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Summary of Contents for INGENIA Denali XCR
- Page 1 Denali XCR - Product Manual Denali XCR Version 8 Revision release date For the most up to date information visit the online version. Danny Shen Precision Motion Group Suite 2302, Tower C Oriental Media Center, No.4 Guang Hua Road, Beijing...
- Page 2 This document is proprietary and confidential. No part of this document may be disclosed in any manner to a third party without the prior written consent of INGENIA-CAT S.L. INGENIA-CAT S.L. AVILA 124, 2B 08018 BARCELONA...
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Page 3: Table Of Contents
1 Table of Contents Table of Contents 3 General Information 6 Manual revision history............................6 Disclaimers and limitations of liability ....................... 6 Contact ................................. 6 Safety Information 7 For your safety..............................7 Warnings................................7 Precautions ................................7 Pour votre sécurité............................... 7 3.4.1 Avertissements.............................. - Page 4 CANopen................................25 Wiring and Connections 27 Capitan XCR Connection Diagram........................27 Communications..............................29 9.2.1 CAP-XCR-C (CANopen & Ethernet Interface) ..................... 29 9.2.1.1 CAN wiring recommendations .......................... 30 9.2.2 CAP-XCR-E (EtherCAT Interface)........................31 9.2.2.1 Recommended EtherCAT cables and connectors .................... 32 9.2.2.2 Ethernet over EtherCAT (EoE) Protocol - Used by Motion Lab 3..............
- Page 5 9.8.2 Absolute Encoder 1 ............................59 9.8.3 Absolute Encoder 2 ............................61 9.8.4 Incremental Encoder ............................62 9.8.5 Feedback wiring recommendations ......................... 64 Connectors Guide 65 10.1 Supply Connector .............................. 65 10.2 Inputs / Outputs and CAN Connector........................ 66 10.3 EtherCAT and Safety Connectors ........................
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Page 6: General Information
The information contained within this document contains proprietary information belonging to INGENIA-CAT S.L. Such information is supplied solely for the purpose of assisting users of the product in its installation. INGENIA-CAT S.L. rejects all liability for errors or omissions in the information or the product or in other documents mentioned in this document. ... -
Page 7: Safety Information
Denali XCR - Product Manual | Safety Information 3 Safety Information 3.1 For your safety The instructions set out below must be read carefully prior to the initial commissioning or installation in order to raise awareness of potential risks and hazards, and to prevent injury to personnel and/or damage to property. ... -
Page 8: Avertissements
Denali XCR - Product Manual | Safety Information Pour garantir la sécurité lors de l'utilisation de ce servomoteur, il est obligatoire de suivre les procédures incluses dans ce manuel. Les informations fournies sont destinées à protéger les utilisateurs et leur zone de travail lors de l'utilisation de l'appareil, ainsi que les autres matériels qui peuvent y être connectés. -
Page 9: Product Description
Denali XCR - Product Manual | Product Description 4 Product Description Denali XCR is a mid-power, highly integrated, ready-to-use digital servo drive. The drive includes all the required interface electronics and connectors, features best-in-class energy efficiency thanks to its state of the art power stage, and can be easily configured with free software MotionLab 3. -
Page 10: Specifications
Denali XCR - Product Manual | Product Description General Label Identification For applications requiring a pluggable drive enabled with EtherCAT or CANopen, please see Denali NET. For applications not requiring CANopen or EtherCAT, please contact us for Denali CORE Specifications 4.2.1... -
Page 11: Motion Control Specifications
Denali XCR - Product Manual | Product Description For disambiguation on current definitions please see Disambiguation on current values and naming for Ingenia Drives. Maximum peak phase current 10 A @ 1 sec Notice that peak current could be limited by an automatic current derating algorithm. -
Page 12: Inputs/Outputs And Protections
Denali XCR - Product Manual | Product Description • Not all the existing absolute encoders are supported. Contact a representative for further information. Supported target sources Network communication (EtherCAT / CANopen) Control modes • Cyclic Synchronous Position • Cyclic Synchronous Velocity •... -
Page 13: Communication For Operation
Denali XCR - Product Manual | Product Description NTC, PTC, RTD, linear voltage sensors , silicon-based sensors and thermal switches are supported. Protections • Hardcoded / hardwired drive protections: • Automatic current derating on voltage, current and temperature • Short-circuit Phase to DC bus •... -
Page 14: Reliability Specifications
Denali XCR - Product Manual | Product Description Maximum Humidity (Non- up to 95%, non-condensing at 85 ºC Operating) Altitude (Operating) -400 m to 2000 m Vibration (Operating) 5 Hz to 500 Hz, 4-5 g Mechanical Shock (Operating) ±15g Half-sine 11 msec ... - Page 15 Denali XCR - Product Manual | Product Description • IEC 60068-2-6:2007: Test Fc: Vibration (sinusoidal) • IEC 60068-2-27:2008: Test Ea: Shock INGENIA | 2023-06-24 13:29:17...
