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Everest XCR - Product manual |

Product Description

INGENIA | 2020-10-01 00:04:38

4.4.5. Energy efficiency

The following graph shows

the electrical

energy efficiency including logic

for various operation points assuming

50 ºC case temperature and the drive delivering the maximum output power (i.e. maximum output voltage and
motor speed). As seen, very high efficiencies > 99% can be achieved at 10 kHz or 20 kHz PWM frequencies.

Summary of Contents for 2147502492

Page 1: ...INGENIA CAT S L AVILA 124 2 B 08018 BARCELONA Everest XCR Product manual Edition 10 01 2020 For the most up to date information visit the online manual...

Page 2: ...3 Current derating 16 4 4 4 Heat dissipation and heatsink calculation 16 4 4 5 Energy efficiency 18 5 EtherCAT Specifications 19 6 CANopen Specifications 20 6 1 Specifications 20 7 Connectors Guide 2...

Page 3: ...8 9 4 3 STO External Diagnostic Test 50 9 4 4 STO Operation States 52 9 4 5 Interface and Connections 53 9 4 6 STO bypass needed when no STO functionality is implemented 55 9 5 Brake and Motor Tempera...

Page 4: ...82 11 1 Unboxing 82 11 2 Installation Safety Requirements 82 11 3 Mounting the Drive to a Heatsink or Cooling Plate 82 11 3 1 Back Installation 82 11 3 2 Front Installation 84 12 Commissioning 86 12...

Page 5: ...ts 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 illus...

Page 6: ...ere 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 ch...

Page 7: ...uts Typical applications Collaborative robot joints Robotic exoskeletons Wearable robots AGVs UAVs Industrial highly integrated servomotors Smart motors Battery powered and e Mobility Low inductance m...

Page 8: ...Typically 30 A RMS can be obtained with appropriate cooling and keeping heatsink at 50 C See Th ermal and Power Specifications below For disambiguation on current definitions please see Disambiguatio...

Page 9: ...loops frequency position velocity 25 kHz 75 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...

Page 10: ...que 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 trans...

Page 11: ...on following error Velocity Position out of limits Communications for Operation CANopen by default CiA 301 CiA 303 CiA 305 CiA 306 and CiA 402 4 0 compliant 125 kbps to 1 Mbps default Non isolated Ter...

Page 12: ...2 environment according to IEC 61800 5 1 Normally only non conductive pollution occurs Occasionally a temporary conductivity caused by condensation is to be expected when the Everest is off Minimum in...

Page 13: ...voltage directive 2014 35 EU EMC Electromagnetic Compatibility Directive 2014 30 EU Safe Torque Off STO IEC 61800 5 2 2016 SIL3 IEC 61508 2010 SIL3 EN ISO 13849 1 2015 PLe Cat 3 Electromagnetic Compa...

Page 14: ...on Improved current sensing measurement 6 24 May 2019 Improvements related to industrialization 7 30 Jan 2020 Improvements related to industrialization 8 11 Sep 2020 STO certified 4 4 Thermal and Powe...

Page 15: ...wing diagram depicts the general dissipation model The Everest is designed to be mounted on a cooling plate or heatsink to achieve its maximum ratings Please see Installation for more details In order...

Page 16: ...vable current including the derating algorithm that limits the current based operation conditions and the power stage temperature Notice that current is expressed in crest value for a 3 phase BLAC mot...

Page 17: ...ed by your application and Power losses graph determine the generated Power Losses PL to be dissipated For example If the application requires 30 A 72 V 20 kHz the PL will be 25 W Determine the Therma...

Page 18: ...llowing graph shows the electrical energy efficiency including logic for various operation points assuming 50 C case temperature and the drive delivering the maximum output power i e maximum output vo...

Page 19: ...Synchronous Current Mode Note 1 Current amplifies mode Profile Velocity Profile Position Homing modes Interpolated Position Mode Cyclic Synchronous Position Mode Note 1 Cyclic Synchronous Velocity Mo...

Page 20: ...Profile velocity Profile position Homing modes Cyclic synchronous position mode Cyclic synchronous velocity mode Process data object RPDO and TPDO 1 to 4 are available Up to 32 bytes on each direction...

Page 21: ...21 7 Connectors Guide 7 1 Connector Overview 7 2 Supply P1 connector 2 6 mm diameter gold plated solder pads or flying leads option Pad pitch is 5 08 mm Pin Signal Function Warning Risk of electric s...

Page 22: ...of I O connector J2 together 7 3 Motor P2 connector 2 6 mm diameter gold plated solder pads or flying leads option Pad pitch is 5 08 mm Pin Signal Function Warning Risk of electric shock 1 PH_A Motor...

