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Product Description

Denali Safe NET (DEN-S-NET-E) is a Functional Safety certified mid-power, highly integrated, low profile, digital servo drive intended to be plugged or soldered to an application-specific daughter board. The drive includes advanced Functional Safety features, like FSoE (Safety over EtherCAT) communication, Safe Stop and Safe Input as well as best-in-class energy efficiency thanks to its state-of-the-art power stage. The product is based on EtherCAT communication and can be easily configured with the Novanta Drives's free software MotionLab 3.

Main features:

  • Ultra-small footprint

  • Functional Safety: STO, SS1, FSoE; SIL3 and PLe certified

  • 48 VDC, 5 A continuous

  • Up to 99% efficiency

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

  • 20 kHz ~ 200 kHz PWM frequency

  • 16 bit ADC current sensing

  • Supports Digital Halls, Quadrature Incremental encoder, Absolute BiSS-C encoder

  • Up to 4 simultaneous feedback sources

  • Full voltage, current, and temperature protections

  • Capable of controlling low inductance motors

Target applications:

  • Collaborative robot joints

  • Robotic exoskeletons

  • Medical applications

  • AGVs and AMRs

  • Humanoid robot joints

Page contents

Part numbering

Product

Ordering part number

Status

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Denali Safe NET

Functional Safety certified pluggable servo drive with EtherCAT communication.

DEN-S-NET-E

IN DESIGN

General Label Identification

Specifications

Electrical and Power Specifications

Minimum absolute DC bus supply voltage

8 VDC

Maximum absolute DC bus supply voltage

60 VDC

Recommended power supply voltage range

8 VDC ~ 48 VDC SELV

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

Internal drive DC bus capacitance

5 µF ± 30%

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

Logic supply voltages

  • 5V ± 3% VDC , 3.3 ± 3% VDC , and Vmagn_ct

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

    • Vmagn_ct can be 3.3 V ± 3% or 1.8 V ± 3% (maximum failure voltage 25 V)

  • 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%.

During an overvoltage fault, system could become non-operational, but safety function is maintained.

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 70 ºC. 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

Maximum DC Bus voltage utilization

99.3% @ 20 kHz
98.5% @ 50 kHz
92.5% @ 100 kHz
78.1% @ 200 kHz

These values assume a Sinusoidal commutation and no load connected.

Minimum Standby Consumption

1.43 W typ.

See details and conditions in Thermal and Power Specifications below

Motion Control Specifications

Supported motor types

Rotary brushless (SVPWM and Trapezoidal)

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 BP3)

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

Check Safe Feedback section.

The following feedback protocols are supported and can be used outside of the Functional Safety certification:

  • EnDAT 2.2

  • SSI

Supported target sources

Network communication: EtherCAT with Safety over EtherCAT (FSoE)

EtherCAT

  • CANopen over EtherCAT (CoE)

  • File over EtherCAT (FoE)

  • Ethernet over EtherCAT (EoE)

Magnetic and capacitive connections supported

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

Functional Safety Specifications

This product is certification pending. Until receiving the certificate any content in this section is subject to change.

DEN-S-NET-E Safe Communication (already implemented)

DEN-S-NET-E Safe Motion (future release)

Safety functions

  • Fail-safe over EtherCAT (FSoE)

  • Safe Torque Off (STO)

  • Safe Stop 1 time controlled (SS1-t)

  • Safe Input (SI)

  • Fail-safe over EtherCAT (FSoE)

  • Safe Torque Off (STO)

  • Safe Stop 1 time controlled (SS1-t)

  • Safe Input (SI)

  • Safe Stop 1 ramp monitored (SS1-r)

  • Safe Stop 2 time controlled (SS2-t)

  • Safe Stop 2 ramp monitored (SS2-r)

  • Safe Operating Stop (SOS)

  • Safe Acceleration Range (SAR)

  • Safely-limited speed (SLS)

  • Safe Speed Range (SSR)

  • Safely-limited Position (SLP)

  • Safely-limited Increment (SLI)

  • Safe Direction (SDI)

  • Safe Velocity (SV)

  • Safe Position (SP)

Safe Feedback

Not Supported

Safe Feedback with the combination of 2 individual encoders:

  • Digital Halls

  • QEI

  • Absolute Encoder - BISS-C BP3

See Safe Feedback Combinations (DEN-S-NET Safe Motion - future release) for further details.

Safety Integrity Level (SIL) according to IEC 61508:2010

SIL3

Performance Level (PL) according to ISO 13849-1:2015

PLe, Cat. 3

Safety Function Reaction Time

≤ 25 ms

Safe inputs

1 x Redundant Safe Input. Non-Isolated. Logic level (3.3 V and 5 V tolerant). Active-low.

Command Source

  • Safety over EtherCAT (FSoE) - ETG.5100 V1.2.0

  • Safe Input

FSoE cycle time

≤ 50 ms

Standards compliance 

Targeted standards (certification pending):

  • EN 61800-5-2:2017

  • EN IEC 62061:2021

  • EN 61508:2010

  • EN ISO 13849-1:2015

  • EN 61784-3:2021

Safe Feedback Combinations (DEN-S-NET-E Safe Motion - future release)

The section below is relevant to the future implementation of the EVS-S-NET drive offering Safe Motion features.

This product is certification pending. Until receiving the certificate any content in this section is subject to change.

