INGENIA Everest XCR Product Manual Download Page 1

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INGENIA-CAT S.L.

AVILA 124

08018 BARCELONA

Everest XCR - Product Manual

Edition 08/04/2019

For the most up to date information visit the online manual.

Summary of Contents for Everest XCR

Page 1: ...INGENIA CAT S L AVILA 124 08018 BARCELONA Everest XCR Product Manual Edition 08 04 2019 For the most up to date information visit the online manual...

Page 2: ...on 16 6 1 Unpacking 16 6 1 1 Back Installation 16 6 1 2 Front Installation 17 6 1 3 Rework 18 7 Connectors Guide 19 7 1 Connector Overview 19 7 2 Supply 19 7 3 Motor 20 7 4 Feedback Connector 20 7 5 E...

Page 3: ...electromechanical brake 43 9 4 3 External temperature sensor wiring 44 9 5 Feedbacks 45 9 5 1 Digital Halls 45 9 5 2 Absolute Encoder 1 47 9 5 3 Absolute Encoder 2 48 9 5 4 Incremental Encoder 49 9 5...

Page 4: ...ioned 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 n...

Page 5: ...ent power source wait at least 10 seconds before touching any parts of the controller that are electrically charged or hot 3 3 Precautions The following statements should be considered to avoid seriou...

Page 6: ...ency 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 Safety Torque Off S...

Page 7: ...ply on its full operating voltage range When supplied from logic an intelligent switch will stop consuming from the DC bus Nominal phase continuous current RMS 30 A Maximum phase peak current RMS 60 A...

Page 8: ...z 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 at the same time combining any of the f...

Page 9: ...x 10 V 16 bit fully 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 outpu...

Page 10: ...switches Position 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 N...

Page 11: ...30 kV contact discharge 30 kV air discharge EFT immunity IEC 61000 4 4 40 A Surge immunity IEC 61000 4 5 IPPM 8 A Mechanical specifications Dimensions 42 1 mm x 29 1 mm x 23 1 mm Dimensions include m...

Page 12: ...rrent measurement 150 mA CANopen under development Trapezoidal commutation under development Halls errors under development Efficiency Bus voltage not yet measured empirically STO certification pendin...

Page 13: ...ed The 10 kHz frequency will reduce power losses but may not be suitable for low inductance motors or acoustic noise sensitive Notice that current is expressed in RMS To obtain the equivalent current...

Page 14: ...on and Power losses graph determine the generated Power Losses PL to be dissipated a For example If the application requires 30 A 80 V 20 kHz the PL will be 28 5 W 3 Determine the Thermal impedance of...

Page 15: ...DS402 drive device profile Voltage mode Current mode Cyclic Synchronous Current Mode Max Update rate up to 100 s 10 kHz Current amplifies mode Profile Velocity Profile Position Homing modes Interpola...

Page 16: ...the surface to dry for some minutes before applying the tape More aggressive solvents such as acetone methyl ethyl ketone MEK or toluene may be required to remove heavier contamination grease machine...

Page 17: ...and 4 x M2 5 x 8 DIN965 screws PN EVE FHS 1 Assemble the Everest XCR to the flat heatsink following the Back Installation process 2 Use appropriate thermal interface material between the previously cl...

Page 18: ...m the heatsink by prying torquing or peeling Make sure the forces are applied to the Everest enclosure and not to the PCB or connectors 3 The thermal tape will be destroyed upon separation and must be...

Page 19: ...NIA 08 04 2019 19 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 1 POW_SUP Po...

Page 20: ...m to prevent collision between wires When using power supply only no logic supply always connect pins 27 LOG_SUP and 29 GND_D of I O connector J2 together 7 3 Motor P2 connector 2 6 mm diameter gold p...

Page 21: ...2 Data 6 ENC_B Differential digital encoder B input Single ended digital encoder Leave unconnected 7 ENC_Z CLK2 Differential digital encoder Index input Single ended digital encoder Index input Absol...

Page 22: ...nected to the feedback cable shield to shield it against electromagnetic interference To do so it is recommended to use a cable shield terminatior like TE S02 16 R S02 16 R Input Outputs Connector J2...

