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Product Description

Denali NET is a mid power, highly integrated, low profile, digital servo drive intended to be plugged or soldered to an application-specific daughter board. 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 software MotionLab 3.

Denali NET is enabled with EtherCAT and CANopen communications.

Main features:

  • Ultra-small footprint

  • 48 VDC, 5 A continuous

  • Up to 50 kHz current loop, 25 kHz servo loops

  • 20 kHz ~ 200 kHz PWM frequency

  • 16 bit ADC

  • Supports Halls, Quadrature encoder, SSI, and Dual BiSS-C

  • Up to 4 simultaneous feedback sources

  • Full voltage, current, and temperature protections

Typical applications:

  • Collaborative robot joints & end effectors

  • Robotic exoskeletons & wearable robots

  • Medical applications

  • UAVs 

  • Low inductance motors

  • Lab equipment

Part numbering

Product

Ordering part number

Status

Image

Denali NET EtherCAT

Pluggable servo drive with with EtherCAT communication.

DEN-NET-E

PRODUCTION

Denali NET CANopen

Pluggable servo drive with with CANopen communication.

DEN-NET-C

PRODUCTION

General Label Identification

For applications requiring a ready-to-go product, please see Denali XCR

For applications not requiring CANopen or EtherCAT, please contact us for Denali CORE

Specifications

Electrical and Power Specifications

Minimum absolute DC bus supply voltage

5 VDC

Maximum absolute DC bus supply voltage

60 VDC

Recommended power supply voltage range

6 VDC ~ 48 VDC

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

Internal drive DC bus capacitance

5.5 µF ± 30%

Note that DEN-NET uses ceramic capacitors. The capacitance value varies with DC bias and temperature.

Logic supply voltages

5 VDC , 3.3 VDC and Vmagn_ct

  • It is required the additional supply of Vmagn_ct (supply for the magnetics center tap, MAGNETICS_CT pin).

    • Vmagn_ct can be 3.3 V or 1.8 V (reduces power consumption by 100 mW). 

  • Power sequencing

    • 3.3 V should be powered up before or together with 5V

    • Vmagn_ct should be powered after 3.3 V (Delay < 100 ms)

  • Power up ramps should be between 20 mV/µs and 100 mV/µs

  • The maximum allowed tolerances for logic supplies is ± 3%.

Boot-up time

4 s

Minimum shutdown time

500 ms

Output reference voltages

3.3 V ± 0.2%, 10 mA source / sink capability

Maximum continuous phase current

5 A

5 A can be obtained working at 48 V with an appropriate dissipation to keep the product plate under 85 ºC. On higher temperatures an automatic current derating will be applied to protect the system. See Thermal and Power Specifications below and Installation for further details.

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.

Maximum continuous output power

> 250 W

Efficiency

TBD

Maximum DC Bus voltage utilization

99.3% @ 20 kHz

98.5% @ 50 kHz

92.5% @ 100 kHz

78.1% @ 200 kHz

Note 1: these values assume a Sinusoidal commutation and no load connected.

Standby logic supply consumption

  • 1.3 W typ. for EtherCAT version (DEN-NET-E)

  • 1.1 W typ. for CANopen version (DEN-NET-C)

See details and conditions in Thermal and Power Specifications below

Motion Control Specifications

Supported motor types

  • Rotary brushless (SVPWM and Trapezoidal)

  • Rotary brushed (DC)

Power stage PWM frequency (configurable)

20 kHz, 50 kHz (default), 100 kHz, 200 kHz

Current sensing

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

Current sense resolution

0.505 mA/counts

Current sense range

± 16.5 Apk (full range)

Max. Current loop frequency (configurable)

50 kHz

Check the Power Stage & Control loops relationship section below.

Max. servo loops frequency (position, velocity & commutation) (configurable)

25 kHz

Check the Power Stage & Control loops relationship section below.

