Product Description

Jupiter is a high performance closed loop servo drive controller suitable for DC brushed, voice coils and brushless motors.

Its incredibly compact design includes multiple communication ports, enabling thus a wide choice of interfacing methods. Its extended voltage operating range allows its use in several applications, and the small footprint and the needless of an external heatsink allow the controller to be a valid OEM for critical-size applications.

The Jupiter Digital Servo Drive has been designed with efficiency in mind. It incorporates cutting-edge MOSFET technology as well as optimized control algorithms to provide the perfect trade-off between EMIs and efficiency.

Jupiter Servo Drive is provided with several general purpose inputs and outputs designed for 5V TTL logic but tolerant up to 24V and fully rugged. By using these inputs and outputs it is possible to implement alarm signals, connect digital sensors, activate external devices (LEDs, actuators, solenoids, etc.). Some of the digital and analog inputs can also be used as command / target sources.

Jupiter part numbering

Ordering part number	Status	Image
JUP-40/80-C	PRODUCTION
JUP-30/130-C	OBSOLETE
JUP-20/80-C-P	ON DEMAND
JUP-15/130-C-P	OBSOLETE
JUP-40/80-E	OBSOLETE	-
JUP-30/130-E	OBSOLETE	-
JUP-20/80-E-P	OBSOLETE	-
JUP-15/130-E-P	OBSOLETE	-

