4.2.8. Compliance ........................................................................................................................................................ 13
4.3. Product Revisions .............................................................................................................................................. 15
4.4. Thermal and Power Specifications ...................................................................................................................15
4.4.1. Standby power consumption............................................................................................................................ 15
4.4.2. Thermal model................................................................................................................................................... 15
4.4.3. Current derating................................................................................................................................................. 16
4.4.4. Heat dissipation and heatsink calculation .......................................................................................................17
4.4.5. Energy efficiency ................................................................................................................................................ 18
5. EtherCAT specifications 20
6. CANopen Specifications 21
7. Connectors Guide 23
7.1. Connector Overview .......................................................................................................................................... 23
7.2. Supply................................................................................................................................................................. 23
7.3. Motor .................................................................................................................................................................. 24
7.4. Feedback Connector.......................................................................................................................................... 24
7.5. Input / Outputs Connector ................................................................................................................................ 26

7.6. EtherCAT Connectors......................................................................................................................................... 28
7.7. Mating Connectors............................................................................................................................................. 29
7.7.1. Common mating terminals and cables for all signal connectors.................................................................... 30
8. Signalling LEDs 33
8.1. LED Signal Definitions........................................................................................................................................ 33
8.2. EtherCAT protocol (CAP-XCR-E) ........................................................................................................................ 34
8.2.1. Start-up Sequence ............................................................................................................................................. 35
8.3. CANopen protocol (CAP-XCR-C) ........................................................................................................................36
8.3.1. Start-up Sequence ............................................................................................................................................. 37
9. Wiring and Connections 39
9.1. Capitan XCR Connection Diagram..................................................................................................................... 39
9.2. Protective Earth ................................................................................................................................................. 41
9.3. Power Supply and Motor Power........................................................................................................................ 43
9.3.1. Single Power Supply .......................................................................................................................................... 43
9.3.1.1 Power Supply Requirements............................................................................................................................. 43
9.3.2. Dual Power Supply............................................................................................................................................. 44
9.3.2.1 Logic Supply Requirements............................................................................................................................... 44
9.3.3. Power Supply EMI Filter..................................................................................................................................... 44
9.3.4. Shunt Braking Resistor Connection ..................................................................................................................45
9.3.5. Motor Connections............................................................................................................................................. 46
9.3.5.1 3 Phase Brushless............................................................................................................................................... 46
9.3.5.2 DC Motor............................................................................................................................................................. 47
9.3.5.3 Motor Choke ....................................................................................................................................................... 47
9.3.6. Power Wiring Recommendations...................................................................................................................... 48
9.3.6.1 Cable Selection .................................................................................................................................................. 48
9.3.6.2 Soldering Power Pins......................................................................................................................................... 48
9.4. Safe Torque Off (STO) ........................................................................................................................................50
9.4.1. Safety Function Specifications.......................................................................................................................... 50
9.4.2. Integration Requirements ................................................................................................................................. 51
9.4.3. STO External Diagnostic Test ............................................................................................................................ 53
9.4.4. STO Operation States ........................................................................................................................................ 54
9.4.5. Interface and Connections ................................................................................................................................ 55
9.4.6. STO bypass (needed when no STO functionality is implemented) ................................................................. 57
9.5. Brake and Motor Temperature.......................................................................................................................... 58
9.5.1. Motor electromagnetic / electromechanical brake.......................................................................................... 58
9.5.2. External temperature sensor............................................................................................................................. 59
9.6. Feedbacks........................................................................................................................................................... 60
9.6.1. Digital Halls ........................................................................................................................................................ 60
9.6.2. Absolute Encoder 1 ............................................................................................................................................ 62
9.6.3. Absolute Encoder 2 ............................................................................................................................................ 63

