Product Description



Everest XCR is a high power, highly-integrated, digital ready-to-go servo drive. The drive features best-in-class energy efficiency thanks to its state of the art power stage, and can be easily configured with Ingenia's free-to-download software MotionLab 3.

Everest XCR is enabled with EtherCAT and CANopen communications.

Main features:

  • Ultra-small footprint
  • 80 VDC, 30 ARMS continuous
  • Up to 99% efficiency
  • Up to 75 kHz current loop, 25 kHz servo loops
  • 10 kHz ~ 100 kHz PWM frequency
  • 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 (STO SIL3 Ple) inputs

Typical applications:

  • Collaborative robot joints
  • Robotic exoskeletons
  • Wearable robots
  • AGVs
  • UAVs 
  • Industrial highly integrated servomotors
  • Smart motors
  • Battery-powered and e-Mobility
  • Low inductance motors

Part Numbering

ProductOrdering part numberStatusImage

Everest XCR

Ready-to-use servo drive featuring EtherCAT and CANopen communications.

EVE-XCR

PRODUCTION

For applications requiring a pluggable drive enabled with EtherCAT or CANopen, please see Everest NET.

For applications not requiring CANopen or EtherCAT, please see Everest CORE. 

Specifications

Part number →EVE-XCR

Electrical and power specifications

Minimum power supply voltage8 VDC

Maximum absolute power supply voltage

80 VDC (continuous)

85 VDC (peak 100 ms)

Recommended power supply voltage

12 VDC ~ 72 VDC

This voltage range ensures a safety margin including power supply tolerances and regulation during acceleration and braking.

Internal drive DC bus capacitance30 μF
Logic power supply voltage (optional)

8 to 50 VDC

Providing the logic supply is optional, as the drive is supplied from the DC bus (single supply) 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 @ 3 sec

Active current limiting based on power stage and motor temperature.

Efficiency

Up to 99% @ 20 kHz, 80 V, 30 A

Bus voltage utilisation> 97% @ 20 kHz, 80 V, voltage mode, no load

Motion control specifications

Standby power

≥ 2.5 W

Lowest standby losses measured with dual supply at 12 V logic, with an active Ethernet communication, and commutation turned OFF

Supported motor types

  • Rotary brushless (SVPWM and Trapezoidal)
  • Rotary brushed (DC)

Power stage PWM frequency (configurable)

10 kHz, 20 kHz (default), 50 kHz & 100 kHz

Current sensing

3 phase, shunt based current sensing. 16 bit ADC resolution. Accuracy is ±2% full scale.

Current sense resolution (configurable)

Current gain is configurable in 4 ranges:

  • 2.475 mA/count
  • 1.352 mA/count
  • 0.570 mA/count
  • 0.379 mA/count

Current sense ranges (configurable)

Current ranges for the 4 configurable current gains:

  • ±81.1 A
  • ±44.3 A
  • ±18.7 A
  • ±12.4 A
Max. Current loop frequency75 kHz
Max. servo 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 at the same time, combining any of the following:
    • BiSS-C (up to 2 in daisy chain topology)
    • SSI

Supported target sources

  • Network communication (EtherCAT or CANopen*)

*CANopen is the communication enabled by default. In order to use EtherCAT, the FW must be updated.

Control modes
  • Cyclic Synchronous Position
  • Cyclic Synchronous Velocity
  • Cyclic Synchronous Current
  • Profile Position (trapezoidal & s-curves)
  • Profile Velocity
  • Interpolated Position (P, PT, PVT)
  • Homing

Inputs/outputs and protections

General purpose Inputs and outputs

4 x non-isolated single-ended digital inputs - 5 V logic level & 3.3 V compatible. Can be configured as:

  • General purpose
  • Positive or negative homing switch
  • Positive or negative limit switch
  • Quick stop input

4 x non-isolated single-ended digital outputs - 5 V logic level (continuous short circuit capable with 470 Ω series resistance) - 8 mA max. current. Can be configured as:

  • General purpose
  • Operation enabled event flag
  • External shunt braking resistor driving signal

1 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 outputs (see above).

Enabling this function would require an external transistor or power driver.

Motor brake output

1 A, 50 V, dedicated brake output. Open drain with re-circulation diode.

Brake enable and disable timing can be configured accurately.
PWM modulation available to reduce brake voltage and power consumption.

Safe Torque OFF inputs

2 x dedicated, isolated (> 4 GΩ, 1 kV) STO inputs (from 3.3 V to 30 V).

The STO inputs include a current limiter at ~ 5 mA to minimize losses.

