INGENIA Everest CORE User manual

INGENIA-CAT S.L.
AVILA 124
08018 BARCELONA
Everest CORE - Product manual
Edition 04/23/2021
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. For your safety........................................................................................................................................................ 5
3.2. Warnings................................................................................................................................................................. 5
3.3. Precautions ............................................................................................................................................................ 5
3.4. Pour votre sécurité................................................................................................................................................. 5
3.4.1. Avertissements....................................................................................................................................................... 6
3.4.2. Précautions ............................................................................................................................................................ 6
4. Product Description 7
4.1. Part numbering ...................................................................................................................................................... 7
4.2. Specifications......................................................................................................................................................... 8
4.2.1. Electrical and Power Specifications......................................................................................................................8
4.2.2. Motion Control Specifications............................................................................................................................... 9
4.2.3. Inputs/Outputs and Protections ......................................................................................................................... 10
4.2.4. Communication for Operation ............................................................................................................................11
4.2.5. Environmental Specifications ............................................................................................................................. 11
4.2.6. Reliability Specifications ..................................................................................................................................... 12
4.2.7. Mechanical Specifications ................................................................................................................................... 12
4.2.8. Compliance .......................................................................................................................................................... 13
4.3. Thermal and Power Specifications .....................................................................................................................14
4.3.1. Standby power consumption.............................................................................................................................. 14
4.3.2. Thermal model..................................................................................................................................................... 14
4.3.3. Current derating................................................................................................................................................... 15
4.3.4. Heat dissipation and heatsink calculation .........................................................................................................15
4.3.5. Energy efficiency .................................................................................................................................................. 17
5. Pinout 18
5.1. Connectors Overview........................................................................................................................................... 18
5.2. P1 and P2 Power pins .......................................................................................................................................... 18
5.3. P3 Feedback connector .......................................................................................................................................20
5.4. P4 Everest CORE Interface connector ................................................................................................................. 24
6. Safe Torque Off (STO) 29
6.1. Safety Function Specifications............................................................................................................................ 29
6.2. Integration Requirements ................................................................................................................................... 30
6.3. STO External Diagnostic Test .............................................................................................................................. 33

6.4. STO Operation States .......................................................................................................................................... 34
6.5. STO Inputs External Requirements..................................................................................................................... 35
6.6. Typical Interface Circuit....................................................................................................................................... 36
7. Dimensions 37

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2. General Information
2.1. Manual revision history
Revision Release Date Changes
v1 12 Apr 2019 Initial version
v2 21 Feb 2020 Added safety-related indications.
v3 25 Aug 2020  Added chapter on Safe Torque Off Compliance with Everest CORE
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 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.

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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 softwareMotionLab 3.
Everest CORE can be interfaced by means of its proprietary SPI-based Motion Control Bus protocol.
Main features:
Ultra-small footprint
Up to 80 VDC, 45 A continuous
Up to 99% efficiency
Up to 50 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
Communicati
ons
Environmen
t
Status Image
Everest CORE
Pluggable servo drive with
communication through
proprietary Motion Control
Bus protocol.
EVE-CORE SPI Industrial PRODUCTION
EVE-CORE-E SPI Extended IN-DESIGN
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 with EtherCAT or CANopen, please see Everest XCR.

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4.2. Specifications
4.2.1. Electrical and Power Specifications
Minimum DC bus supply voltage 8 VDC
Maximum DC bus supply voltage 80VDC(continuous)
85VDC(peak 100 ms)
Working at 80 V will require a stable power supply able to absorb any possible reinjection coming
back from the driver.
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
19 µF
Note that EVE-CORE uses ceramic capacitors. The capacitance value varies with DC bias and
temperature.
Logic supply voltage 4.9 VDC ~ 5.1 VDC
A minimum of 500 mA should be provided. Higher current may be needed depending on the
feedbacks used.
Rise time of the 5 V supply must be between 2 ms and 10 ms to guarantee a proper initialisation.
Nominal phase continuous
current
45 A @ 60 ºC
Typically, 45 A can be obtained working at 48 V, 20 kHz with an appropriate cooling to keep case
temperature under 60 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 phase peak current 60 A @ 1 sec
Notice that peak current could be limited by an automatic current derating algorithm. In order to
get 60 A, case temperature should be kept below 35 ºC.
Efficiency Up to 99% @ 20 kHz, 80 V, 30 A

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Maximum DC Bus voltage
utilization
97.4% @ 10 kHz
94.8% @ 20 kHz
87% @ 50 kHz
74% @ 100 kHz
Note 1: these values assume a Sinusoidal commutation. Trapezoidal commutation can reach even
higher levels.
Note 2: the absolute maximum DC bus utilization can only be achieved with no load connected. As
soon as current is being delivered to the motor, small voltage drops in the switched elements will
slightly decrease these utilization ratings.
Standby logic supply
consumption
≤1 W
Measured with commutation turned OFF.
4.2.2. 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
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
(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 50 kHz

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Max. servo loops frequency
(position, velocity &
commutation)
25 kHz @ 50 kHz current loop
Feedbacks Digital Halls
Quadrature / Incremental encoder: Up to 2 at the same time.
Absolute Encoder: up to 2 at the same time, combining any of the
following:
BiSS-C (up to 2 in daisy chain topology)
SSI
All feedback inputs are single ended, 3.3 V logic levels.
*Only a specific subset of absolute encoders are supported. Contact Ingenia for further information.
Supported target sources Network communication (Motion Control Bus based on SPI)
Control modes Cyclic Synchronous Position
Cyclic Synchronous Velocity
Cyclic Synchronous Current
Profile Position (trapezoidal & s-curves)
Profile Velocity
Interpolated Position (P, PT, PVT)
Homing
4.2.3. Inputs/Outputs and Protections
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.