9.6.4. Incremental Encoder ......................................................................................................................................... 64
9.6.5. Feedback wiring recommendations ................................................................................................................. 67
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. CAP-XCR-C (CANopen & Ethernet Interface)..................................................................................................... 73
9.8.1.1 CAN wiring recommendations .......................................................................................................................... 74
9.8.2. CAP-XCR-E (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 81
11.1. Unboxing ............................................................................................................................................................ 81
11.2. Installation Safety Requirements...................................................................................................................... 81
11.3. Mounting the Drive to a Heatsink or Cooling Plate ..........................................................................................81
11.3.1. Back Installation ................................................................................................................................................ 81
11.3.2. Front Installation ............................................................................................................................................... 83
12. Commissioning 85
12.1. Safety first........................................................................................................................................................... 85
12.2. Decommissioning .............................................................................................................................................. 86
13. Service 87

Capitan XCR - Product Manual|General Information
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2. General Information
2.1. Manual revision history
Revision Release Date Changes PDF
v1 13.11.2020 Initial version
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

Capitan XCR - Product Manual|Safety Information
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3. Safety Information
3.1. For your safety
The instructions set out below must be read carefully prior to the 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. An 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.
3.4. Pour votre sécurité
Les instructions ci-dessous doivent être lues attentivement avant la mise en service ou l'installation initiale afin de
sensibiliser aux risques et dangers potentiels et de prévenir les blessures aux personnes et/ou les dommages aux biens.

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Pour garantir la sécurité lors de l'utilisation de ce servomoteur, il est obligatoire de suivre les procédures incluses dans
ce manuel. Les informations fournies sont destinées à protéger les utilisateurs et leur zone de travail lors de
l'utilisation de l'appareil, ainsi que les autres matériels qui peuvent y être connectés.
3.4.1. Avertissements
Les servo-entraînements électriques sont dangereux : Les déclarations suivantes doivent être prises en compte pour
éviter des blessures graves aux personnes et/ou des dommages à l'équipement :
Ne pas toucher les bornes d'alimentation de l'appareil (alimentation et phases) car elles peuvent véhiculer des
tensions dangereusement élevées > 50 V.
Ne jamais connecter ou déconnecter l'appareil lorsque l'alimentation est en marche afin d'éviter tout danger
pour le personnel, la formation d'arcs électriques ou de contacts électriques indésirables.
Déconnectez l'appareil de toutes les sources d'alimentation avant de procéder à tout changement de câblage.
La surface de l'appareil peut dépasser 100 ºC pendant le fonctionnement et peut causer de graves brûlures au
contact direct.
Après avoir éteint et déconnecté toutes les sources d'alimentation de l'appareil, attendez au moins 10 secondes
avant de toucher une partie quelconque de l'appareil, car il peut rester chargé électriquement ou être chaud.
3.4.2. Précautions
Les déclarations suivantes doivent être prises en compte pour éviter des blessures graves aux personnes qui effectuent
les procédures et/ou des dommages à l'équipement :
Respectez toujours les conditions de connexion et les spécifications techniques. En particulier en ce qui
concerne la section des fils et la mise à la terre.
Certains composants se chargent électriquement pendant et après le fonctionnement.
L'alimentation électrique connectée à ce contrôleur doit être conforme aux paramètres spécifiés dans ce
manuel.
Lorsque vous connectez ce variateur à une source d'alimentation approuvée, faites-le par une ligne séparée de
toute tension dangereuse éventuelle, en utilisant l'isolation nécessaire conformément aux normes de sécurité.
Les équipements de control de mouvement à haute performance peuvent se déplacer rapidement avec des
forces très élevées. Un mouvement inattendu peut se produire, notamment lors de la mise en service du
produit. Restez à l'écart de toute machine opérationnelle et ne la touchez jamais pendant qu'elle fonctionne.
N'effectuez aucune connexion à un circuit interne. Seules les connexions à des connecteurs désignés sont
autorisées.
Tous les travaux d'entretien et de maintenance doivent être effectués par un personnel qualifié.
Avant de mettre le le contrôleur en marche, vérifiez que toutes les précautions de sécurité ont été prises, ainsi
que les procédures d'installation.