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Page 16: Product Revisions
STO circuitry supplied at 5 V (consumption considered). 4.4.2 Thermal model The Denali XCR is designed to be mounted on a cooling plate or heatsink to achieve its maximum ratings. 4.4.3 Current derating The figure below shows the maximum motor phase current at different case temperatures and operating points. -
Page 17: Heat Dissipation And Heatsink Calculation
Denali XCR - Product Manual | Product Description 4.4.4 Heat dissipation and heatsink calculation The following figure shows the estimated total power losses at different operating points. As can be seen, lower PWM frequency and voltage lead to lower power losses. ... -
Page 18: Energy Efficiency
Denali XCR - Product Manual | Product Description Please, use the following procedure to determine the required heatsink: Based on the voltage & continuous (averaged) current required by your application and Current derating graph determine the Case temperature T . Remember that Case temperature must be always below 85 ºC (T <... -
Page 19: Power Stage & Control Loops Relationship
Denali XCR - Product Manual | Product Description Power Stage & Control loops relationship The power stage PWM frequency can be adjusted in 4 different frequencies. Each frequency has an associated rate for the control loops, as specified in the following table. -
Page 20: Canopen Specifications
Denali XCR - Product Manual | CANopen Specifications 5 CANopen Specifications Ports available 1 CAN port LED Signals CANopen run LED (according to CiA-303) CANopen error LED (according to CiA-303) Modes of operation CiA-402 drive device profile • Voltage mode •... - Page 21 Denali XCR - Product Manual | CANopen Specifications Supported baudrates 50 kbps 20 kbps 10 kbps Fast-scan service is supported. Life guard protocol Implemented. Heartbeat Supported heartbeat producer. Time Stamp Supported time stamp consumer. INGENIA | 2023-06-24 13:29:17...
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Page 22: Ethercat Specifications
Denali XCR - Product Manual | EtherCAT specifications 6 EtherCAT specifications Ports available LED Signals Status LED Link/Act LED Supported Mailbox CoE, FoE, EoE SDO info Supported Segmented SDO Supported SDO complete access Supported Modes of Operation DS402 drive device profile •... -
Page 23: Dimensions
Denali XCR - Product Manual | Dimensions 7 Dimensions All dimensions are in mm. All tolerances ≤ ±0.2 mm. The drawings shown below could be downloaded here. Assembly instructions are indicated in the Installation chapter. 3D Model For further detail, download the STEP model or the PDF3D. -
Page 24: Signalling Leds
Denali XCR - Product Manual | Signalling LEDs 8 Signalling LEDs The drive provides information through 5 signaling LEDs: Type Color Description LED1 Single FAULT LED. LED2 Single Green EtherCAT / Ethernet 0 link (ECAT 0 Link or LINK0) LED3... -
Page 25: Canopen
Denali XCR - Product Manual | Signalling LEDs LED signal Expected start-up behavior If EtherCAT cables are connected on ECAT Port 0/1, Link LEDs will light according to the definition. EtherCAT firmware starts with no other LED because the slave will stay in INIT State after power-up until an EtherCAT master forces it to transition to another state. - Page 26 Denali XCR - Product Manual | Signalling LEDs LED signal Start-up behavior • This indicates a CAN Bus Off error, most probably generated by a short between CAN high and CAN low lines. RUN & ERROR LED • Both alternating On-Off (Orange) at 5 Hz.