Specifications

Electrical and power specifications
Part number →	JUP-20/80-y-P	JUP-40/80-y	JUP-15/130-y-P	JUP-30/130-y
Nominal power supply voltage	10 V_DC to 80 V_DC		10 V_DC to 130 V_{_DC}
Maximum absolute continuous power supply voltage	85 V_DC		135 V_DC
Transient peak voltage	95 V @ 100 ms		145 V @ 100 ms
Logic supply voltage	10 V_DC to 90 V_DC If logic supply is not connected, the board is powered from power supply with a bypass diode		10 V_DC to 90 V_DC Two different supplies are needed for this version. Note that logic supply voltage < power supply voltage. Do not connect them together at voltages > 95 V !
Logic supply power	5 W (considering I/O and feedback supplies)
Internal DC bus capacitance	600 µF		450 µF
Minimum motor inductance	300 µH
Nominal phase continuous current	20 A_RMS	40 A_RMS	15 A_RMS	30 A_RMS
Maximum phase peak current	40 A_RMS (5 s)	80 A_RMS (5 s)	30 A_RMS (5 s)	60 A_RMS (5 s)
Current sense range	± 75 A	± 110 A	± 75 A	± 110 A
Current sense resolution	146.48 mA/count	213.85 mA/count	146.48 mA/count	213.85 mA/count
Shunt braking transistor	Shunt braking transistor on board. 40 A maximum current. Product Description
Cold plate	Yes	Yes	Yes	Yes
Power stage	Same power semiconductors for both references. The cold plate allows better heat dissipation and therefore greater current rating.		Same power semiconductors for both references. Power stage in 130 V part numbers is less efficient than the one in 80 V part number. This explains the reduced current range of high voltage references.
Power connectors	Pluggable terminal 5 mm pitch	Screw terminal 6.35 mm pitch	Pluggable terminal 5 mm pitch	Screw terminal 6.35 mm pitch
Standby power consumption	1.5 W (max)
Efficiency	> 97% at the rated power and current
Motion control specifications
Motion control core	Ingenia E-Core with EMCL2.
Supported motor types	Rotary brushless (trapezoidal and sinusoidal) Linear brushless (trapezoidal and sinusoidal) DC brushed Rotary voice coil Linear voice coil
Power stage PWM frequency	20 kHz (default) 40 kHz (alternative PWM frequency, configurable)
Current sensing	On phases A, B and C using 3 terminal shunt resistors. Accuracy is ± 1% full scale. 10 bit ADC resolution.
Sensors for commutation (brushless motors)	Digital Halls (Trapezoidal) Analog Halls (Sinusoidal / Trapezoidal) Quad. Incremental encoder (Sinusoidal / Trapezoidal) PWM encoder (Sinusoidal / Trapezoidal) Analog potentiometer (Sinusoidal / Trapezoidal) Sin-Cos encoder (Sinusoidal / Trapezoidal) Absolute encoder SSI (Sinusoidal / Trapezoidal) It is recommended to install the SSI only firmware variant if absolute encoder SSI is used for commutation.
Sensors supported for servo loops	Digital Halls Analog Halls Quad. Incremental encoder PWM encoder Analog potentiometer Sin-Cos encoder Absolute encoder DC tachometer
Supported target sources	Network communication – USB Network communication – CANopen Network communication – RS485/RS422 (RS-232 on demand). Custom Protocol. Network communication – EtherCAT Standalone (execution from internal EEPROM memory) Analog input (±10 V or 0 V to 5 V) Step and Direction (Pulse and direction) PWM command Encoder follower / Electronic Gearing
Inputs/outputs and protections
Inputs and outputs	2 x non isolated single ended digital inputs. GPI1, GPI2 (5 V TTL logic, 24 V tolerant). 2 x non isolated high speed differential digital inputs. HS_GPI1 Pulse, HS_GPI2 Direction (5 V logic, 24 V tolerant). 1 x (±10 V) differential analog input (12 bits). AN_IN2. (24 V tolerant). 1 x 0 V... 5 V single ended analog input (12 bits). AN_IN1. (24 V tolerant). 2 x Open open drain digital outputs with a weak pull-up to 5 V. (24 V tolerant and 1 A short-circuit and over-current rugged). 1 x 5 V output supply for powering external circuitry (up to 200 mA).
Protections	User configurable: DC bus over-voltage DC bus under-voltage Drive over-temperature Drive under-temperature Over-current Overload (I²t) Short-circuit protections: Phase to DC bus Phase to phase Mechanical limits for homing functions Hall sequence/combination error Encoder broken wire (for differential quadrature encoders only). ESD protections in all inputs, outputs, feedbacks and communications. EMI protections (noise filters) in all outputs and feedbacks. Inverse polarity supply protection (bidirectional) High power transient voltage suppressor for short braking (600 W peak TVS diode)
Safe Torque Off (STO)	Fully functional STO inputs. 2 x 4.5 V to 24 V tolerant isolated inputs.
Motor brake	Dedicated motor brake output. Up to 130 V and 1 A. PWM operation and integrated freewheeling diode.
Communications
USB	µUSB (2.0) connector. The board can be supplied from USB for configuration purposes but will not power the motor.
Serial	RS485 full-duplex (compatible with RS422), isolated (> 2.5 kV). Includes jumper to enable 120 Ω termination.
CANopen	Available. Isolated (> 2.5 kV). Includes jumper to enable 120 Ω termination. CiA-301, CiA-305 and CiA-402 compliant
EtherCAT	Available.
Environmental and mechanical specifications
Ambient air temperature	-40 ºC to +50 ºC full rated current (operating). If the Jupiter is mounted on a heatsink plate the range can be extended up to 85ºC heatsink temperature. +50 ºC to +100 ºC current derating (operating) -40 ºC to +125 ºC (storage)
Maximum humidity	5% - 85% (non-condensing)
Dimensions	120 mm x 101 mm x 28.1 mm (with plate)	120 mm x 101 mm x 28.1 mm (with plate)	120 mm x 101 mm x 28.1 mm (with plate)	120 mm x 102 mm x 30.1 mm (with plate)
Weight (exc. mating connectors)	258 g	258 g	258 g	263 g
MTBF	On demand	> 450.000 h _{Based on FIDES method for Standard Life Profile at 40 °C average. Other scenarios available on demand.}	On demand	On demand

Hardware revisions

Hardware revision*

Description and changes

1.0.1B

May 2015

First product demo.

1.1.0R

September 2015

First product release. Changes from previous version:

High speed inputs were "high" by default - changed default to "low".
RS485 should be the default communication interface.
Change current sense gain to 20 for low current and to 13.7 for high current variants.
Reduced USB connector protrusion on board edge.
Reduce switching losses, set default PWM frequency 20 kHz.
Improve HW overcurrent noise immunity to prevent unwanted short-detections.
Reduce noise generated by the power stage.
Adjusted STO LED brightness.
Improved USB connection ruggedness and reliability at high motor current.
Improve CAN communication performance at high current / voltage.
Silkscreen improvements for clarity and aesthetics.
Include a protection against overvoltage for the main internal power supply DC/DC.
Manufacturing improvements.
Add new INGENIA Logo.

