INGENIA Neptune User manual

05-abr-2016 14:02Date:
4Version:
Neptune Servo Drive
Product Manual
Table of Contents

Table of Contents
1 Revision History 4
1.1 Preliminary notes 5
1.2 Disclaimers and limitations of liability 5
2 Safety Information 5
2.1 Warnings 6
2.2 Precautions 6
3 Product Description 6
3.1 Specifications 7
3.2 Hardware revisions 9
3.3 Power and current ratings 10
3.4 Architecture 12
4 Connectors 13
4.1 Connectors position and pinout 14
4.1.1 CAN interface 15
4.1.2 Feedbacks connector 16
4.1.3 IO connector 17
4.1.4 RS232 interface connector 19
4.1.5 Supply and motor connector 19
4.1.6 USB connector 20
4.2 Mating connectors 21
4.2.1 CAN interface mating connector 21
4.2.2 Feedbacks mating connectors 22
4.2.3 I/O mating connectors 23
4.2.4 RS232 mating connectors 24
4.2.5 USB mating connector 24
4.3 Pin header variant pinout 24
4.3.1 Pinout 25
4.3.2 Integrating the Neptune pin header variant on a PCB 28
4.3.3 Recommended mating connectors 29
4.4 EtherCAT variant pinout 30
4.4.1 EtherCAT input and output connector 31

5 Wiring and Connections 32
5.1 Power supply wiring 33
5.1.1 Recommended power supply connection 33
5.1.2 Simplified battery supply connection 34
5.1.3 Connection of multiple drivers 34
5.1.4 Power supply wiring recommendations 35
5.2 Motor output wiring 36
5.2.1 AC and DC Brushless motors 36
5.2.2 DC motors and voice coil actuators 37
5.2.3 Stepper motors 37
5.2.4 Motor wiring recommendations 38
5.3 Feedback connections 39
5.3.1 Digital encoder interface 39
5.3.2 Digital Halls interface 43
5.3.3 Analog Halls interface 46
5.3.4 Analog input feedback - Potentiometer 47
5.3.5 PWM encoder interface 50
5.3.6 DC tachometer 53
5.3.7 Feedback wiring recommendations 54
5.4 IO connections 55
5.4.1 Low-Speed (LS) single ended digital inputs interface 55
5.4.2 High-Speed (HS) digital inputs interface 57
5.4.3 Analog inputs interface 60
5.4.4 Digital outputs interface 63
5.5 Command sources 67
5.5.1 Network interface 67
5.5.2 Standalone 67
5.5.3 Analog input 68
5.5.4 Step and direction (Pulse and direction) 69
5.5.5 PWM command 70
5.5.6 Encoder following or electronic gearing 73
5.6 Communications 74
5.6.1 CAN interface 74
5.6.2 RS232 interface 76
5.6.3 USB interface 79
5.6.4 EtherCAT interface 80
6 Signalling LEDs 80
6.1 Power and motor signalling LEDs 81
6.2 CAN signalling LEDs 81

6.3 EtherCAT signalling LEDs 82
6.3.1 EtherCAT status LED 83
6.3.2 EtherCAT in-connector LED 83
7 Software 83
7.1 Before you begin 84
7.2 Hardware Installation: 84
7.3 Software Installation and Drive Communication Setup: 84
7.4 Updating your drive Firmware 85
7.5 Configuring your drive 86
8 Dimensions 86
8.1 Standard version 87
8.2 Pin header version 88
8.3 EtherCAT version 89
Revision History

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Revision History
Revision Release Date Changes PDF
v1 January 2015 First version –
v2 September 2015 Major update Download
v3 March 2016 Minor changes and aesthetic improvements Download
v4 April 2016 Added EtherCAT information. Structure improvements. 
Preliminary notes
Please refer to page for information on previous hardware revisions and product hardware revisions
changes.
Disclaimers and limitations of liability
Except in cases specifically indicated in other agreements and , this product and its INGENIA-CAT
documentation are provided "as is", with no warranties or 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 notified that said damage INGENIA-CAT
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.
Safety Information

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

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Product Description
Neptune 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 Neptune 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.
Neptune Servo Drive is provided with several general purpose inputs and outputs designed for 5V 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.
Neptune includes many protections to ensure its safe operation and easy integration.
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.
Supply voltage 9 V to 48 V
DC DC
Maximum phase
peak current
5 ARMS (2 s)
Maximum phase
continuous current
2.5 ARMS
Standby power
consumption
1.5 W (max)
1 W (typ)
Efficiency > 95% at the rated power and current.
Supported motor
types
Rotary or linear brushless (trapezoidal and sinusoidal)
DC brush
Voice coil
2 phases bipolar stepper *
3 phases stepper
Minimum motor
inductance
100 µH (without external inductors)
Power stage PWM
frequency
80 kHz

