INGENIA Jupiter JUP-20/80 User manual

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Installation Guide
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Author: INGENIA MOTION CONTROL
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i033-01-Jupiter Servo Drive
09-Sep-2015 17:31
http://doc.ingeniamc.com/display/JUP/Installation+Guide

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Table of Contents
1 Contents ________________________________________________________________________________________________________________________ 7
1.1 Safety Information ____________________________________________________________________________________________________________ 7
1.2 Product Description ___________________________________________________________________________________________________________ 7
1.3 Installation __________________________________________________________________________________________________________________ 7
1.4 Wiring and Connections _______________________________________________________________________________________________________ 7
1.5 Dimensions _________________________________________________________________________________________________________________ 8
2 Revision History __________________________________________________________________________________________________________________ 9
3 Preliminary notes ________________________________________________________________________________________________________________ 10
4 Disclaimers and limitations of liability ________________________________________________________________________________________________ 11
5 Safety Information _______________________________________________________________________________________________________________ 12
5.1 Warnings __________________________________________________________________________________________________________________ 12
5.2 Precautions ________________________________________________________________________________________________________________ 12
6 Product Description ______________________________________________________________________________________________________________ 14
6.1 Specifications ______________________________________________________________________________________________________________ 15
6.2 Power ratings ______________________________________________________________________________________________________________ 19
6.3 Jupiter power specifications ___________________________________________________________________________________________________ 21
6.3.1 Jupiter without cold plate _______________________________________________________________________________________________ 23
6.3.2 Jupiter with cold plate, choosing appropriate heatsink ________________________________________________________________________ 26
6.3.3 Dynamic applications with non constant current _____________________________________________________________________________ 29
6.4 Architecture ________________________________________________________________________________________________________________ 30
6.5 Hardware revisions __________________________________________________________________________________________________________ 32
6.6 Specifications ______________________________________________________________________________________________________________ 33
6.7 Power and current ratings _____________________________________________________________________________________________________ 38
6.7.1 Jupiter power specifications _____________________________________________________________________________________________ 39
6.8 Architecture ________________________________________________________________________________________________________________ 49

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6.9 Hardware revisions __________________________________________________________________________________________________________ 51
7 Installation _____________________________________________________________________________________________________________________ 53
7.1 Installing the USB Driver ______________________________________________________________________________________________________ 53
7.1.1 Windows 8 Installation _________________________________________________________________________________________________ 55
7.2 Connectors position and pinout _________________________________________________________________________________________________ 57
7.2.1 CAN interface connector _______________________________________________________________________________________________ 60
7.2.2 Feedbacks connector __________________________________________________________________________________________________ 61
7.2.3 Absolute encoder connector ____________________________________________________________________________________________ 63
7.2.4 I/O connector ________________________________________________________________________________________________________ 64
7.2.5 RS232 interface connector _____________________________________________________________________________________________ 66
7.2.6 Supply and shunt connector ____________________________________________________________________________________________ 67
7.2.7 Supply, shunt and motor connector _______________________________________________________________________________________ 68
7.2.8 Motor connector ______________________________________________________________________________________________________ 69
7.2.9 STO connector _______________________________________________________________________________________________________ 70
7.2.10 Motor safety connector ________________________________________________________________________________________________ 71
7.2.11 USB connector ______________________________________________________________________________________________________ 71
7.2.12 CAN interface connector ______________________________________________________________________________________________ 73
7.2.13 Feedbacks connector _________________________________________________________________________________________________ 74
7.2.14 Absolute encoder connector ___________________________________________________________________________________________ 76
7.2.15 IO connector ________________________________________________________________________________________________________ 77
7.2.16 RS232 interface connector ____________________________________________________________________________________________ 79
7.2.17 Supply and shunt connector ___________________________________________________________________________________________ 80
7.2.18 High current connector ________________________________________________________________________________________________ 81
7.2.19 Motor connector _____________________________________________________________________________________________________ 82
7.2.20 STO connector ______________________________________________________________________________________________________ 82
7.2.21 Motor safety connector ________________________________________________________________________________________________ 83
7.2.22 USB connector ______________________________________________________________________________________________________ 84
7.3 Mating connectors ___________________________________________________________________________________________________________ 85
7.3.1 CAN interface mating connector _________________________________________________________________________________________ 85
7.3.2 Feedbacks mating connectors ___________________________________________________________________________________________ 87