Page 23: ...s pin 24 AN1 Analog input 1 negative 10V range Connect to GND if a single ended analog input is used 25 BRAKE_DIODE_ K Cathode of the freewheeling diode for the brake should be connected to the power...

Page 24: ...olex 079758 1016 for this purpose 7 5 EtherCAT Connectors J3 J4 connectors 5 pins 1 row Pico Clasp 1 mm pitch header Molex 501940 0507 Pin Signal Function Suggested pinout M12 4 D coded Suggested pino...

Page 25: ...p 1 0 mm pitch 20 position dual row receptacle with locking ramp Image Part number Molex 501189 2010 J2 mating connector Description Molex Pico Clasp 1 0 mm pitch 30 position dual row receptacle with...

Page 26: ...mmon for all signal connectors Everest XCR signal connectors are of Molex Pico Clasp family All share the same crimp terminals and jumper wires Given the small size of the connectors crimping must be...

Page 27: ...t to socket 150 mm lenght Gold plated Image Part number Molex 079758 1016 J1 J2 J3 J4 Crimped wires 300 mm Description Molex Pico Clasp 28 AWG black jumper lead socket to socket 300mm lenght Gold plat...

Page 28: ...de INGENIA 08 04 2019 28 Wiring accessory wire to wire solder sleeve Description Wire to Wire Solder Sleeve Heat shrinkable Can be used to reliably connect pre crimped wires to specific sensor feedbac...

Page 29: ...next one Protocol EtherCAT 0 Link EtherCAT 1 Link Drive Status EtherCAT Status CANopen See below See below Switch off if initialization is OK RED if an error has been detected during initialization 1...

Page 30: ...us Off INIT Off No error Flickering BOOTSTRAP Blinking Invalid configuration Blinking PRE OPERATIONAL Single flash Local error Single Flash SAFE OPERATIONAL Double flash Watchdog timeout On OPERATIONA...

Page 31: ...ation cycle period time out On Bus off The CAN controller is bus off RUN LED indicates the status of the CANopen network state machine Next table shows the meaning of the RUN LED states LED4 RUN LED s...

Page 32: ...Everest XCR Product Manual Wiring and Connections INGENIA 08 04 2019 32 9 Wiring and Connections 9 1 Everest XCR Connection Diagram Detailed wiring diagram for each module Protective Earth...

Page 33: ...ng Special emphasis is placed on the power wiring Some considerations for a proper earth connection are detailed next Switching noise by the phases is coupled to earth through the housing of the motor...

Page 34: ...trolytic corrosion issues or leakage currents However this may be done on some special cases like battery powered systems systems with isolated power supply and with good knowledge of the whole wiring...

Page 35: ...eeping position information with incremental sensors while power is off the drive can be powered from a logic supply input on the I O connector There are no special power supply sequencing requirement...

Page 36: ...een GND_P and PE the drive aluminum enclosure For lowest EMC it is recommended to use a 2 stage filter like TE Connectivity 30EMC6 9 3 4 Shunt Braking Resistor Connection A shunt braking resistor can...

Page 37: ...Wiring and Connections INGENIA 08 04 2019 37 9 3 5 Motor Connections 3 Phase Brushless DC Motor Shunt resistor calculation tool Additional information on shunt braking resistor sizing and a calculati...

Page 38: ...e Everest XCR Type Manufacturer Part number Remarks Wide frequency oval ferrite cable core Laird Technology 28B0773 050 Single turn Preferred option Wide frequency cylindrical ferrite cable core Lair...

Page 39: ...ns with the solder balls not to create any short Do not fill the hole 5 Position the wire inside the hole with the desired cable exit direction and solder them with a clean solder tip Additional solde...

Page 40: ...4 5 Surge IPPM 8 A STO activation time power stage disable 400 s 1000 s STO deactivation time 1 5 ms 2 ms STO abnormal fault minimum latching time 1 4 s 2 s Minimum non detected STO active pulse 400...

Page 41: ...E ready to run 1 2 5 V 1 2 5 V Can be enabl ed 1 0 Drive is enabled to run under firmware control The drive can supply power to the motor Abn orm al ope rati on Abnormal STO ACTIVE 0 1 8 V 1 2 5 V OFF...