Capitan XCR - Product Manual|Product Description
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4. Product Description
Capitan XCR is a high power, highly integrated, ready to use digital servo drive. The drive includes all the required
interface electronics and connectors, features best-in-class energy efficiency thanks to its state of the art power
stage, and can be easily configured with Ingenia's free softwareMotionLab 3.
Capitan XCR is enabled with EtherCAT and CANopen communications.
Main features:
Ultra-small footprint
48 VDC, 10 Acontinuous
Up to 98% efficiency
Up to 50 kHz current loop, 25 kHz servo loops
20 kHz ~ 200 kHz PWM frequency
16 bit ADC
Supports Halls, Quadrature encoder, SSI and Dual 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
Robot end effectors
Robotic exoskeletons & wearable robots
Low power AGVs
UAVs
Industrial highly integrated servomotors
Smart motors
Battery-powered and e-Mobility
Low inductance motors
Lab equipment
4.1. Part Numbering
Product Ordering part
number
Status Image Label
Capitan XCR EtherCAT
Ready-to-use servo drive
featuring EtherCAT
communications.
CAP-XCR-E PRODUC
TION
Capitan XCR CANopen
Ready-to-use servo drive
featuring CANopen. Ethernet
port 1 could be used for
commissioning.
CAP-XCR-C PRODUC
TION
For applications requiring a pluggable drive enabled with EtherCAT or CANopen, please seeCapitan NET.
For applications not requiring CANopen or EtherCAT, please seeCapitan CORE.

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4.2. Specifications
4.2.1. Electrical and Power Specifications
Minimum power supply
voltage
8 VDC
Maximum absolute power
supply voltage
60VDC(continuous)
Recommended power supply
voltage
12 VDC ~ 48VDC
This voltage range ensures a safety margin including power supply tolerances and regulation during
acceleration and braking.
Internal drive DC bus
capacitance
47 µF
Note that CAP-XCR uses ceramic capacitors. The capacitance value varies with DC bias and
temperature.
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.
Maximum continuous phase
current
10 A
Typically, 10 A can be obtained working at 48 V, 50 kHz with an appropriate cooling to keep case
temperature under 85 ºC. On higher temperatures an automatic current derating will be applied to
protect the system. SeeThermal and Power Specificationsbelow.
For disambiguation on current definitions please seeDisambiguation on current values and naming
for Ingenia Drives.
Maximum peak phase current 20 A @ 1 sec
Notice that peak current could be limited by an automatic current derating algorithm. In order to get
20 A, case temperature should be kept below 60 ºC.
Maximum continuous switch-
off rectified current
Without heatsink: 1 A @ 25 ºC
With heatsink: 1 A @ 85 ºC
Notice that maximum current is dependent on temperature and heatsink attached. At higher
temperature, the lower the current. For more information about heatsink applied, see Thermal and
Power Specificationsbelow.
A continuous use of disabled power stage as rectifier is not recommended for thermal limitations.
Maximum continuous output
power
> 500 W
How the output power is calculated in an Ingenia drive.
Efficiency Up to 98.5%

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Maximum DC Bus
voltageutilization
99.5% @ 20 kHz
98.9% @ 50 kHz
97.95% @ 100 kHz
96% @ 200 kHz
Note 1: these values assume a Sinusoidal commutation and no load connected.
Standby logic supply
consumption
1.5 W ~ 2.1 W (for EtherCAT-enabled version)
See details and conditions in the section below.
4.2.2. Motion Control Specifications
Supported motor types Rotary brushless (SVPWM and Trapezoidal)
Rotary brushed (DC)
Power stage PWM frequency
(configurable)
20 kHz, 50 kHz (default) & 100 kHz
200 kHz option available upon request
Current sensing 3 phase, shunt-based current sensing. 16 bit ADC resolution. Accuracy is ±2%
full scale.
Current sense resolution 1.007 mA/count
Current sense range ± 33 A
Max. Current loop frequency 50 kHz
Max. servo loops frequency
(position, velocity &
commutation)
25 kHz @ 50 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
*Not all the existing absolute encoders are supported. Contact Ingenia for further information.
Supported target sources Network communication (EtherCAT / CANopen)
Control modes Cyclic Synchronous Position
Cyclic Synchronous Velocity
Cyclic Synchronous Current
Profile Position (trapezoidal & s-curves)
Profile Velocity
Interpolated Position (P, PT, PVT)
Homing