Page 23: ...DATA2 Differential digital incremental encoder A input Single ended digital incremental encoder A input Absolute encoder 2 Data 4 ENC_B Differential digital incremental encoder B input Single ended d...

Page 24: ...5 GND_D Digital signal ground 16 DATA1 Absolute encoder 1 DATA positive signal input 17 CLK1 Absolute encoder 1 CLK positive signal output 18 DATA1 Absolute encoder 1 DATA negative signal input For si...

Page 25: ...it is recommended to use a cable shield terminator like TE S02 16 R 3 STO_RET Safe Torque Off common optocoupler LEDs cathode ISOLATED 4 5V_OUT 5 V output can be used for STO circuit 5 STO_2 Safe Torq...

Page 26: ...e anode of the diode is connected to pin 23 BRAKE_OUT 26 GND_D Digital signal ground 27 LOG_SUP Logic supply positive Providing the logic supply is optional as the drive is automatically powered from...

Page 27: ...p Gree n 4 6 5 GND_ETH Connection for the EtherCAT cable shield This pin is directly connected to the chassis of the drive PE To do so it is recommended to use a cable shield termination like TE S02 1...

Page 28: ...age Part number Molex 501189 3010 J3 J4 mating connectors with latch holder Description Molex Pico Clasp 1 0 mm pitch 5 positions single row receptacle with Latch Holder Provides stronger locking perf...

Page 29: ...Clasp family All share the same crimp terminals and jumper wires Given the small size of the connectors crimping must be done with appropriate tools and application guides provided by Molex Otherwise...

Page 30: ...28 AWG black jumper lead socket to socket 300mm length Gold plated Image Part number Molex 079758 1017 Wiring accessory Spiral wire wrap Description Nylon spiral wrap abrasion resistant Internal diame...

Page 31: ...Everest XCR Product manual Connectors Guide INGENIA 2020 10 01 00 04 38 31 Image TE B 155 9001...

Page 32: ...8 1 Start up Sequence After power on the drive LEDs sequence is the next one Protocol EtherCAT 0 Link EtherCAT 1 Link Drive Status EtherCAT Status CANopen See below See below Switch off if initializat...

Page 33: ...tion regarding communication status according to EtherCAT specification The EtherCAT green and red LEDs shared with CANopen communication indicate the EtherCAT status The green LED is the RUN LED and...

Page 34: ...level too many error frames Double flash Error control event A guard event NMT slave or NMT master or a heartbeat event heartbeat consumer has occurred Triple flash Sync error The sync message has not...

Page 35: ...Everest XCR Product manual Signalling LEDs INGENIA 2020 10 01 00 04 38 35 LINK LED state Slave State On Port opened no activity on port...

Page 36: ...Everest XCR Product manual Wiring and Connections INGENIA 2020 10 01 00 04 38 36 9 Wiring and Connections 9 1 Everest XCR Connection Diagram Detailed wiring diagram for each module...

Page 37: ...CR Product manual Wiring and Connections INGENIA 2020 10 01 00 04 38 37 Protective Earth Power Supply and Motor Power Safe Torque Off STO Brake and Motor Temperature Feedbacks Inputs and Outputs Commu...

Page 38: ...Earth wiring is shown following Some considerations for a proper earth connection are detailed next Connecting PE to GND_P near the power supply can provide an advantage for EMC and electrical safety...

Page 39: ...low impedance connections use wires that are short thick multi strand PE wire section should be the same as power supply cables Always minimize PE connection length For best EMC performance Everest X...

Page 40: ...tion against electric shock The current should be the one able to provide the electrical power of the application The conservative approach is to choose the power supply rated current as your maximum...

Page 41: ...he following criteria The logic supply must be isolated with a minimum Overvoltage Category of II Typ 2500 V isolation or battery powered The recommended voltage is range is 8 V to 26 4 V SELV PELV Th...

Page 42: ...ds a certain threshold Shunt braking resistor The digital outputs provide a 0 5 V output with a 470 in series resistance inside the drive This will typically be enough to turn on off a power MOSFET tr...

Page 43: ...ing and Connections INGENIA 2020 10 01 00 04 38 43 9 3 5 Motor Connections 9 3 5 1 3 Phase Brushless Shunt resistor calculation tool Additional information on shunt braking resistor sizing and a calcu...

Page 44: ...possible The objective is to cancel the noise close to its source the switching power stage Make sure the chosen choke does not saturate at the maximum operating phase current If this happens the chok...

Page 45: ...ing RMS current Minimum Cross Sectional Area CSA mm Minimum wire gauge Recommended Cross Sectional Area CSA mm Recommended wire gauge 30 ARMS 1 3 mm 16 AWG 3 3 mm 12 AWG 18 ARMS 0 8 mm 18 AWG 1 3 mm 1...