2.0.0

December 2016

Second Jupiter release.

Improved robustness of USB port.
Manufacturing improvements.
Improved overvoltage protection cutout for the logic supply.
Added termination jumper for RS485.
Reduced switching EMI of the power stage.
Changed power MOSFET footprint to a more standard one with greater clearances.
Increased clearances and creepage of the power stage to allow for higher voltage version of Jupiter (up to 300V).
Increased current capacity of the shunt braking MOSFET for 80V versions.

2.2.0

February 2021

Changed PCB finish to gold plating.

Identifying the hardware revision

Hardware revision is screen printed on the board.

Power and current ratings

To achieve Jupiter current ratings it is necessary to provide sufficient heat dissipation. For the JUP-20/80-x and JUP-15/130-x versions (that do not include an aluminium cooling plate), convection cooling is typically enough to provide nominal current from up to 50ºC ambient air temperature. From 50ºC to 100ºC of ambient temperature a current derating is needed.

For the high current versions JUP-40/80-x and JUP-30/130-x, that are supplied with aluminum plate or cold plate, additional cooling (apart from natural air convection) is necessary to achieve its nominal ratings. This means screwing the plate to a cooling surface, such as a heatsink, cooling plate or most typically a metallic structure of the machine or motor.

Excessive power losses lead to over temperature that will be detected and cause a the drive to turn off. The system temperature is available in E-Core registers and is measured near the power stage. The temperature parameter that can be accessed from USB 2.0, CAN or serial interfaces does not indicate the air temperature. Above 110ºC the Jupiter automatically turns off the power stage and stay in fault state avoiding any damage to the drive. A Fault LED will be activated and cannot be reseted unless temperature decreases.

To determine whether it is necessary to use an additional heatsink, and the current ratings that are achievable, please see the following points.

Drive safety is always ensured by its protections. However, power losses and temperature limit the allowable motor current.

Some parts of the Jupiter exceed 110ºC when operating, especially at high load levels.
Do not touch the Jupiter when operating and wait at least 5 minutes after turn off to allow a safe cool down.

Following figure shows the basic power flow and losses in a servo drive system.

Power losses calculation (heat dissipation)

Operation of the Jupiter causes power losses that should be transferred to the surrounding environment as heat. Heat dissipation depends on various parameters. Principally:

Motor RMS current: positive correlation.
DC bus voltage: positive correlation.
Jupiter product number: 130 V variants JUP-15/130 and JUP-30/130 have different power transistors compared to the 80 V variants. The 130 V variants have greater power losses for a given motor current. Different charts are provided for each variant, see below.

Other less relevant parameters affect also the power loss but are not considered in the graphs:

Air temperature, higher power semiconductor temperatures reduce their efficiency.
Motor speed. Faster motor speeds result in higher overall power loss since the input current is greater. This increases conduction losses on the reverse polarity protection circuitry.

Current (A)	130 V	100 V	80 V	48 V
0	3.65	2.94	2.58	2.16
5	5.05	4.15	3.64	3.01
10	7.23	6.12	5.48	4.63
15	10.18	8.86	8.09	7.03
20	13.89	12.38	11.47	10.19
25	18.38	16.66	15.62	14.12
30	23.64	21.72	20.54	18.83
35	29.66	27.54	26.23	24.30
40	36.46	34.13	32.69	30.54

Current ratings (without cold plate)

In the Jupiter Servo Drive without cold plate, the board itself is the heatsink. Power losses cause the drive to increase its temperature according to:

Power losses have a positive correlation with the motor RMS current. For this reason, when the ambient temperature rises, the output current must be limited to avoid an excessive drive temperature (T_P< 110ºC). The threshold temperature where the current derating should start depends on the DC bus voltage and the Jupiter part number.