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Page 27: Wiring And Connections
Denali XCR - Product Manual | Wiring and Connections 9 Wiring and Connections 9.1 Capitan XCR Connection Diagram Detailed wiring diagram for each module: • Communications • Protective Earth INGENIA | 2023-06-24 13:29:17... - Page 28 Denali XCR - Product Manual | Wiring and Connections • Power Supply and Motor Power • Safe Torque Off (STO) • Inputs and Outputs • Brake and Motor Temperature • Feedbacks INGENIA | 2023-06-24 13:29:17...
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Page 29: Communications
Denali XCR - Product Manual | Wiring and Connections 9.2 Communications The Capitan XCR provides the following network communication interfaces. Part Communication J4 connector (ECAT 0) functionality J3 connector (ECAT 1) J2 (I/O) connector pins number Option functionality 9, 11... -
Page 30: Can Wiring Recommendations
Denali XCR - Product Manual | Wiring and Connections 9.2.1.1 CAN wiring recommendations • Build CAN network using cables with 2-pairs of twisted wires (2 wires/pair) as follows: one pair for CAN_H with CAN_L and the other pair for GND. • Do not make a 2 wire only interface. Not connecting the CAN GND may result in loss of data and poor EMC performance. ... -
Page 31: Cap-Xcr-E (Ethercat Interface)
Denali XCR - Product Manual | Wiring and Connections 9.2.2 CAP-XCR-E (EtherCAT Interface) Capitan XCR Servo Drive provides access to the EtherCAT field bus system (CAP-XCR-E). EtherCAT is an isolated bus suitable for hard and soft real-time requirements in automation technology, test and measurement, and many other applications. -
Page 32: Recommended Ethercat Cables And Connectors
Denali XCR - Product Manual | Wiring and Connections 9.2.2.1 Recommended EtherCAT cables and connectors The following table shows the recommended connectors and cable colors for EtherCAT according to IEC 61918 Appendix H. INGENIA | 2023-06-24 13:29:17... - Page 33 Denali XCR - Product Manual | Wiring and Connections Signal Function Corresponding Pin for RJ45 M12-4 M8-4 Cable colour as Cable colour as pin on Capitan per TIA-568B per EN61918 D coded D coded TX_D+ Transmit data White Orange Yellow...
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Page 34: Ethernet Over Ethercat (Eoe) Protocol - Used By Motion Lab 3
Denali XCR - Product Manual | Wiring and Connections 9.2.2.2 Ethernet over EtherCAT (EoE) Protocol - Used by Motion Lab 3 Capitan XCR Servo Drive supports Ethernet over EtherCAT protocol. This protocol encapsulates Ethernet frames into EtherCAT packets allowing to establish a communication between standard Ethernet clients and EtherCAT devices over an EtherCAT network in a transparent way. -
Page 35: Protective Earth
Denali XCR - Product Manual | Wiring and Connections 9.3 Protective Earth Connection of Capitan XCR Servo Drive and motor housing to Protective Earth (PE) is required for safety and Electromagnetic Compatibility (EMC) reasons. Electrical faults can electrically charge the housing of the motor or cabinet, increasing the risk of electrical shocks. - Page 36 Denali XCR - Product Manual | Wiring and Connections • Connecting PE to GND_P near the power supply can provide an advantage for EMC and electrical safety by keeping a low voltage. Dis can only be done when the drive is powered with an isolated power supply or battery.