Page 46: ...s free solder Take precautions with the solder balls not to create any short Do not fill the hole Position the wire inside the hole with the desired cable exit direction and solder them with a clean s...

Page 47: ...igured as enable input because enable input is firmware controlled and does not guarantee intrinsic safety as it can be reconfigured by a user In order to ensure redundancy and safety the Everest XCR...

Page 48: ...ctrical characteristics Input pins STO1 STO2 and STO_RET Number of independent channels 2 Type of Inputs Isolated inputs STO1 STO2 with common reference STO_RET ESD protected with input current limit...

Page 49: ...e 1 Logic supply must be provided to the system 24 V SELV range from 8V to 26 4V maximum failure voltage 60 V Power Supply Voltage Range 1 48 V SELV range from 8V to 60V maximum failure voltage 60 V M...

Page 50: ...he standards 9 4 3 STO External Diagnostic Test The operation of the STO diagnostic circuits must be verified at least once per 3 months The following procedure details a method to verify the STO diag...

Page 51: ...or in teh wiring could exist 7 Shut down Everest XCR supply and remain in this state for more than 10 seconds 8 Power on the Everest XCR with STO1 low STO2 high Remain in this state more than 3 4 sec...

Page 52: ...eration States The truth table of the STO inputs is shown next indicating the different states of the system Mode State STO1 status level STO2 status level Power stage status STO report bit status STO...

Page 53: ...motor If this persists for 1 4 s 3 4 s the STO will lock in FAULT state To reset this fault a power cycle is needed 1 3 6 V 0 1 1 V OFF 0 1 Abnormal STO Latched x x OFF NOR STO1 STO2 1 After 1 4 s 3...

Page 54: ...next no need for 24 V supply Note that as the 5V_OUT is connected to other circuits like feedbacks and isolation on STO inputs is lost The example emphasizes the recommended connection when using var...

Page 55: ...IA 2020 10 01 00 04 38 55 9 4 6 STO bypass needed when no STO functionality is implemented If STO is not be used it must be overridden with 3 wire jumpers on the I O connector otherwise it will not be...

Page 56: ...t powered This kind of brakes increases the safety of the application because in a drive power failure the switch would be opened therefore the brake activated Main ratings of the brake switch are det...

Page 57: ...istance PTC thermistor bimetal NTC PT100 silicon temperature sensors to measure the motor temperature The motion controller includes linearization for various sensors so the motor temperature can be r...

Page 58: ...2020 10 01 00 04 38 58 CAUTION motor overload The Everest XCR may allow currents that can damage or cause a fire to the motor Always ensure that the continuous and peak current ratings of the motor a...

Page 59: ...se with the stator position Using these 3 signals the drive is capable to detect the position direction and velocity of the rotor The Halls effect sensors are a good way to detect the phasing of the m...

Page 60: ...oltage range 0 5 5 5 V Maximum recommended working frequency 5 kHz 1st order filter cutting frequency 3dB 16 kHz Sampling frequency 10 ksps Type of sensors Open collector Logic output Push pull output...

Page 61: ...e encoder inputs electrical specifications Specification Value Type of inputs Differential Single ended ESD protected ESD capability IEC 61000 4 2 ESD 30 kV air 30 kV contact IEC 61000 4 5 tp 8 20 s 1...

Page 62: ...s applies to both the differential and single ended encoders both incremental and absolute Data and clock connections remain the same between the encoder and the drive 5V_OUT pin of the drive is not c...

Page 63: ...ntial Single ended ESD protected ESD capability IEC 61000 4 2 ESD 30 kV air 30 kV contact IEC 61000 4 5 tp 8 20 s 12 A 200 W Maximum operating voltage range 0 5 5 5 V Operating frequency 100 kHz to 10...

Page 64: ...perform sinusoidal commutation Channel A and channel B signals should have a phase shift of 90 degrees indicating the rotation direction The drive has an optional index signal input Index signal Z is...

Page 65: ...Specification Value Maximum readable pulse frequency 50 MHz Termination resistor 220 between ENC_x and ENC_x Fail safe bias resistors ENC_x positive input 1 k to 5 V ENC_x negative input 1 k to 2 5 V...

Page 66: ...s gain or loss of counts and analog feedbacks wrong voltage levels To minimize these problems some wiring recommendations are shown Use differential signals whenever is possible That is connect both p...

Page 67: ...housing is essential to provide a low impedance path and minimize noise coupling to the feedback For further information see Protective Earth wiring For better noise immunity use shielded cables with...