Motor temperature input

1 x dedicated, 5 V, 12-bit, single-ended analog input for motor temperature (1.65 kΩ pull-up to 5 V included).

Protections

  • Hardcoded / hardwired Drive protections:
    • Automatic current derating on voltage, current and temperature
    • Short-circuit Phase to DC bus
    • Short-circuit Phase to Phase
    • Short-circuit Phase to GND
  • Configurable protections:
    • DC bus over-voltage
    • DC bus under-voltage
    • Drive over-temperature
    • Drive under-temperature
    • Motor over-temperature (requires external sensor)
    • Current overload (I2t). Configurable up to Drive limits
    • Voltage mode over-current (with a closed current loop, protection effectiveness depends on the PID).
  • Motion Control protections:
    • Halls sequence / combination error (Pending implementation)
    • Limit 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).

Note: when configured as CANopen the Ethernet ports can still be used to configure the drive.

EtherCAT (Software selectable)

CANopen over EtherCAT (CoE)

File over EtherCAT (FoE)

Ethernet over EtherCAT (EoE)

Note: CANopen is the communication enabled by default. In order to use EtherCAT, the FW must be updated.

Environmental conditions

Aluminium case
Yes (interface board not covered)
Isolation between case and live circuits

> 200 MΩ. Measured between PE (case) and GND_P and +SUP.

Maximum voltage between PE (case) and live circuits: 440 V continuous, 800 V impulse according to IEC 61800-5-1.

Note: The drive includes 2 nF capacitance between the power supply negative (GND_P) and the enclosure (PE).

Case temperature

Operation:

  • -40 ºC to +60 ºC at full current (Minimum power up temperature is -30 ºC)
  • +60 ºC to +85 ºC with derated current

For further information, see Thermal Specifications below.

Storage:

  • -40 ºC to +100 ºC
Maximum humidity5% ~ 85% non-condensing
ESD and EMC immunity

ESD immunity IEC 61000-4-2: ± 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 mating connectors

Weight38 gr
Certifications
Certification

CE, RoHS

STO SIL3 (certification pending)

Environmental Specifications

IEC 60068-2-1: 2007-03 - Cold (Operational) test

IEC 60068-2-2: 2007-07 - Dry heat (Operational) test

IEC 60068-2-78: 2012-10 - Damp heat, steady state (operational) test

IEC 60068-2-38: 2009-01 - Composite temperature / humidity cyclic (operational) test

Product Revisions

RevisionDateNotes
1

 

Initial prototype

2

 


Second prototype. Known issues or pending features:

  • Ethernet physical layer is affected by commutation noise
3

 

Known issues or pending features:

  • Noisy phase current measurement (+/- 150 mA)
  • CANopen under development
  • Trapezoidal commutation under development
  • Halls errors under development
  • Efficiency & Bus voltage not yet measured empirically
  • STO certification pending
4

 

First official product release.

5

 

  • Added CANopen variant
  • Added trapezoidal commutation
  • Improved current sensing measurement
6

  • Improvements related to industrialization

Thermal Specifications

The following diagram depicts the general dissipation model and the equivalent thermal model.

Everest_thermal_path

Following figure show the maximum phase current at different Everest Case temperature. For highest current at a given temperature, low PWM frequency is preferred. 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 in amplitude just multiply it by √2 . 

To ensure a proper performance of Everest XCR, the case temperature must be held always below 85 ºC (Tc-max =  85 ºC)


Following figure show the theoretical Power Losses at different operating points.

Please, use the following procedure to determine the required heatsink:

  1. Based on the voltage & continuous current required by your application and Current derating graph determine the Case temperature Tc. Remember that Case temperature must be always below 85 ºC (Tc < 85 ºC)
    1. For example: If the application requires 30 A @ 80 V (20 kHz) the Tc will be 72.5 ºC
  2. Based on the voltage & continuous current required by your application and Power losses graph determine the generated Power Losses PL to be dissipated. 
    1. 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 the used thermal sheet Rth(c-h)
    1. For example, a thermal sheet TGX-150-150-0.5-0, which has an estimated thermal impedance of Rth(c-h) = 0.2 K/W
  4. Based on the ambient temperature and using the following formula determine the maximum thermal impedance to air of the required heatsink Rth(h-a)

    \[ R_{th(h-a)} \leq \frac{T_{c} + P_L \cdot R_{th(c-h)} - T_a}{P_L}\]
    1. For example: If the application requires 30 A @ 80 V (20 kHz) working at Ta = 25 ºC and we use a thermal sheet with Rth(c-h) = 0.2 K/W the required thermal impedance of the heatsink will be Rth(h-a) = 1.87 K/W