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Current sensing On phases A and B (phase C generated internally).
Accuracy is ± 1% full scale.
10 bit resolution.
Current sense
range
± 6.3 A
Current sense
resolution
12.28 mA/count
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)
Sensors supported
for servo loops
DC tachometer
Digital halls
Analog halls
Quad. Incremental encoder
PWM encoder
Analog potentiometer
Supported
Command Sources
Network communication – (µUSB connector)USB
Network communication – (CiA-301, CiA-303, CiA-305, CiA-306 CANopen
and CiA-402 compliant)
Network communication – (Single or daisy chain)RS-232
Standalone (execution from Internal EEPROM memory)
Analog input (±10 V or 0 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 overcurrent rugged)

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Protections User configurable:
Bus overvoltage
Bus undervoltage
Over temperature
Under temperature
Over current
Overload (I t)
2
Short-circuit protections:
Phase-GND
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 USB. All inputs, outputs, feedbacks and motor connections have a
ferrite bead to reduce EMI
Inverse polarity supply protection: A P-Channel MOSFET provides
protection against polarity inversion
High power transient voltage suppressor for short braking: A TVS diode
(600 W peak) protects the circuitry from the voltage transients events
Ambient air
temperature
-25 ºC to +50 ºC full current (operating)
+50 ºC to +100 ºC current derating (operating)
-50 ºC to +125 ºC (non-operating)
Maximum
humidity
5% - 85% (non-condensing)
Dimensions 40 mm x 40 mm x 15 mm
Weight 20 g
*Stepper motor control capabilities are limited. Please contact our engineers for assistance.
The Neptune servo drive can work with stepper but is not specially designed for that. The
servo drive is specially designed to work with steppers.Hydra
The steppers control can be improved by upgrading .firmware
Hardware revisions

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Hardware
revision*
Description and changes
1.0.0B First product demo.
1.0.1R First product release. Changes from previous version:
Minor manufacturing improvements.
Increased minimum absolute system voltage to 8 V to ensure integrated power
supply performance at all ranges.
Assembly slots slightly redefined to improve assembly.
Increased default PWM frequency to 80 kHz.
Increased overcurrent range.
*Hardware revision is screen printed on the board.
Power and current ratings
The Neptune Servo drive is capable of providing the nominal current from -25ºC to 50ºC ambient air
temperature without the need of any additional heatsink or forced cooling system. From 50ºC to 100ºC of
ambient temperature a current derating is needed to avoid a system overtemperature. Exceeding this
current range may lead to a system overtemperature that will be detected by the internal temperature
sensor and cause a the driver to enter safely in Fault state turning off the power stage. Driver safety will
always be ensured by its thermal protections.
Current derating
The current derating graph is indicative and is based on thermal tests performed in a climatic
room where there was enough room for natural air convection. Each application may reach
different ratings depending on the installation, ventilation or housing.

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The system temperature available in and is measured near the power stage. The EMCL registers
temperature parameter that can be accessed from USB 2.0, CAN or RS232 indicates the board
temperature (not the air temperature) and should not exceed 110ºC. Above 110ºC the Neptune
automatically turn off the power stage and stay in fault state avoiding any damage to the drive.
Some parts of the Neptune Servo Drive exceed 110ºC when operating, especially at high load
levels or high ambient temperature.
and wait at least 5 minutes after turn off to allow a Do not touch the Neptune when operating
safe cool down.
Thermal image of the Neptune Servo Drive operating at nominal current. Do not touch any live part when
in operation and wait at least 5 minutes after power off:
To improve the heat dissipation, an small heatsink attached to the hottest ic with a good thermal interface
material can be added. Following are shown the suggested ones:
Manufacturer PN Datasheet Picture
Wakefield Solutions 651-B Dimensions
Bergquist
BP100-0.005-00-1112
Application guide

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Manufacturer PN Datasheet Picture
Assembly recommendations for best heat dissipation
Always allow natural air convection by ensuring ≥ 10 mm air space around the drive.
Place the Neptune in vertical position.
If housed, use a good thermal conductivity material such as black anodized aluminum.
Placing the driver in a small plastic package will definitively reduce its temperature range.
Temperature range can be increased by providing forced cooling with a fan or by placing a
thermal gap pad on top of the board. Always ensure electrical isolation between live parts
and the heatsink.
Architecture
Following figure shows a simplified hardware architecture of the Neptune.

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Connectors

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Connectors
Connectors position and pinout
Next figures show Neptune Servo Drive connectors. Connector functionalities and pinouts are described in
detail in the next subchapters. For the Neptune pin header version please visit the Pin header variant
section. For EtherCAT connectors pinout see .below

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CAN interface
The connector is a 4 pin TE Micro-Match connector. Part number . Polarization hole CAN interface 338068-4
on PCB indicates pin 1 and ensures correct mating connector position.
Pin numbers and pinout are shown below.
Pin Name Description
1 CAN_GND CAN ground (connected to circuit ground)