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Page 37: Power Supply And Motor Power
Denali XCR - Product Manual | Wiring and Connections 9.4 Power Supply and Motor Power 9.4.1 Single Power Supply The Capitan XCR can be powered from a single power supply as shown in the following figure. Since the power cables are soldered to the board it is essential to provide mechanical fastening to avoid ripping them off. -
Page 38: Dual Power Supply
Denali XCR - Product Manual | Wiring and Connections 9.4.2 Dual Power Supply For systems where it is necessary to keep communications alive, or keeping position information with incremental sensors while power is off, the drive can be powered from a logic supply input on the I/O connector. Choose the main power supply as indicated above. There are no special power supply sequencing requirements. ... -
Page 39: Shunt Braking Resistor Connection
Denali XCR - Product Manual | Wiring and Connections For the lowest EMC, it is recommended to use a 2 stage filter like Cosel NBC-10-472. 9.4.4 Shunt Braking Resistor Connection A shunt braking resistor can be activated from Capitan XCR by using an external transistor. Any of the 4 general- purpose outputs can be configured to turn-on when the dc bus exceeds a certain threshold: Shunt braking... -
Page 40: Motor Connections
Denali XCR - Product Manual | Wiring and Connections 9.4.5 Motor Connections 9.4.5.1 3 Phase Brushless 9.4.5.2 DC Motor 9.4.5.3 Motor Choke In applications where electromagnetic compatibility is needed, the use of an external common mode choke is necessary for the motor phases. Please see this document to understand why this is relevant Electromagnetic... -
Page 41: Power Wiring Recommendations
Denali XCR - Product Manual | Wiring and Connections Type Manufacturer Part number Remarks Wide frequency oval ferrite cable core Laird 28B0773-050 Single turn. Preferred option. Technology Wide frequency cylindrical ferrite cable core Laird 28B0999-000 Double turn option. Higher attenuation. - Page 42 Denali XCR - Product Manual | Wiring and Connections Cut and peel the power cables in advance with the appropriate length. The peeled length can be around 3 mm. Do not cut them after soldering as it will cause permanent tensions.
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Page 43: Safe Torque Off (Sto)
Denali XCR - Product Manual | Wiring and Connections 9.5 Safe Torque Off (STO) The STO is a safety system that prevents motor torque in an emergency event while Capitan XCR remains connected to the power supply. When STO is activated, the power stage is disabled by hardware and the drive power transistors are disconnected, no matter what control or firmware does. The motor shaft will slow down until... -
Page 44: Integration Requirements
Denali XCR - Product Manual | Wiring and Connections Fault Reaction Time t< 33 ms The worst-case fault reaction time is on the event of a 5V DC/DC supply overvoltage. High-demand mode The EUC (Equipment Under Control) is considered as a high-demand or continuous demand mode system. - Page 45 Denali XCR - Product Manual | Wiring and Connections Minimum, non- t < 400 µs detected STO short The Safety controller can transmit short pulses to STOx inputs for pulse diagnostics purposes. These pulses will be ignored by the safety circuit and...
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Page 46: Sto External Diagnostic Test
Denali XCR - Product Manual | Wiring and Connections Status of STO1, STO2, STO_REPORT, ABNORMAL_FAULT, and SUPPLY_FAULT can be read from the communications. STO firmware notification A STO stop is notified to the motion controller and creates a fault... -
Page 47: Sto Operation States
Denali XCR - Product Manual | Wiring and Connections Procedure Step Action Try to perform a "Motor Enable" (using Motionlab 3 or network commands). Verify that the power stage is not enabled by software (a fault should appear) or by hardware (checking the Motor phases voltage with a multimeter). -
Page 48: Interface And Connections
Denali XCR - Product Manual | Wiring and Connections Mode State STO1 STO2 Power State description status / status / stage report abnorma level level status l fault status state. To reset this fault a power cycle is > 3.6 V <... -
Page 49: Sto Bypass (Needed When No Sto Functionality Is Implemented)
Denali XCR - Product Manual | Wiring and Connections Wiring for a simplified version using the Capitan-XCR +5V_out supply is shown 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 various safety elements. - Page 50 Denali XCR - Product Manual | Wiring and Connections INGENIA | 2023-06-24 13:29:17...
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Page 51: Inputs And Outputs
Denali XCR - Product Manual | Wiring and Connections 9.6 Inputs and Outputs The Capitan XCR Servo Drive provides several inputs and output terminals for parameter observation and drive control options. • 4x Inputs and Outputs#INPUTS (IN1, IN2, IN3, IN4). • 1x Inputs and Outputs#ANAL (AN1+, AN1-) - Page 52 Denali XCR - Product Manual | Wiring and Connections The interface for 3 wire NPN and PNP sensors is shown next. INGENIA | 2023-06-24 13:29:17...
