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Product Description

Everest S Safe NET (EVS-S-NET-E) is a Functional Safety certified high-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, such as FSoE (Safety over EtherCAT) communication, Safe Stop Safe Torque Off and Safe Input. It offers 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' free software MotionLab 3.

Main features:

  • Ultra-small footprint

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

  • Up to 60 VDC, 45 A continuous

  • Up to 99% efficiency

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

  • 10 kHz ~ 100 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

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Part numbering

Product

Ordering part number

Status

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Everest S Safe NET

Functional Safety certified pluggable servo drive with EtherCAT communication.

EVS-S-NET-E

IN DESIGN

EverestSSafe 1.png

General Label Identification

Specifications

Electrical and Power Specifications

Minimum absolute DC bus supply voltage

8 VDC

Maximum absolute DC bus supply voltage

60 VDC 

Internal drive DC bus capacitance

20 µF

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

Logic supply voltages

Recommended voltage range is 5 V ± 2% (4.9 VDC ~ 5.1 VDC). Maximum voltage in case of external failure 25 V.

A minimum of 500 mA should be provided. Higher current may be needed depending on the feedbacks used.

Rise time of the 5 V supply must be between 2 ms and 10 ms to guarantee a proper initialization.

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

45 A @ 60 ºC

Typically, 45 A can be obtained working at 48 V, 20 kHz with an appropriate cooling to keep case temperature under 60 ºC. On higher temperatures an automatic current derating will be applied to protect the system. See Thermal and Power Specifications..
For disambiguation on current definitions please see Disambiguation on current values and naming for Ingenia Drives

Maximum peak phase current

60 A @ 1 sec

Notice that peak current could be limited by an automatic current derating algorithm.

Maximum continuous output power

> 3 kW

For more information, please see How to calculate the output power of a Servo Drive

Maximum DC Bus voltage utilization

99.73% @ 10 kHz

99.55% @ 20 kHz

99.04% @ 50 kHz

95.25% @ 100 kHz

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

Minimum Standby Consumption

1.85W 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)

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

Current sensing

3 phase, shunt-based current sensing.

16-bit ADC resolution.

Accuracy is ±2% full scale.

Current sense resolution

Current gain is configurable in 3 ranges:

  • 2.475 mA/count

  • 1.352 mA/count

  • 0.570 mA/count

Current sense range

Current ranges for the 3 configurable current gains:

  • ±81.1 A

  • ±44.3 A

  • ±18.7 A

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 (Phase 2):

  • 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.

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

EVS-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)

  • Redundant Safe Output (SOUT)

  • 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.

Safe Output

None

1 x Redundant Safe Output. Logic level, active-low.

Designed to be used with an external SBC (Safe Brake Control).

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

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

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

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

Feedback Combination

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

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

Safe Feedback 1

Safe Feedback 2

Safety Functions allowed

-

-

STO, SS1-t, and SI

STO, SOUT, SS1-t, and SI

BISS-C BP3 - Port 1

BISS-C BP3 - Port 2

N/A

STO, SOUT, 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, SOUT, 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, SOUT, 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, SOUT, 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 +70ºC

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 

Maximum Humidity (Operating)

up to 93%, non-condensing at 60 ºC

Maximum Humidity (Non-operating)

up to 93%, non-condensing at 60 ºC

Over-voltage category

II

Inputs/Outputs and Protections

General purpose Inputs and outputs

4x 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

4x 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, 5 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

37x 28.5x 17.14mm

Weight

28g

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 61800-3:2018 (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 Everest S Safe power stage is disabled assuming 2 EtherCAT/Ethernet port is active and communicating at full speed, no feedbacks or I/Os are connected. At this point the power consumption comes from the 5 V supply input only. The table also shows the "active standby" dc bus power consumption when the power stage is enabled, motor current is set to 0 and housing temperature is kept at under 70 ºC. 

Power supply voltage

Standby 5 V logic supply consumption

Power stage DC bus consumption switching at 0 current

10 kHz

20 kHz

50 kHz

100 kHz

8 V

1.94W

(logic supply consumption does not depend on bus voltage)

0.01W

0.02W

0.05W

0.10W

48 V

0.22W

0.42W

1.00W

1.97W

60 V

0.32W

0.60W

1.45W

2.85W

Thermal model

The Everest S Safe NET is designed to be mounted on a cooling plate or heatsink to achieve its maximum ratings. In order to calculate the heatsink requirements, the power dissipation can be estimated below. 

In some low power applications, the Everest S Safe NET is NOT required to be mounted to any heatsink. In this case its thermal resistance from housing/case to ambient Rth(h-a) can be estimated between 8 K/W, to 12 K/W assuming 10 cm clearance to allow air convection at sea level. Typically 7 W can be dissipated without heatsink, refer to the graph below to know which current can be handled.

*Product shown differ from Everest S NET.

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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