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Pin Name Description
2 CANL CAN bus line dominant low
3 CANH CAN bus line dominant high
4 CAN_GND CAN ground (connected to circuit ground)
Feedbacks connector
Neptune has a 12 pin TE Micro-Match connector for motor feedbacks. Part number .TE 1-338068-2
Polarization hole on PCB indicates pin 1 and ensures correct cable position. See Feedback
for more information about different feedbacks wiring.connections
Pin numbers and connectors pinout are shown below.
Pin Name Description
1 +5V_OUT 5 V @ 250mA supply for feedbacks
2 GND Ground connection
3 ENC_A+ Single ended digital encoder: A input
Differential digital encoder: A+ input
4 ENC_A- Differential Encoder: A- input
5 ENC_B+ Single ended digital encoder: B input
Differential digital encoder: B+ input
6 ENC_B- Differential Encoder: B- input
7 ENC_Z+ Single ended digital encoder: Index input
Differential digital encoder: Index+ input
8 ENC_Z- Differential Encoder: Index- input
9 GND Ground connection

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Pin Name Description
10 HALL_1 Analog Halls: A input
Digital Halls: A input
11 HALL_2 Analog Halls: B input
Digital Halls: B input
12 HALL_3 Analog Halls: C input
Digital Halls: C input
The connector pinout is identical as in Pluto Servo drive. See: .Cable Kit Manual
Feedback connector pinout is shared with , , and servo drives, which allows Pluto Nix Hydra Jupiter
using the with Neptune. IO starter kit
IO connector
Neptune has a 16 pin TE Micro-Match connector for inputs and outputs. Part number . See 1-338068-6
and for wiring information. Polarization hole on PCB indicates pin 1 Potentiometer PWM encoder interface
and ensures correct cable position.
Pin numbers and connectors pinout are shown below.
Pin Name Description
1 HS_GPI2+ / DIR+ High speed digital differential input 2+
Command source: Direction+ input
2 HS_GPI2- / DIR- High speed digital differential input 2-
Command source: Direction- input
3 GND Ground
4 GPO2 Digital output 2
5 GPO1 Digital output 1

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Pin Name Description
6 GND Ground
7 HS_GPI1+ / PULSE+ / PWM+ High speed digital differential input 1+
Command source: Pulse+ input
Feedbacks: PWM+ input
8 HS_GPI1- / PULSE- / PWM- High speed digital differential input 1-
Command source: Pulse- input
Feedbacks: PWM- input
9 GND Ground
10 AN_IN1 Single ended analog input 1
11 AN_IN2- Differential analog inverting input 2
Single ended analog input 2 ground
12 AN_IN2+ Differential analog non inverting input 2
Single ended analog input 2
13 GND Ground
14 LS_GPI2 Low speed digital single ended input 2
(Could be safe torque off input on request, please contact us)
15 LS_GPI1 Low speed digital single ended input 1
16 +5V_EXT +5V 200mA max output (shared with feedback connector)
The connector pinout is identical as in Pluto Servo drive. See: .Cable Kit Manual
I/O connector pinout is shared with and servo drives, which allows using thePluto Jupiter IO
with Neptune.starter kit
Connector alternatives
2 alternative connectors are offered:
Pin header termination. For board stacking on backplane.
Right angle alternative Part number .1-338070-6

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RS232 interface connector
The connector is a 6 pin TE Micro-Match connector. Part number . Polarization RS232 interface 338068-6
hole on PCB indicates pin 1 and ensures correct cable position.
Pin numbers and connector pinout are shown below:
Pin Name Description
1 RETURN_TX Internally connected to pin 6. Used only to simplify daisy chain wiring.
2 GND Common (internally connected to driver GND)
3 RX RS232 receive data (should be connected to master TX)
4 TX RS232 transmit data (should be connected to master RX)
5 GND Common (internally connected to driver GND)
6 RETURN_TX Internally connected to pin 1. Used only to simplify daisy chain wiring.
Supply and motor connector
The supply and motor connector is a 5 pin screw terminal block with 2.54 mm pitch. See Power supply
for power wiring information and see for detailed information about wiring wiring Motor output wiring
different motors.
Pin numbers and connectors pinout are shown below:
Pin Name Description
1 PH_A Motor phase A connection (+ in DC motors)
2 PH_B Motor phase B connection (- in DC motors)

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Pin Name Description
3 PH_C Motor phase C connection (not connected in DC motors)
4 GND Negative power supply input (Ground)
5 +SUP Positive power supply input
Wire gauges
Dimension the wiring according to the application current ratings. Higher section is preferred to
minimize resistance and wire self-heating. Recommended wire section is shown next:
Stranded wire: 0.25 mm² ~ 0.75 mm²
Solid wire: 0.25 mm² ~ 1 mm²
Using cables > 1 mm²
For cables with a wire gauge between 0.2 mm and 1.6 mm², you can use a tab insulated crimp
terminal. Part number . Note that overall diameter exceeds the TE Connectivity - 165446
connector pitch, however therefore it is not recommended to use more than 3 terminals.
USB connector
Neptune includes a 5 pin micro-USB connector for USB interface. This allows easy access to the driver
configuration using or downloading . Please see MotionLab Documentation Home firmware upgrades USB
page for further information.interface
Pin numbers and standard pinout are shown below:
Pin Name Description
1 USB_SUPPLY USB +5 V supply input. Used to power logic circuits when no external power
supply is available.
2 USB D- USB Data- line
3 USB D+ USB Data+ line