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7.3.3 Absolute encoder mating connectors ______________________________________________________________________________________ 88
7.3.4 I/O mating connectors _________________________________________________________________________________________________ 89
7.3.5 RS232 mating connectors ______________________________________________________________________________________________ 91
7.3.6 Supply and shunt mating connector _______________________________________________________________________________________ 92
7.3.7 Motor mating connector ________________________________________________________________________________________________ 93
7.3.8 STO mating connector _________________________________________________________________________________________________ 94
7.3.9 Motor safety mating connector ___________________________________________________________________________________________ 95
7.3.10 USB mating connector ________________________________________________________________________________________________ 96
7.4 Signalling LEDs _____________________________________________________________________________________________________________ 96
7.4.1 Power and motor signalling LEDs ________________________________________________________________________________________ 98
7.4.2 CAN signalling LEDs __________________________________________________________________________________________________ 98
8 Wiring and Connections __________________________________________________________________________________________________________ 101
8.1 Power supply wiring ________________________________________________________________________________________________________ 101
8.1.1 Contents ___________________________________________________________________________________________________________ 101
8.1.2 Recommended power supply connection _________________________________________________________________________________ 102
8.1.3 Simplified battery supply connection _____________________________________________________________________________________ 105
8.1.4 Connection of multiple drivers __________________________________________________________________________________________ 106
8.1.5 Power supply wiring recommendations ___________________________________________________________________________________ 107
8.1.6 Recommended power supply connection _________________________________________________________________________________ 110
8.1.7 Simplified battery supply connection _____________________________________________________________________________________ 112
8.1.8 Connection of multiple drivers __________________________________________________________________________________________ 114
8.1.9 Power supply wiring recommendations ___________________________________________________________________________________ 115
8.2 Motor output wiring _________________________________________________________________________________________________________ 118
8.2.1 AC and DC Brushless motors __________________________________________________________________________________________ 119
8.2.2 DC motors and voice coil actuators ______________________________________________________________________________________ 120
8.2.3 Stepper motors ______________________________________________________________________________________________________ 121
8.2.4 External Shunt resistor ________________________________________________________________________________________________ 122
8.2.5 MOTOR WIRING RECOMMENDATIONS _________________________________________________________________________________ 135
8.2.6 AC and DC Brushless motors __________________________________________________________________________________________ 138
8.2.7 DC motors and voice coil actuators ______________________________________________________________________________________ 139

