INGENIA Pluto User manual

13-Apr-2016 12:09Date:
4Version:
Pluto Servo Drive
Product Manual
Table of Contents

Table of Contents
1 Manual revision History 4
2 Preliminary notes 5
3 Safety Information 6
3.1 Warnings 7
3.2 Precautions 7
4 Product Description 7
4.1 Specifications 8
4.2 Hardware revisions 11
4.3 Power and current ratings 12
4.3.1 Power losses calculation (heat dissipation) 13
4.3.2 Current ratings 13
4.3.3 System temperature 14
4.3.4 Dynamic application (non-constant current) 14
4.4 Pluto architecture 15
5 Connectors 15
5.1 CAN interface connector 17
5.2 Feedbacks connector 18
5.3 I/O connector 19
5.4 Supply and shunt connector 20
5.5 Motor connector 21
5.6 USB connector 21
5.7 Mating connectors 22
5.7.1 CAN interface mating connector 22
5.7.2 Feedbacks mating connectors 22
5.7.3 I/O mating connectors 23
5.7.4 Motor mating connector 24
5.7.5 Supply and shunt mating connector 24
5.7.6 USB mating connector 25

5.8 EtherCAT variant pinout 25
5.8.1 EtherCAT input and output connector 26
6 Wiring and Connections 27
6.1 Power supply wiring 28
6.1.1 How to dimension the power supply 28
6.1.2 Recommended power supply connection 29
6.1.3 Simplified battery supply connection 30
6.1.4 Connection of multiple drivers 30
6.1.5 Power supply wiring recommendations 31
6.2 Motor output wiring 32
6.2.1 AC and DC brushless motors 32
6.2.2 DC motors and voice coils actuators 33
6.2.3 Stepper motors 33
6.2.4 External shunt resistor 34
6.2.5 Motor wiring recommendations 37
6.3 Feedback connections 39
6.3.1 Digital encoder interface 39
6.3.2 Digital Halls interface 43
6.3.3 Analog Halls interface 45
6.3.4 Analog input feedback - Potentiometer 46
6.3.5 PWM encoder interface 49
6.3.6 DC tachometer 52
6.3.7 Feedback wiring recommendations 52
6.4 IO connections 53
6.4.1 Low speed (LS) single ended digital inputs interface 54
6.4.2 High speed (HS) digital inputs interface 56
6.4.3 Analog inputs interface 59
6.4.4 Digital outputs interface 61
6.4.5 Torque off input 65
6.5 Command sources 66
6.5.1 Network interface 67
6.5.2 Standalone 67
6.5.3 Analog input 67
6.5.4 Step and direction 68
6.5.5 PWM command 69
6.5.6 Encoder following or electronic gearing 72
6.6 Communications 73
6.6.1 CAN interface 74
6.6.2 USB interface 76
6.6.3 EtherCAT interface 76

7 Signalling LEDs 78
7.1 Power and motor signalling LEDs 79
7.2 CAN signalling LEDs 79
7.3 EtherCAT signalling LEDs 80
7.3.1 EtherCAT status LED 81
7.3.2 EtherCAT in-connector LED 81
8 Software 82
8.1 Installing MotionLab Configuration Software 83
8.1.1 Before you begin 83
8.1.2 Hardware Installation: 83
8.1.3 Software Installation and Drive Communication Setup: 83
8.2 Updating your drive Firmware 84
8.3 Configuring your drive 85
9 Dimensions 85
9.1 Standard version 86
9.2 EtherCAT version 86
10 Disclaimers and limitations of liability 87
Manual revision History

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Manual revision History
Revision Release Date Changes PDF
v1 January 2013 Initial Version --
v2 April 2014 Update for hardware revision 1.1.0R Download
v3 March 2016 Several improvements after revision 2.0.1R Download
v4 April 2016 Added EtherCAT information. Structure improvements. 
Preliminary notes

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Preliminary notes
Please refer to for information on previous hardware revisions and changes.Hardware revisions
Please refer to the for the most up to date revision.online manual
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
Pluto Servo Drive.
To ensure maximum safety in operating the Pluto 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
Pluto Servo Drive, as well as other hardware that may be connected to it. Please read this chapter carefully
before starting the installation process. Please also make sure all system components are properly
grounded.
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 Pluto Servo Drive while the power supply is on.
Power cables may be exposed to high voltages, even when the motor is not in motion. Disconnect
the Pluto 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 1 minute
before touching any parts of the controller that are electrically charged or hot (such as capacitors or
contacts).
Precautions
The following statements should be considered to avoid serious injury to those individuals performing the
procedures and/or damage to the equipment:
The Pluto Servo Drive components temperature may exceed 75ºC during operation.
Some components become electrically charged when in operation.
The power supply connected to this controller should comply with the parameters specified in this
document.
When connecting the Pluto Servo Drive to an approved 10 V to 48 V power source, do so
DC DC
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 Pluto Servo Drive, check that all safety precautions have been followed, as
well as the installation procedures.
Product Description

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Product Description
Pluto is a high performance closed loop servo drive controller suitable for DC brushed, steppers, voice
coils and brushless motors.
Its 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 design also includes a wide variety of self protection mechanisms.
Specifications
There are 3 variants of the Pluto, specs are shown next.
Electrical and power specifications
Variant PLU-1/48 (HS) PLU-5/48 (STD) PLU-8/48 (EXT)
Supply voltage 10 V to 48 V
DC DC
Transient peak
voltage
60 V
Internal DC bus
capacitance
112 µF
Minimum motor
inductance
200 µH
Maximum phase
peak current
2 ARMS (5 s) 10 ARMS (5 s) 16 ARMS (5 s)
Maximum phase
continuous
current
1 ARMS 5 ARMS 8 ARMS
Current sense
range
± 4.8 A ± 19.2 A ± 32 A
Current sense
resolution
9.35 mA/count 37.39 mA/count 62.32 mA/count
Cold plate No
Power connectors Pluggable terminal
Standby power
consumption
1.5 W (max)
Efficiency > 97% at the rated power and current

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Electrical and power specifications
Motion control specifications
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
40 kHz (default)
80 kHz (high PWM frequency, )configurable
Current sensing On phases A, B and C using 3 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)
Sensors supported
for servo loops
DC tachometer
Digital halls
Analog halls
Quad. Incremental encoder
PWM encoder
Analog potentiometer
Supported target
sources
Network communication – (µUSB connector)USB
Network communication – (Isolated, self-supplied, CiA-301, CiA-CANopen
303, CiA-305, CiA-306 and CiA-402 compliant)
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

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Electrical and power specifications
Inputs/outputs and protections
Inputs and
outputs
2 x non isolated single ended digital inputs. GDI1, GDI2 (5 V TTL logic, 24 V
tolerant)
2 x non isolated high speed differential digital inputs. HS_GPI1 Pulse,
HS_GPI2 Direction (5 V logic, 24 V tolerant)
1 x (±10 V) differential analog input (12 bits). AN_IN2. (24 V tolerant)
1 x 0 V... 5 V single ended analog input (12 bits). AN_IN1. (24 V tolerant)
2 x Open open drain digital outputs with a weak pull-up to 5 V. (1 A short-
circuit and over-current rugged)
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
Phase-GND
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
(1500 W peak) protects the circuitry from the voltage transients events
Encoder broken wire (for differential quadrature encoders only).
Communications
USB µUSB (2.0) connector.
CANopen Yes.
EtherCAT Option.