Page 68: ...ESD 15 kV air 8 kV contact Input current 0 2 mA at 5 V 25 k equivalent input resistance Maximum input voltage range 2 V 7 V High level input voltage 3 V Low level input voltage 2 V Minimum hysteresis...

Page 69: ...Everest XCR Product manual Wiring and Connections INGENIA 2020 10 01 00 04 38 69 The interface for 3 wire NPN and PNP sensors is shown next...

Page 70: ...ADC coun Theoretical values 10 V 65535 counts 10 V 0 counts Accuracy 0 05 from 9 8 V to 9 8 V 0 5 full range Maximum absolute voltage on any pin AN1 or AN1 15 V 1st order filter cutting frequency 3 d...

Page 71: ...sed to drive optocouplers LEDs or other digital circuits Specification Value Number of outputs 4 Type of output Push pull output at 5 V ESD protected Overload short circuit protected ESD capability IE...

Page 72: ...Everest XCR Product manual Wiring and Connections INGENIA 2020 10 01 00 04 38 72...

Page 73: ...Servo Drive supports the CANopen interface a multi terminal communication protocol based on CAN Controller Area Network bus When the drive is configured with the CANopen interface the J4 connector ET...

Page 74: ...ivation is taken from the main bus If stubs cannot be avoided keep them as short as possible For maximum speed 1 Mbps use a stub length lower than 0 3 meters For a total CAN bus length over 40 meters...

Page 75: ...gy test and measurement and many other applications The drive can be accessed and configured using any EtherCAT master over EtherCAT connecting the PC to the port 0 in The next figure shows how to con...

Page 76: ...al Wiring and Connections INGENIA 2020 10 01 00 04 38 76 9 8 2 1 Recommended EtherCAT cables and connectors The following table shows the recommended connectors and cable colors for EtherCAT according...

Page 77: ...olour as per TIA 568B Cable colour as per EN61918 TX_D Transmit data 1 1 1 1 White Orange Yellow TX_D Transmit data 2 2 3 4 Orange Orange RX_D Receive data 3 3 2 2 White Green White RX_D Receive data...

Page 78: ...col is possible to configure a specific Everest XCR of the network using Motion Lab without requiring to modify the wiring of the installation The next figure shows how to connect the Everest XCR in a...

Page 79: ...NGENIA 2020 10 01 00 04 38 79 EoE and TwinCAT You can find more information on how to configure EoE on Beckhoff TwinCAT in the following link http doc ingeniamc com summit manuals reference manual tri...

Page 80: ...Everest XCR Product manual Dimensions INGENIA 2020 10 01 00 04 38 80 10 Dimensions All dimensions are in mm All tolerances 0 2 mm Assembly instructions are indicated here Installation...

Page 81: ...Everest XCR Product manual Dimensions INGENIA 2020 10 01 00 04 38 81 3D Model For further detail download the STEP model http distext ingeniamc com products EVE XCR steps...

Page 82: ...GER ELECTRIC SHOCK Power and motor pins have live voltages which can exceed 50 V which can cause electric shock Perform installation procedures without voltage Ensure the drive is mounted on a closed...

Page 83: ...rers precautions and directions when using primers and solvents Cut a 34 mm x 27 mm piece of the thermal tape Apply the tape to the bottom of the drive at a modest angle with the use of a squeegee rub...

Page 84: ...thermal interface material is also acceptable for low power applications since any imperfection on the heatsink or case surfaces will create air bubbles that would reduce the heat transfer 11 3 2 Fron...

Page 85: ...Everest XCR Product manual Installation INGENIA 2020 10 01 00 04 38 85...

Page 86: ...ng some extra minutes on safety keeping the workspace clean and ordered can save several days or weeks in case of malfunction or damage DANGER ROTATING PARTS can cause serious injury Keep hands clear...

Page 87: ...ctors Then removing the Everest from the plate or heatsink carefully following this sequence Remove the 4x M2 5 screws Separate the Everest from the heatsink by prying torquing or peeling Make sure th...

Page 88: ...rbances Performance criterion B IEC 61000 4 3 2006 Radio frequency electromagnetic field disturbances amplitude modulated 80 MHz to 2 7 GHz Performance criterion A IEC 61000 4 4 2012 Fast transients d...

Page 89: ...ance Details Environmental Testing Compliance IEC 60068 2 1 2007 Test Ad Cold IEC 60068 2 2 2007 Test Be Dry Heat IEC 60068 2 38 2009 Test Z AD Composite temperature humidity cyclic IEC 60068 2 78 201...

Page 90: ...ARCELONA 14 Service We are committed to quality customer service In order to serve in the most effective way please open a ticket on our service desk at www ingeniamc com support or contact your local...

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