Denali Safe NET can provide advanced Safe Motion functions by using two individual non-certified encoders:

Feedback Combination

DEN-S-NET-E Safe Communication (already implemented)

DEN-S-NET-E Safe Motion (future release)

Safe Feedback 1

Safe Feedback 2

Safety Functions allowed

-

-

STO, SS1-t and SI

STO, SS1-t and SI

BISS-C BP3 - Port 1

BISS-C BP3 - Port 2

N/A

STO, SS1-t and SI

Safe Velocity Functions: SS1-r, SAR, SLS, SSR, SDI, SV

Safe Position Functions: SS2-r, SS2-t, SOS, SLP, SLI, SP

BISS-C BP3 - Port 1

QEI

N/A

STO, SS1-t and SI

Safe Velocity Functions: SS1-r, SAR, SLS, SSR, SDI, SV

Safe Position Functions: SS2-r, SS2-t, SOS, SLP, SLI, SP

Digital Halls 

BISS-C BP3 - Port 2

N/A

STO, SS1-t and SI

Safe Velocity Functions: SS1-r, SAR, SLS, SSR, SDI, SV

Safe Position Functions: SS2-r, SS2-t, SOS, SLP, SLI, SP

Digital Halls 

QEI

N/A

STO, SS1-t and SI

Safe Velocity Functions: SS1-r, SAR, SLS, SSR, SDI, SV

Safe Position Functions: SS2-r, SS2-t, SOS, SLP, SLI, SP

Note: To guarantee enough diversity, the encoders must be of different technology or manufacturer.

Note: Other feedback combinations can be used for Motion Control purposes out of Functional Safety certification.

Environmental Conditions

Environmental test methods

IEC 60068-2

Case temperature (Operating)

-20 ºC to +70 ºC

Ambient temperature (Operating)

-20 ºC to +60 ºC

Case and Ambient temperature (Non-Operating)

-40 ºC to +100 ºC

Altitude (Operating)

< 2000 m above sea level.

Vibration (Operating and Non-operating)

10 Hz to 150 Hz, 1 g

Mechanical Shock (Operating and Non-operating)

±5g Half-sine 30 msec 

Pollution degree

Pollution degree 2 with an IP54 enclosure installation.

Over-voltage category 

II

Maximum Humidity (Operating)

up to 93%, non-condensing at 60 ºC

Maximum Humidity (Non-operating)

up to 93%, non-condensing at 60 ºC

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.

Safe Inputs

1 x Redundant Safe Input. Non-Isolated. Logic level (3.3 V and 5 V tolerant). Active-low.

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.

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 (Configurable up to Drive limits):

    • DC bus over-voltage

    • DC bus under-voltage

    • Drive over-temperature

    • Drive under-temperature

    • Motor over-temperature (requires external sensor)

    • Current overload (I2t).

    • Voltage mode over-current (with a closed current loop, protection effectiveness depends on the PID).

The configurable protections are configurable up to the drive limits. In any case when the limits are reached, the drive is completely switched off with the current reduced to 0.

  • Motion Control protections:

    • Halls sequence / combination error

    • Limit switches

    • Velocity / Position following error

    • Velocity / Position out of limits

Over-current

An overcurrent device in series (i.e. fuse or similar) is needed with a rating of maximum x3 of the max current of the motor on the system and a minimum voltage rating of 60V

Consider Vbus overshoots and reinjections to dimension the protection accordingly.

Communication for Operation

EtherCAT

CANopen over EtherCAT (CoE)

File over EtherCAT (FoE)

Ethernet over EtherCAT (EoE)

Failsafe over EtherCAT (FSoE)

Magnetic and capacitive connections supported

Mechanical Specifications

Dimensions

33 mm x 17.6 mm x 9.5 mm

Weight

7 g

Compliance

EC Directives

  • CE Marking (Certification pending)

  • LVD: Low voltage directive (2014/35/EU) (Certification pending)

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

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

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

Electromagnetic Compatibility (EMC) Standards

  • IEC 61800-3:2017 (Certification pending)

  • IEC 61000-6-2:2016 (Certification pending)

Product Safety Standards

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

Functional Safety Standards

See section Functional Safety Specifications

Environmental Test methods

IEC 60068-2:

  • EN 60068-2-1:2007 - Test A: Cold

  • EN 60068-2-2:2007 - Test B: Dry heat

  • EN 60068-2-78:2013 - Test Cab: Damp heat, steady-state

  • EN 60068-2-6:2008 - Test Fc

  • EN 60068-2-27:2009 - Shock

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)

20 kHz

50 kHz

100 kHz

200 kHz

8 V

< 1.4 W

The measurement includes:

  • 0.018 W corresponding to 5V

  • 1.23 W corresponding to 3.3 V

  • 0.11 W corresponding to Vmagn_ct = 1.8V

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

0.007 W

0.01 W

0.03 W

0.07 W

48 V

0.13 W

0.32 W

0.63 W

1.25 W

60 V

0.19 W

0.46 W

0.92 W

1.83 W

Measurement environment

  • No feedbacks connected

  • No I/Os connected

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

  • STO circuitry supplied at 3.3 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:

  • Drive plugged into a 70 mm x 100 mm interface board.

  • 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 Safe NET. See the Installation section for further details.

The following figure shows the maximum motor phase current when dissipating the Denali Safe 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 Safe 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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