Feedbacks

  • Digital Halls

  • Quadrature / Incremental encoder 

  • 2x Absolute Encoder:

    • BiSS-C (up to 2 in daisy chain topology or simultaneously)

    • SSI (up to 2 simultaneous)

All feedback inputs are single-ended, 3.3 V logic levels.

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

  • Cyclic Synchronous Torque

  • 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

2x non-isolated single-ended digital inputs - 3.3 V logic level.

Can be configured as:

  • General purpose

  • Positive or negative homing switch

  • Positive or negative limit switch

  • Quick stop input

  • Halt input

2x non-isolated single-ended digital outputs - 3.3 V logic level, 3 mA max. sink / source current. 

Can be configured as:

  • General purpose

  • Operation enabled event flag

  • External shunt braking resistor driving signal

  • Health flag

2x ±3.3 V ,16-bit, differential analog inputs for load cells or torque sensors. Can be read by the Master to close a torque loop.

1x 0.3 V ~ 3 V, unbuffered analog output.

Dedicated digital output

Dedicated 3.3 V digital output for Fault Signal status.

Shunt braking resistor output

Configurable over any of the digital outputs (see above).

Enabling this function would require an external transistor or power driver.
The update rate of this output is synchronous to the servo loops frequency.

Motor brake output

Dedicated, PWM-capable, 3.3 V digital output for driving a mechanical brake. Turn-on and turn-off times are configurable.

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

Safe Torque OFF inputs

2x dedicated, non-isolated STO digital inputs (3.3 V and 5 V tolerant).

Motor temperature input

1x dedicated, 3.3 V, 12-bit, single-ended analog input for measuring motor temperature.

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

    • Short-circuit Phase to GND

    • Short-circuit Phase to Phase

  • 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

    • Limit switches

    • Position following error

    • Velocity / Position out of limits

Communication for Operation

EtherCAT

(DEN-NET-E)

CANopen over EtherCAT (CoE)

File over EtherCAT (FoE)

Ethernet over EtherCAT (EoE)

Magnetic and capacitive connections supported

CANopen / Ethernet

(DEN-NET-C)

CiA-301, CiA-303, CiA-305, CiA-306 and CiA-402 (4.0) compliant.

125 kbps to 1 Mbps (default). Non-isolated. Termination resistor not included. 

Note: Ethernet port 1 can be used to configure the drive

Environmental Conditions

Environmental test methods

IEC 60068-2 (pending certification)

Case Temperature (Operating)

-20 ºC to 70 ºC

Check the Current Derating section below.

Ambient temperature (Operating)

-20 ºC to 60 ºC

Altitude (Operating)

< 2000 m above sea level

Vibration (Operating)

10 Hz to 150 Hz, 1 g

Mechanical Shock (Operating)

±5g Half-sine 30 msec 

Mechanical Shock (Non-Operating)

±5g Half-sine 30 msec

Maximum Humidity (Operating)

up to 93%, non-condensing at 60ºC

Maximum Humidity (Non-Operating)

up to 93%, non-condensing at 60ºC

Reliability Specifications

MTBF

> 600.000 h 

Based on FIDES method for Standard Life Profile at 40 °C average. Other scenarios available on demand.

Mechanical Specifications

Dimensions

33 mm x 17.6 mm x 6 mm

Weight

3.86 g

Compliance

EC Directives

CE Marking

  • EMC: Electromagnetic Compatibility Directive (2014/30/EU) 

  • Safety: Machinery Directive (2006/42/EC)

  • RoHS 3: Restriction of Hazardous Substances Directive (2011/65/UE + 2015/863/EU)

Electromagnetic Compatibility (EMC) Standards

  • EN 61800-3:2018 Category C3

Product Safety Standards

  • IEC/EN 61800-5-1: Adjustable speed electrical power drive systems - Safety requirements - Electrical, thermal and energy

Functional Safety Standards

Safe Torque Off (STO) - Certification pending

  • EN 61800-5-2:2017 : SIL3

  • EN IEC 62061:2021 : SIL3

  • EN ISO 13849-1:2015 : PLe Cat. 3

Environmental Test methods

IEC 60068-2:

  • 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 60068-2-78:2012: Test Cab, Damp heat, steady state

  • IEC 60068-2-6:2007: Test Fc: Vibration (sinusoidal)

  • IEC 60068-2-27:2008: Test Ea: Shock

Product Revisions

Revision

Date

Notes

D

 

First commercial version


Thermal and Power Specification

Standby power consumption 

The following table shows the standby power consumption when the Denali power stage is enabled.