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8.2.8 Stepper motors ______________________________________________________________________________________________________ 140
8.2.9 External Shunt resistor ________________________________________________________________________________________________ 141
8.2.10 Safe Torque Off connection ___________________________________________________________________________________________ 145
8.2.11 Motor safety systems connection _______________________________________________________________________________________ 147
8.2.12 Motor wiring recommendations ________________________________________________________________________________________ 152
8.3 Feedback connections ______________________________________________________________________________________________________ 155
8.3.1 Position feedback interfaces ___________________________________________________________________________________________ 156
8.3.2 Velocity feedback interfaces ___________________________________________________________________________________________ 210
8.3.3 Feedback wiring recommendations ______________________________________________________________________________________ 213
8.4 IO connections ____________________________________________________________________________________________________________ 214
8.4.1 Contents ___________________________________________________________________________________________________________ 214
8.4.2 Low-speed (LS) single ended digital inputs interface ________________________________________________________________________ 215
8.4.3 High-speed (HS) digital inputs interface __________________________________________________________________________________ 218
8.4.4 Analog inputs interface _______________________________________________________________________________________________ 224
8.4.5 Digital outputs interface _______________________________________________________________________________________________ 229
8.4.6 Low-Speed (LS) single ended digital inputs interface ________________________________________________________________________ 235
8.4.7 High-Speed (HS) digital inputs interface __________________________________________________________________________________ 239
8.4.8 Analog inputs interface _______________________________________________________________________________________________ 245
8.4.9 Digital outputs interface _______________________________________________________________________________________________ 250
8.5 Command sources _________________________________________________________________________________________________________ 256
8.5.1 CONTENTS ________________________________________________________________________________________________________ 257
8.5.2 Network interface ____________________________________________________________________________________________________ 258
8.5.3 Standalone _________________________________________________________________________________________________________ 258
8.5.4 Analog input ________________________________________________________________________________________________________ 259
8.5.5 Step and direction ___________________________________________________________________________________________________ 260
8.5.6 PWM command _____________________________________________________________________________________________________ 262
8.5.7 Encoder following or Electronig gearing __________________________________________________________________________________ 267
8.5.8 Network interface ____________________________________________________________________________________________________ 269
8.5.9 Standalone _________________________________________________________________________________________________________ 270
8.5.10 Analog input _______________________________________________________________________________________________________ 270

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8.5.11 Step and direction (Pulse and direction) _________________________________________________________________________________ 272
8.5.12 PWM command ____________________________________________________________________________________________________ 274
8.5.13 Encoder following or electronic gearing __________________________________________________________________________________ 279
8.6 Communications ___________________________________________________________________________________________________________ 281
8.6.1 CAN interface _______________________________________________________________________________________________________ 282
8.6.2 USB interface _______________________________________________________________________________________________________ 285
8.6.3 RS232 interface _____________________________________________________________________________________________________ 286
8.6.4 RS485 interface _____________________________________________________________________________________________________ 291
9 Dimensions ___________________________________________________________________________________________________________________ 295
9.1 JUP-20/80 ________________________________________________________________________________________________________________ 295
9.2 JUP-50/80 ________________________________________________________________________________________________________________ 299
9.3 JUP-15/130 _______________________________________________________________________________________________________________ 301
9.4 JUP-35/130 _______________________________________________________________________________________________________________ 303
9.5 EtherCAT version __________________________________________________________________________________________________________ 305

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1 Contents
1.1 Safety Information
1.2 Product Description
Specifications
Power and current ratings
Architecture
Hardware revisions
1.3 Installation
Installing the USB Driver
Connectors position and pinout
Mating connectors
Signalling LEDs
1.4 Wiring and Connections
Power supply wiring
Motor output wiring
Feedback connections
IO connections

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Command sources
Communications
1.5 Dimensions

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2 Revision History
Revision Release Date Changes
1.0 May 2015 Private preliminary draft. Not for public use.
2.0 September 2015 First public manual.

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3 Preliminary notes
A PDF version of this manual is available in the section.Downloads
Please refer to page for information on previous hardware revisions and changes.product hardware revisions

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4 Disclaimers and limitations of liability
Except in cases specifically indicated in other agreements and , this product and its documentation are provided "as is", with no warranties or INGENIA-CAT
conditions of any type, whether express or implied, including, but not limited to the implied warranties or conditions of merchantability, fitness for a particular
purpose or non-infringement.
INGENIA-CAT rejects all liability for errors or omissions in the information or the product or in other documents mentioned in this document.
INGENIA-CAT shall in no event be liable for any incidental, accidental, indirect or consequential damages (including but not limited to those resulting from: (1)
dependency of equipment presented, (2) costs or substituting goods, (3) impossibility of use, loss of profit or data, (4) delays or interruptions to business operations
(5) and any other theoretical liability that may arise as a consequence of the use or performance of information, irrespective of whether has been INGENIA-CAT
notified that said damage may occur.
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.
This document may contain technical or other types of inaccuracies. This information changes periodically.