Page 42: ...e 5V_OUT is connected to other circuits like feedbacks and isolation on STO inputs is lost 9 4 1 STO bypass needed when no STO functionality is implemented If STO is not be used it must be override wi...

Page 43: ...ergized Its operation is usually configured for normally locked electromechanical brakes that is brakes that by default block the movement of the motor shaft when not powered This kind of brakes incre...

Page 44: ...systems Note that it is possible to operate a 24 V brake with a 48 V power supply by configuring the maximum PWM duty cycle of the brake to 50 In this case configure it carefully before physically co...

Page 45: ...Absolute encoder 2 1 to 8 Quadrature incremental encoder S0S90 SSI absolute encoder 9 5 1 Digital Halls The Hall sensors are Hall effect devices that are built into the motor to detect the position o...

Page 46: ...Halls inputs main features Specification Value Type of inputs Single ended with pull up and low pass filter ESD rugged Number of inputs 3 ESD capability IEC 61000 4 2 ESD 30 kV air 30 kV contact IEC...

Page 47: ...oder 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 12 A 2...

Page 48: ...nnection Dual BISS C can be used for redundancy or to read position of the rotor before and after a gearbox 9 5 3 Absolute Encoder 2 The Absolute Encoder 2 interface can be used as a position velocity...

Page 49: ...Everest XCR servo drive 9 5 4 Incremental Encoder Everest XCR can use single ended or differential digital incremental encoder inputs also known as quadrature incremental encoders for velocity and or...

Page 50: ...0 4 2 ESD 30 kV air 30 kV contact IEC 61000 4 5 tp 8 20 s 12 A 200 W Maximum voltage range 0 5 5 5 V Maximum recommended working frequency 10 MHz differential Maximum readable pulse frequency 50 MHz T...

Page 51: ...n if the encoder supply is not provided by the drive Connection between Everest XCR PE and the motor metallic housing is essential to provide a low impedance path and minimize noise coupling to the fe...

Page 52: ...le ended ESD protected Low pass filtered ESD capability IEC 61000 4 2 ESD 15 kV air 8 kV contact Input current 0 2 mA at 5 V 25 k equivalent input resitance Maximum input voltage range 2 V 7 V High le...

Page 53: ...6 bit analog input AN1 See the specifications next Specification Value Type of input Differential ESD protected ESD capability IEC 61000 4 2 ESD 15 kV air 8 kV contact Input voltage range 10 V differe...

Page 54: ...e negative AN1 to GND_D Also for long distances twisted pair shielded cables are preferred Connecting the shield to GND will improve signal to noise ratio However take precautions not to connect the s...

Page 55: ...ort circuit protected ESD capability IEC 61000 4 2 ESD 15 kV air 8 kV contact Maximum sink source current 10 mA Unloaded output high voltage 4 5 5 V Unloaded output low voltage 0 0 5 V The wiring of t...

Page 56: ...an be accessed via Beckhoff Twincat tool from a PC EtherCAT OUTPUT port 1 CAN port not used when the drive is configured as EtherCAT 9 7 1 CANopen interface Everest XCR Servo Drive supports the CANope...

Page 57: ...ep 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 it is mandatory to use shielded twisted cables Connect the cable...

Page 58: ...st 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 connect...

Page 59: ...nction Corresponding pin on Everest XCR Pin for RJ45 M12 4 D coded M8 4 D coded Cable colour as per TIA 568B Cable colour as per EN61918 TX_D Transmit data 1 1 1 1 White Orange Yellow TX_D Transmit da...

Page 60: ...transparent way Thanks to this protocol 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 show...

Page 61: ...ons INGENIA 08 04 2019 61 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 tricks...

Page 62: ...INGENIA 08 04 2019 62 10 Dimensions All dimensions are in mm All tolerances 0 2 mm Assembly instructions are indicated here Installation 3D Model For further detail download the STEP model http distex...

Page 63: ...info servotecnica com Norway ELECTRO DRIVES AS www electro drives no firmapost electro drives no Portugal MEC NICA MORDERNA www mecmod com pt vendas mecmod com Russia AVI SOLUTIONS www avi solutions...

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