Power supply voltage

Logic supply consumption (5V, 3.3V and Vmagn_ct)

Power stage DC bus consumption switching at 0 current

EtherCAT (2 ports active)

CANopen

20 kHz

50 kHz

100 kHz

200 kHz

7 V

< 1.3 W

The measurement includes:

  • 0.063 W corresponding to 5V

  • 1.01 W corresponding to 3.3 V

  • 0.22 W corresponding to Vmagn_ct = 1.8V

The measurements DO NOT include 100 mW corresponding to ethernet magnetics, not included in the Denali NET.

< 1.1 W

The measurement includes:

  • 0.063 W corresponding to 5V

  • 0.9 W corresponding to 3.3 V

  • 0.135 W corresponding to Vmagn_ct = 1.8V

0.006 W

0.015 W

0.028 W

0.055 W

24 V

0.050 W

0.115 W

0.223 W

0.436 W

48 V

0.16 W

0.36 W

0.69 W

1.35 W

Measurement environment

  • No feedbacks connected

  • No I/Os connected

  • Motor current is set to 0 (Voltage mode 0 V)

  • STO circuitry supplied at 5 V (consumption considered). 

Thermal model

Current derating without plate

The following figure shows the maximum motor phase current at different ambient temperatures and operating points. The graph expresses the achievable 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 motor, not RMS. For further clarifications and conversion to equivalent RMS values please refer to Disambiguation on current values and naming for Ingenia Drives.

The following considerations apply to this measure:

  • DEN-NET-C plugged into a 70 mm x 100 mm interface board.

  • DEN-NET-C power pins are soldered to the board.

  • Convection dissipation to the air without forced airflow

Current derating with case

It is highly recommended to use a case or heatsink to dissipate Denali NET. See the Installation section for further details.

The following figure shows the maximum motor phase current when dissipating the Denali NET with a case or heatsink. Results are referenced to the case temperature, providing a known interface for any system. The graph expresses the achievable 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 motor, not RMS. For further clarifications and conversion to equivalent RMS values please refer to Disambiguation on current values and naming for Ingenia Drives.

To ensure proper performance of Denali NET, the case temperature should always be held below 85 ºC (Tc-max =  85 ºC).

Heat dissipation and heatsink calculation

The following figure shows the total estimated power losses at different operating points. This includes logic supply which is an important contributor at low loads. As can be seen, lower PWM frequency and voltage lead to lower power losses. 

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

  1. Based on the voltage & continuous (averaged) current required by your application and Current derating graph determine the Case temperature Tc. Remember that Case temperature must always be below 85 ºC (Tc < 85 ºC)

    1. For example: If the application requires 4 A @ 48V (100 kHz) the Tc maximum will be 85 ºC

  2. Based on the voltage & continuous current required by your application and the Power losses graph determine the generated Power Losses PL to be dissipated. 

    1. For example: If the application requires 4 A @ 48V (100 kHz) the PL will be 2.5 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 the air of the required heatsink Rth(h-a)

a. For example: If the application requires 4 A @ 48V (100 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) = 24.2 K/W

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.

Power stage PWM frequency

Current loop frequency

Servo loops frequency (position, velocity, commutation & shunt)

20 kHz

20 kHz

20 kHz

50 kHz

50 kHz

25 kHz

100 kHz

50 kHz

25 kHz

200kHz

50 kHz

25 kHz

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