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5 Safety Information
Read carefully this chapter to raise your awareness of potential risks and hazards when working with the Jupiter Servo Drive.
To ensure maximum safety in operating the Jupiter 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 Jupiter Servo Drive, as well as other hardware that may be connected to it. Please read this chapter carefully before
starting the installation process.
5.1 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 Jupiter Servo Drive while the
power supply is on.
Disconnect the Jupiter 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.
5.2 Precautions
The following statements should be considered to avoid serious injury to those individuals performing the procedures and/or damage to the equipment:
The Jupiter Servo Drive components temperature may exceed 100 ºC during operation.
Some components become electrically charged during and after operation. Expect voltages > 100 V that could be lethal.
The power supply connected to this controller should comply with the parameters specified in this document.

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When connecting the Jupiter Servo 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 Jupiter Servo Drive, check that all safety precautions have been followed, as well as the installation procedures.

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6 Product Description
CONTENTS
Specifications
Power ratings
Jupiter power specifications
Jupiter without cold plate
Jupiter with cold plate, choosing appropriate heatsink
Dynamic applications with non constant current
Easy approach (quadratic mean of current)
Dynamic model
Architecture
Hardware revisions
Jupiter is a high performance closed loop servo drive controller suitable for DC brushed, voice coils, brushless and stepper motors.
Its incredibly compact design includes multiple communication ports, enabling thus a wide choice of interfacing methods. Its extended voltage operating range
allows its use in several applications, and the small footprint and the needless of an external heatsink allow the controller to be a valid OEM for critical-size
applications.
The Jupiter Digital Servo Drive has been designed with efficiency in mind. It incorporates cutting-edge MOSFET technology as well as optimized control algorithms
to provide the perfect trade-off between EMIs and efficiency.
Jupiter Servo Drive is provided with several general purpose inputs and outputs designed for 5V TTL logic but tolerant up to 24V and fully rugged. By using these
inputs and outputs it is possible to implement alarm signals, connect digital sensors, activate external devices (LEDs, actuators, solenoids, etc.). Some of the digital
and analog inputs can also be used as command / target sources.
Jupiter includes many protections to ensure its safe operation and easy integration.

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6.1 Specifications
Each Ingenia Digital Servo Drive has a separate datasheet that contains important information on the options and productspecific features available with that
particular drive. The datasheet is to be used in conjunction with this manual for system design and installation.
Variant JUP-20/80 JUP-40/80 JUP-15/130 JUP-30/130
Power supply voltage 10 V to 80 V
DC DC 10 V to 130 V DC DC
Transient peak voltage 95 V 145 V
Logic supply voltage 10 V to 95 V
DC DC
(If not connected, logic supply is bypassed from power
supply)
10 V to 95 V
DC DC
(Note that the logic supply voltage < power supply voltage. Do not connect them together at
voltages > 95 V)
Internal DC bus capacitance 600 µF 450 µF
Maximum phase peak current 40 A
RMS (5 s) 80 ARMS (5 s) 30 A RMS (5 s) 70 A RMS (5 s)
Maximum phase continuous
current
20 ARMS 40 ARMS 15 ARMS 35 ARMS
Standby power consumption 1.5 W (max)
Efficiency > 97% at the rated power and current

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Supported motor types
Rotary or linear brushless (trapezoidal and sinusoidal)
DC brush
Voice coil
2 phases bipolar stepper
3 phases stepper
Power stage PWM frequency 20 kHz (default)
40 kHz (high PWM frequency, )configurable
Current sensing On phases A, B and C using 4 terminal shunt resistors.
Accuracy is ± 1% full scale.
10 bit ADC resolution.
Sensors for commutation
(brushless motors)
Digital halls (Trapezoidal)
Analog halls (Sinusoidal / Trapezoidal)
Quad. Incremental encoder (Sinusoidal / Trapezoidal)
PWM encoder (Sinusoidal / Trapezoidal)
Analog potentiometer (Sinusoidal / Trapezoidal)

