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.

Denali XCR is enabled with EtherCAT or CANopen communications.

Main features:

Ultra-small footprint
48 V_DC, 5 A continuous
Up to 50 kHz current loop, 25 kHz servo loops
20 kHz ~ 200 kHz PWM frequency
16 bit ADC current sensing
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
Lab equipment
Low inductance motors

Part Numbering

Product

Ordering part number

Status

Image

Denali XCR EtherCAT

Ready-to-use servo drive featuring EtherCAT communications.

DEN-XCR-E

PRODUCTION

Denali XCR CANopen

Ready-to-use servo drive featuring CANopen.

DEN-XCR-C

PRODUCTION

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

Electrical and Power Specifications

Minimum absolute power supply voltage	7 V_DC
Maximum absolute power supply voltage	60 V_DC
Recommended power supply voltage	8 V_DC ~ 48 V_DC This voltage range ensures a safety margin including power supply tolerances and regulation during acceleration and braking.
Internal drive DC bus capacitance	19.7 µF _{Note that DEN-XCR uses ceramic capacitors. The capacitance value varies with DC bias and temperature.}
Boot-up time	4 s
Minimum shutdown time	500 ms
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 How the output power is calculated.
Efficiency	Up to 98%
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	2.5W typ. for EtherCAT version (DEN-XCR-E) 2.1W typ. for CANopen version (DEN-XCR-C) See details and conditions in the 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)
Maximum Current loop frequency	50 kHz _{Check the}_{Power Stage & Control loops relationship}_{section below.}
Maximum servo loops frequency (position, velocity & commutation)	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 (up to 2 in daisy chain topology or simultaneously) SSI Not all the existing absolute encoders are supported. Please consult the Feedbacks section.
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 & 5 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, short-circuit protected. Can be configured as: General purpose Operation enabled event flag External shunt braking resistor driving signal Health flag 2x ±11 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 buffered analog output: Max. current: 1 mA (Output resistance ~ 55 Ω). Short-circuit protected Find more detailed information in the Inputs and Outputs page.
Shunt braking resistor output	Configurable over any of the general purpose digital outputs (see above). _{Enabling this function requires an external transistor or power driver.} _{The update rate of this output is synchronous to the servo loops frequency.}
Safe Torque OFF inputs	2x Dedicated, isolated (> 4 GΩ, 1 kV) STO input. 24 V Industrial Logic level. Active-low. VIL / VIH = 5 V / 15 V Details: Safe Torque Off (STO).
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). NTC, PTC, RTD, linear voltage sensors , silicon-based sensors and thermal switches are supported. Find more detailed information in the Motor Temperature page.
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-XCR-E)

CANopen over EtherCAT (CoE)

File over EtherCAT (FoE)

Ethernet over EtherCAT (EoE)

CANopen

(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.

Environmental Conditions

Environmental test methods	IEC 60068-2 (under validation)
Case temperature (Operating)	-20 ºC to +85 ºC Check the Current Derating section below.
Case temperature (Non-Operating)	-40 ºC to +100 ºC
Maximum Humidity (Non-Operating)	up to 93%, non-condensing at 40 ºC
Altitude (Operating)	-400 m to 2000 m
Vibration (Operating)	10 Hz to 150 Hz, 1 g (TBC)
Mechanical Shock (Operating)	±5g Half-sine 30 msec (TBC)
Mechanical Shock (Non-Operating)	±5g Half-sine 30 msec (TBC)

Mechanical Specifications

Dimensions	49.8 mm x 26.50 mm x 14.73 mm
Weight	25.6 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 (rev F) IEC 61800-5-2:2016 : SIL3 IEC 61508:2010 : SIL3 EN ISO 13849-1:2015 : PLe Cat. 3 See Safe Torque Off (STO) section for mandatory Integration Requirements. This section has been updated through the different product revisions. Take a look to the PCN section.
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	30 Dec 2022	Initial version
E	01 Aug 2023	Brake capability removed. Removed 3.3 Feedback voltage
F	28 Nov 2023	STO specification update
G

Thermal and Power Specification

Standby power consumption

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

Power supply voltage	Power stage disabled		Power stage enabled and switching at 0 current (EtherCAT with 2 ports active)
Power supply voltage	EtherCAT (2 ports active)	CANopen	20 kHz	50 kHz	100 kHz	200 kHz
7 V	2.05 W	1.74 W	2.05 W	2.07 W	2.08 W	2.11 W
24 V	2.28 W	1.84 W	2.33 W	2.40 W	2.50 W	2.72 W
48 V	2.47 W	2.05 W	2.63 W	2.83 W	3.16 W	3.82 W

Considered 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

The Denali XCR is designed to be mounted on a cooling plate or heatsink to achieve its maximum ratings.

Current derating

The figure below shows the maximum motor phase current at different case temperatures and operating points. 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 the proper performance of Denali XCR, the case temperature should always be held below 85 ºC (T_c-max = 85 ºC).

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.

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_c. Remember that Case temperature must be always below 85 ºC (T_c < 85 ºC)
1. For example: If the application requires 3 A @ 48 V (200 kHz) the T_c maximum could be 90 ºC. Since this is above 85ºC the T_c should be limited to 85ºC.
Based on the voltage & continuous current required by your application and Power losses graph determine the generated Power Losses P_L to be dissipated.
1. For example: If the application requires 3 A @ 48 V (200 kHz) the P_L will be 4.75 W
Determine the Thermal impedance of the used thermal sheet R_th(c-h)
1. For example, a thermal sheet TGX-150-150-0.5-0, which has an estimated thermal impedance of R_th(c-h) = 0.2 K/W
Based on the ambient temperature and using the following formula determine the maximum thermal impedance to air of the required heatsink R_th(h-a)

a. For example: If the application requires 3 A @ 48 V (200 kHz) working at T_a = 25 ºC and we use a thermal sheet with R_th(c-h) = 0.2 K/W the required thermal impedance of the heatsink will be R_th(h-a) ≤ 13.53K/W.

Energy efficiency

The following graph shows the estimated electrical energy efficiency including logic for various operation points assuming 50 ºC case temperature and the drive delivering the maximum output power (i.e. maximum output voltage and motor speed). As seen, very high efficiencies > 95% can be expected at all PWM frequencies.

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
200 kHz	50 kHz	25 kHz