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Page 53: Analog Input Interface
Denali XCR - Product Manual | Wiring and Connections 9.6.2 Analog Input Interface The Capitan XCR has a high accuracy fully differential 16-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 differential (AN1+ - AN1-) -
Page 54: Digital Outputs Interface
Denali XCR - Product Manual | Wiring and Connections 9.6.3 Digital Outputs Interface Capitan XCR Servo Drive has 4 non-isolated digital outputs. These outputs can be used to drive optocouplers, LEDs or other digital circuits. Specification Value Number of outputs Type of output Push-pull output at 5 V ESD protected. - Page 55 Denali XCR - Product Manual | Wiring and Connections INGENIA | 2023-06-24 13:29:17...
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Page 56: Brake And Motor Temperature
Denali XCR - Product Manual | Wiring and Connections 9.7 Brake and Motor Temperature 9.7.1 Motor electromagnetic/electromechanical brake Electromechanical brakes are needed in critical applications where the disconnection of the motor or a lack of electric braking could be dangerous or harmful (i.e. falling suspended loads). Capitan XCR Servo Drive includes a brake output on the I/O connector J2. -
Page 57: External Temperature Sensor
Denali XCR - Product Manual | Wiring and Connections 9.7.2 External temperature sensor The Capitan XCR motor safety system connector allows the connection of an external temperature sensor based on changes of resistance (PTC thermistor, bimetal, NTC, PT100, silicon temperature sensors) to measure the motor temperature. -
Page 58: Feedbacks
Denali XCR - Product Manual | Wiring and Connections 9.8 Feedbacks The Capitan XCR can be connected to a maximum of 3 feedback devices at the same time that might be used for commutation and/or velocity/position control purposes. These devices are connected in the J1 connector of the... -
Page 59: Absolute Encoder 1
Denali XCR - Product Manual | Wiring and Connections Specification Value IEC 61000-4-5; tp = 8/20 μs 12 A, 200 W Maximum voltage range -0.5 ~ 5.5 V Maximum recommended working 5 kHz frequency 1st order filter cutting frequency (-3dB) - Page 60 Denali XCR - Product Manual | Wiring and Connections information, speed and direction of motion is calculated. The position is not lost even if the encoder is powered down, which means that it is not necessary to move to a reference position as with incremental type encoders. The following table shows the absolute encoder inputs electrical specifications.
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Page 61: Absolute Encoder 2
Denali XCR - Product Manual | Wiring and Connections In the case that the encoder has a current consumption higher than 200 mA (maximum current output of the +5V_OUT pin of the Capitan XCR) or that the encoder has an input supply > 5V, an external power supply will need to... -
Page 62: Incremental Encoder
Denali XCR - Product Manual | Wiring and Connections 9.8.4 Incremental Encoder Capitan XCR can use single-ended or differential digital incremental encoder inputs (also known as quadrature incremental encoders) for velocity and/or position control, as well as for commutation purposes. The encoder provides incremental position feedback that can be extrapolated into precise velocity or position information. - Page 63 Denali XCR - Product Manual | Wiring and Connections Specification Value ENC_x- (negative input) 1 kΩ to 2.5 V (equivalent) The wiring of a single-ended encoder to the Capitan XCR is shown next: Sometimes encoders require different supply voltages than 5 V or need more than the 200 mA provided by the drive. In those cases, the connection from the external power source should be as shown next: ...