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Sensors supported for servo
loops DC tachometer
Digital halls
Analog halls
Quad. Incremental encode
PWM encoder
Analog potentiometer
Sin-Cos encoder
Absolute encoder
Supported target sources
Network communication – (µUSB connector)USB
Network communication – (Isolated, self-supplied, CiA-301, CiA-303, CiA-305, CiA-306 and CiA-402 compliant)CANopen
Network communication – (Isolated, self-supplied, single or daisy chain). on demand.RS-485 RS-232
Network communication – EtherCAT (CoE)(Option)
Standalone (execution from Internal EEPROM memory)
Analog input (±10 V or 0 V to 5 V)
Step and Direction (Pulse and direction)
PWM command
Encoder follower / Electronic Gearing
Inputs and outputs
2 x non isolated single ended digital inputs. GDI1, GDI2 (5V logic, 24V tolerant)
2 x non isolated high speed differential digital inputs. HS_GPI1 Pulse, HS_GPI2 Direction (5V logic, 24V tolerant)
1 x (±10 V) differential analog input (12 bits). AN_IN2.
1 x 0 V... 5 V single ended analog input (12 bits). AN_IN1.
2 x Open open drain digital outputs with a weak pull-up to 5 V. (1 A short-circuit and over-current rugged)

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Protections
User configurable:
Bus over-voltage
Bus under-voltage
Over temperature
Under temperature
Over current
Overload (I t)
2
Short-circuit protections:
Phase-DC bus
Phase-phase
Mechanical limits for homing functions
Hall sequence/combination error
ESD & EMI protections: ESD protections are available in all inputs, outputs and communications. All inputs, outputs,
feedbacks include noise filters.
Inverse polarity supply protection (bidirectional)
High power transient voltage suppressor for short braking: A TVS diode (600 W peak) protects the circuitry from the voltage
transients events
Encoder broken wire (for differential quadrature encoders only).
Ambient air temperature
-40 ºC to +50 ºC full current (operating)
+50 ºC to +100 ºC current derating (operating)
-50 ºC to -40ºC and 100ºC to +125 ºC (non-operating)
Maximum humidity 5% - 85% (non-condensing)

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Dimensions 100 mm x 100 mm
x 26 mm
(no plate)
120 mm x 101 mm
x 28.1 mm
(with plate)
100 mm x 100 mm
x 28 mm
(no plate)
120 mm x 102 mm
x 30.1 mm
(plate)
Weight (exc. mating
connectors)
109 g - 114 g -
Variant JUP-20/80 JUP-40/80 JUP-15/130 JUP-30/130
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6.2 Power ratings
To determine which is suited for an application and choose a heatsink (if needed) the power losses must be known.Jupiter variant
Excessive power losses lead to over temperature that will be detected and cause a the driver to turn off. The system temperature is available in and EMCL registers
is measured near the power stage in different points for best reliability. The temperature parameter that can be accessed from USB 2.0, CAN or serial interface does
not indicate the air temperature. Above 110ºC the Jupiter automatically turns off the power stage and stay in fault state avoiding any damage to the drive. A Fault
LED will be activated and cannot be reseted unless temperature decreases.
Driver safety is always ensured by its protections. However, power losses and temperature limit the allowable motor current.
Future will allow an automatic current foldback based on temperature. This means the current will be reduced before an versions of firmware
overtemperature occurs. Stay tuned for upgrades!

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Some parts of the Jupiter exceed 110ºC when operating, especially at high load levels.
and wait at least 5 minutes after turn off to allow a safe cool down.Do not touch the Jupiter when operating
Following figure shows the basic power flow and losses in a servo drive system.