The thermal impedance typical value is shown below, however its exact value will vary according to:

Air flow around the drive.
Position (vertical allows natural convection).

Parameter		Value	Units	Notes
Maximum over-temperature fault		110	ºC	Measured on the power stage (not the heatsink) and accessible via register
Thermal resistance from power stage to air	no cold plate	4.6	ºK/W	Variants 20/80, 15/130 (this variants do not include cold plate)
Thermal resistance from power stage to air	with cold plate	2.1	ºK/W	Variants 40/80, 30/130 (this variants include cold plate)
Maximum power dissipation without heatsink	no cold plate	13.3	W	At T_A 50ºC
Maximum power dissipation without heatsink	with cold plate	28.6	W	At T_A 50ºC
Thermal resistance from power stage to heatsink (cold plate version)		1.2	ºK/W	Thermal resistance between cold plate and heatsink not considered
Thermal time constant	no cold plate	600	s	Temperature stabilization is found after ~ 3 τ
Thermal time constant	with cold plate	3700	s	Temperature stabilization is found after ~ 3 τ

Typically, the Jupiter without cold plate is suitable when power dissipation is < 13.3 W. This indicates that the maximum current it can withstand at 50 ºC is 20 A at 80 V bus voltage.

Current derating

The current derating graph is only indicative and is based on thermal tests performed in a climatic room where there was enough room for natural air convection. Each application may reach different ratings depending on the installation, ventilation or housing. Current derating is only a recommendation and is not performed automatically by the drive.

Dynamic application (non-constant current)

The Jupiter has a great thermal inertia that allows storing heat during short power pulses (exceeding nominal current) without overpassing the maximum temperature. This allows achieving high peak current ratings without need of additional heatsink.

For most systems where the cycle time is shorter than 3 τ (thermal time constant) the equivalent current can be calculated as the quadratic mean of the current during the full cycle. The load cycle can be simplified as different constant currents during some times:

Where:

T is the full cycle period.

I₁ is the current during t₁

I₂ is the current during t₂

I_n is the current during t_n

System temperature

Next thermal image shows an example of the heat distribution in a JUP-20/80-y. This test has been performed without cold plate at maximum load and air temperature in a 3 phase application.

The drive is getting hot even at 0 current!

This is normal. Jupiter power stage includes high power MOSFET transistors which have parasitic capacitances. Switching them fast means charging and discharging those capacitors thousands of times per second which results in power losses and temperature increase even at 0 current!

Recommendation: when motor is off, exit motor enable mode which will switch off the power stage.

Improving heat dissipation with a heatsink (Jupiter with cold plate)

In Jupiter variants with cold plate, a heatsink may be needed to extend the current range at high temperatures. As a general rule, if the power dissipation is < 28.6 W, no heatsink is needed. When using high efficiency heatsinks or in enclosed spaces the equation can be simplified as follows.

Assembly recommendations for best heat dissipation

Always allow natural air convection by ensuring ≥ 10 mm air space around the drive.
Place the Jupiter in vertical position.
Use a good thermal interface material to improve the heat dissipation when using heatsink. See Product Description for details.
If housed, use a good thermal conductivity material such as black anodized aluminum. Placing the drive in a small plastic package will definitively reduce its temperature range.
Temperature range can be increased by providing forced cooling with a fan or by placing a thermal gap pad on top of the board. Always ensure electrical isolation between live parts and the heatsink.

Current (A)	80 V	48 V	24 V
0	3.39	2.66	2.35
5	4.67	3.61	3.05
10	6.57	5.18	4.37
15	9.10	7.37	6.31
20	12.24	10.18	8.87
25	16.00	13.61	12.06
30	20.38	17.66	15.86
35	25.38	22.33	20.28
40	31.00	27.62	25.32

Air temperature (ºC)	80 V	48 V	24 V
-25	20	20	20
0	20	20	20
25	20	20	20
50	20	20	20
75	10	13	15
100	1	1	1

Air temperature (ºC)	80 V	48 V	24 V
-25	40	40	40
0	40	40	40
25	40	40	40
50	37	40	40
75	25	28	30
100	5	7	10