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Everest XCR - Product manual | 

Commissioning

INGENIA | 2020-10-01 00:04:38

86

12. Commissioning

12.1. Safety first

Always keep the recommendations of 

Safety Information

 in mind. Spending 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. Before starting motors, ensure that all moving parts are reliably 
secured and assembled. High speed moving parts are very dangerous. 

Never try to 

brake the motor with your hands. 

Содержание 2147502492

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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