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 Ingenia's free software MotionLab 3.

Denali XCR is enabled with EtherCAT and CANopen communications.

Main features:

  • Ultra-small footprint
  • 48 VDC, 5 A continuous
  • Up to TBD% efficiency
  • Up to 50 kHz current loop, 25 kHz servo loops
  • 20 kHz ~ 150 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
  • Safety Torque Off (STO SIL3 Ple) inputs

Typical applications:

  • Collaborative robot joints & end effectors
  • Robotic exoskeletons & wearable robots
  • Medical applications 
  • UAVs
  • Low inductance motors
  • Lab equipment


Part Numbering

ProductOrdering part numberStatusImage

Denali XCR EtherCAT

Ready-to-use servo drive featuring EtherCAT communications.

DEN-XCR-E

DESIGN

Denali XCR CANopen

Ready-to-use servo drive featuring  CANopen. Ethernet port 1 could be used for commissioning.

DEN-XCR-C

DESIGN

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 see Denali CORE.

Specifications

Electrical and Power Specifications

Minimum power supply voltage5 VDC

Maximum absolute power supply voltage

60 VDC (continuous)

Recommended power supply voltage

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

14.2 µF

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

Boot-up time4 s
Minimum shutdown time500 ms

Maximum continuous phase current

5 A 

Typically, 5 A can be obtained working at 48 V, 40 kHz with an appropriate cooling to keep the product under 85 ºC. On higher temperatures an automatic current derating will be applied to protect the system. See Product Description#Thermal and Power Specifications below.

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. In order to get 10 A, drive temperature should be kept below 60 ºC.

Maximum continuous output power

> 250 W

How the output power is calculated in an Ingenia drive.

Efficiency

Up to TBD %

Maximum DC Bus voltage utilization

98 % @20 kHz

Standby logic supply consumption

~ 1.98 W typ. for ECAT version and ~ 1.75 W typ. for CANopen version 

See details and conditions in the section 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, 150 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 (Single-ended)
  • Quadrature Incremental encoder (RS-422 or Single-ended)
  • 2x Absolute Encoder (RS-422 or Single-ended):
    • BiSS-C
    • SSI

Not all the existing absolute encoders are supported. Contact Ingenia for further information.

Supported target sources

Network communication (EtherCAT / CANopen)

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

2x 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
  • Halt input

2x non-isolated single-ended digital outputs - 3.3 V logic level (continuous short circuit capable with 470 Ω series resistance) - 4 mA max. current. Can be configured as:

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

2x ±10 V ,16-bit, differential analog inputs for load cells or torque sensors. Can be read by the Master to close a torque loop.

1x 3.3 V, analog output.

Dedicated digital outputDedicated 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

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 activation/holding voltage and power consumption.

Safe Torque OFF inputs

2x dedicated, isolated (> 4 GΩ, 1 kV) STO inputs (from 3.6 V to 30 V). (TBC)

The STO inputs include a current limiter at ~ 5 mA to minimize losses. Details: https://novantamotion.atlassian.net/wiki/spaces/DENXCRSI/pages/26805512.

Motor temperature input

1x dedicated, 3.3 V, 12-bit, single-ended analog input for motor temperature (1.65 kΩ pull-up to 3.3 V included). (TBC)

NTC, PTC, RTD, linear voltage sensors , silicon-based sensors and hermal 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 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-XCR-E)

CANopen over EtherCAT (CoE)

File over EtherCAT (FoE)

Ethernet over EtherCAT (EoE)

CANopen / Ethernet

(DEN-XCR-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 methodsIEC 60068-2
Case temperature (Operating)

-20 ºC to +85 ºC

Check the Current Derating section below.

Case temperature (Non-Operating)-40 ºC to +100 ºC
Thermal Shock (Operating)25 ºC to 60 ºC in 25 min
Maximum Humidity (Operating)up to 95%, non-condensing at 60 ºC
Maximum Humidity (Non-Operating)up to 95%, non-condensing at 85 ºC
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 
Mechanical Shock (Non-Operating)±15g Half-sine 11 msec

Reliability Specifications

MTBF

> TBC

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

Mechanical Specifications

Dimensions49.8 mm x 23.2 mm x 14.0 mm
Weight14 g

Compliance

EC Directives

CE Marking

  • LVD: Low voltage directive (2014/35/EU)
  • 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
  • IEC 61800-3:2017
  • IEC 61000-6-2:2016
Product Safety Standard
  • IEC/EN 61800-5-1: Adjustable speed electrical power drive systems - Safety requirements - Electrical, thermal and energy
Functional Safety Standard

Safe Torque Off (STO) - Certification pending

Safe Brake Control (SBC) - Certification Pending

  • IEC 61800-5-2:2016 : SIL3
  • IEC 61508:2010 : 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

RevisionDateNotes
1

  

Initial 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 voltageSafe input 5 V consumptionEtherCATCANopen
Power stage DC bus consumption switching at 0 currentPower stage DC bus consumption switching at 0 current
20 kHz50 kHz100 kHz150 kHz20 kHz50 kHz100 kHz150 kHz
12 V0.027 W



1.95 W2.05 W2.21 W2.36 W1.71 W1.81 W1.98 W2.13 W
24 V2.11 W2.30 W2.58 W2.86 W1.86 W2.04 W2.34 W2.63 W
48 V2.45 W2.82 W3.36 W3.90 W2.25 W2.59 W3.14 W3.69 W
60 V2.68 W3.12 W3.81 W4.50 W2.43 W2.86 W2.91 W4.30 W

Measurement environment

  • No feedbacks connected
  • No I/Os connected
  • Motor current is set to 0 (Voltage mode 0 V)

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 frequencyCurrent loop frequencyServo loops frequency (position, velocity, commutation & shunt)
20 kHz20 kHz20 kHz
50 kHz50 kHz25 kHz
100 kHz50 kHz25 kHz
150 kHz50 kHz25 kHz