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Page 64: Feedback Wiring Recommendations
Denali XCR - Product Manual | Wiring and Connections 9.8.5 Feedback wiring recommendations Signal distortion and electrical noise is a common problem in feedback signals. These problems can result in a bad position or velocity calculation for both digital feedbacks (gain or loss of counts) and analog feedbacks (wrong voltage levels).To minimize these problems some wiring recommendations are shown:... -
Page 65: Connectors Guide
Denali XCR - Product Manual | Connectors Guide 10 Connectors Guide 10.1 Supply Connector P1 Connector 2 pin Molex Pico-Lock PCB gold-plated right-angle header. Molex 2053380002. Signal Function Warning! Risk of electric shock! +V_BUS Power supply positive GND_P Power supply return. -
Page 66: Inputs / Outputs And Can Connector
Denali XCR - Product Manual | Connectors Guide 10.2 Inputs / Outputs and CAN Connector P2 connector 20 pins 2-row Pico-Clasp 1 mm pitch gold-plated right-angle header. Molex 501571-2007. Signal Function +5V_I/O +5 V 60 mA output, can be used for peripherals such as switches, I/Os, or even supply the safety inputs. ... -
Page 67: Ethercat And Safety Connectors
Denali XCR - Product Manual | Connectors Guide BOOT This pin can be pulled down to GND_D to force enter boot mode during power-up in FTP mode. Typically not necessary. If not used, always leave unconnected. GND_D Digital signal ground. -
Page 68: Feedback Connector
Denali XCR - Product Manual | Connectors Guide SAFETY_RETURN Safe Inputs Return common (optocoupler LEDs cathode, ISOLATED). Internal bypass from P3 to P4. SAFETY_IN_B Safe Input B for STO and SCB (positive, active from 5 V to 30 V, ISOLATED). - Page 69 Denali XCR - Product Manual | Connectors Guide P5 connector 30 pins 2-row Pico-Clasp 1 mm pitch gold-plated right-angle header. Molex 501571-3007. Signal Function GND_D Digital ground. MOTOR_TEMP_RET Motor temperature sensor return (referred to GND_D). Do not use this pin as GND for any other purpose than the negative for motor temperature sensing.
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Page 70: Motor Connector
Denali XCR - Product Manual | Connectors Guide ABS1_DATA- Absolute encoder 1 DATA negative signal input. For single-ended absolute encoders with TTL or CMOS levels leave this pin floating and connect the signal to ABS1_DATA+. ABS2_DATA- Absolute encoder 2 DATA negative signal input. For single-ended absolute encoders with TTL or CMOS levels leave this pin floating and connect the signal to ABS2_DATA+. -
Page 71: Brake Connector
Denali XCR - Product Manual | Connectors Guide 10.6 Brake Connector P7 connector 6 pins Pico-Clasp 1 mm pitch gold-plated right-angle header. Molex 2035580607. Signal Function Warning! Risk of electric shock! +V_BUS DC bus voltage of the drive. Connect to pin 2... - Page 72 Denali XCR - Product Manual | Connectors Guide P1 mating connector Image Part number Molex 2053410202 P2 mating connector Description Molex Pico-Clasp™ 1.0 mm pitch 20 positions dual row receptacle with locking ramp Image Part number Molex 501189-2010 P3 and P4 mating connectors Description Molex Pico-Clasp™...
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Page 73: Common Mating Terminals And Cables For All Signal Connectors
Denali XCR - Product Manual | Connectors Guide P7 mating connectors Image Part number Molex 5013300600 P7 cable assembly Description Molex Pico-Clasp™ 1.0 mm pitch 6 positions cable assembly Image Part number Molex 0151330601 (100 mm), 0151330603 (300 mm) 0151330606 (600 mm), ... - Page 74 Denali XCR - Product Manual | Connectors Guide Part Molex 63819-1500 number P2, P3, P4, P5, P7 Crimped wires 150 mm Descript Molex Pico-Clasp™ 28 AWG black jumper lead socket to socket 150 mm length. Gold plated. Image Part Molex 079758-1016 number P2, P3, P4, P5, P7 Crimped wires 300 mm...
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Page 75: Common Mating Terminals And Cables For Power Connectors
Denali XCR - Product Manual | Connectors Guide Image B-155-9001 10.7.2 Common mating terminals and cables for power connectors The power connectors are all based on Molex Pico-Lock 2.0 connectors. Please refer to the Application note to find detailed instructions. - Page 76 Denali XCR - Product Manual | Connectors Guide Wiring accessory: wire to wire solder sleeve Descript Wire to Wire Solder Sleeve Heat shrinkable. Can be used to reliably connect pre-crimped wires to a specific sensor, feedback, or other thin wires.
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