Product Description

Everest S Safe NET (EVS-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 Safe Torque Off 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, SI, FSoE - SIL3 and PLe certified
Up to 60 V_DC, 45 A continuous
Up to TBD 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 encoders
Up to 4 simultaneous feedback sources
Full voltage, current, and temperature protections
Capable to control low inductance motors

Typical applications:

Collaborative robot joints & end effectors
Robotic exoskeletons & wearable robots
Medical applications
AGVs and UAVs
Lab equipment

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Everest S Safe NET

Functional Safety certified pluggable servo drive with EtherCAT communication.

EVS-S-NET-E

IN DESIGN

General Label Identification

Specifications

Electrical and Power Specifications

Minimum absolute DC bus supply voltage	8 V_DC
Maximum absolute DC bus supply voltage	60 V_DC (continuous)
Internal drive DC bus capacitance	19 µF Note that EVS-S-NET 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	TBD% @ 10 kHz TBD% @ 20 kHz TBD% @ 50 kHz TBD% @ 100 kHz _{Note: The values assume a Sinusoidal commutation and no load connected.}
Standby logic supply consumption	≤ TBD 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)	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: 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 Safe Communication (already implemented)	EVS-S-NET 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 Limited Acceleration (SLA) 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 Speed Monitor (SSM)
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 Safe Motion - future release)

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

Feedback Combination		EVS-S-NET Safe Communication (already implemented)	EVS-S-NET 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, SLA, SAR, SLS, SSR, SDI, SV, SSM 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, SLA, SAR, SLS, SSR, SDI, SV, SSM 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, SLA, SAR, SLS, SSR, SDI, SV, SSM 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, SLA, SAR, SLS, SSR, SDI, SV, SSM 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

Reliability Specifications

MTBF	TBD

Mechanical Specifications

Dimensions	37x 28.5x 17.14mm
Weight	TBD 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 61800-3:2018 (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 1 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 50 ºC.

Power supply voltage	Standby 5 V logic supply consumption	Power stage DC bus consumption switching at 0 current
Power supply voltage	Standby 5 V logic supply consumption	10 kHz	20 kHz	50 kHz	100 kHz
12 V	TBC (logic supply consumption does not depend on bus voltage)	TBC	TBC	TBC	TBC
24 V		TBC	TBC	TBC	TBC
48 V		TBC	TBC	TBC	TBC
60 V		TBC	TBC	TBC	TBC

Thermal model

The Everest S 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 is NOT required to be mounted to any heatsink. In this case its thermal resistance from housing/case to ambient R_th(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.}

Current derating

The following figure show the maximum motor phase current at different case temperatures and operating points. As can be seen lower temperature, bus voltage or PWM frequency allows higher current due to lower heat dissipation. For highest current, Everest S can be configured at 10 kHz PWM frequency, however this may not be suitable for low inductance motors or acoustic noise sensitive applications. 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. For further clarifications and conversion to equivalent RMS values please refer to Disambiguation on current values and naming for Ingenia Drives.

To ensure a proper performance of Everest S NET, the case temperature should be held always below 70 ºC (T_c-max = 70 ºC).

Maximum Allowable continuous current vs Case temperature TBC

Heat dissipation and heatsink calculation

Following figure show the total 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 leads to lower power losses.

Power losses vs Phase current TBC

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 70 ºC (T_c < 70 ºC)
1. For example: TBC
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: TBC
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)
CODE
```
R_{th(h-a)} \leq \frac{T_{c} + P_L \cdot R_{th(c-h)} - T_a}{P_L}
```
1. For example: TBC

Energy efficiency

The following graph shows the net energy efficiency including logic for various operation points assuming 50 ºC case temperature and maximum output power. Very high efficiencies > 99% can be achieved at 10 kHz or 20 kHz PWM frequencies.

Estimated energy efficiency vs Phase current TBC

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