Everest XCR - Product manual

Edition 07/30/2021
For the most up to date information visit the online manual.

INGENIA-CAT S.L.
AVILA 124 2-B
08018 BARCELONA
1. Table of Contents
1. Table of Contents 2
2. General Information 5
2.1. Manual revision history........................................................................................................................................ 5
2.2. Disclaimers and limitations of liability ............................................................................................................... 5
2.3. Contact ................................................................................................................................................................. 5
3. Safety Information 6
3.1. For your safety...................................................................................................................................................... 6
3.2. Warnings............................................................................................................................................................... 6
3.3. Precautions .......................................................................................................................................................... 6
3.4. Pour votre sécurité............................................................................................................................................... 6
3.4.1. Avertissements..................................................................................................................................................... 7
3.4.2. Précautions .......................................................................................................................................................... 7
4. Product Description 8
4.1. Part Numbering.................................................................................................................................................... 8
4.2. Specifications ....................................................................................................................................................... 9
4.2.1. Electrical and Power Specifications.................................................................................................................... 9
4.2.2. Motion Control Specifications........................................................................................................................... 10
4.2.3. Inputs/Outputs and Protections ....................................................................................................................... 11
4.2.4. Communication for Operation .......................................................................................................................... 12
4.2.5. Environmental Conditions................................................................................................................................. 12
4.2.6. Reliability Specifications ................................................................................................................................... 13
4.2.7. Mechanical Specifications ................................................................................................................................. 13
4.2.8. Compliance ........................................................................................................................................................ 14
4.3. Product Revisions .............................................................................................................................................. 15
4.4. Thermal and Power Specifications ................................................................................................................... 15
4.4.1. Standby power consumption............................................................................................................................ 15
4.4.2. Thermal model................................................................................................................................................... 16
4.4.3. Current derating................................................................................................................................................. 16
4.4.4. Heat dissipation and heatsink calculation ....................................................................................................... 17
4.4.5. Energy efficiency ................................................................................................................................................ 19
5. EtherCAT specifications 20
6. CANopen Specifications 21
7. Connectors Guide 23
7.1. Connector Overview .......................................................................................................................................... 23
7.2. Supply................................................................................................................................................................. 23
7.3. Motor .................................................................................................................................................................. 24
7.4. Feedback Connector.......................................................................................................................................... 24
7.5. Input / Outputs Connector ................................................................................................................................ 26
7.6. EtherCAT Connectors......................................................................................................................................... 28
7.7. Mating Connectors............................................................................................................................................. 29
7.7.1. Common mating terminals and cables for all signal connectors.................................................................... 30
8. Signalling LEDs 33
8.1. LED Signal Definitions........................................................................................................................................ 33
8.2. EtherCAT protocol (EVE-XCR-E)......................................................................................................................... 34
8.2.1. Start-up Sequence ............................................................................................................................................. 35
8.3. CANopen protocol (EVE-XCR-C)......................................................................................................................... 37
8.3.1. Start-up Sequence ............................................................................................................................................. 38
9. Wiring and Connections 39
9.1. Everest XCR Connection Diagram ..................................................................................................................... 39
9.2. Protective Earth ................................................................................................................................................. 41
9.3. Power Supply and Motor Power........................................................................................................................ 43
9.3.1. Single Power Supply .......................................................................................................................................... 43
9.3.1.1 Power Supply Requirements............................................................................................................................. 43
9.3.2. Dual Power Supply............................................................................................................................................. 44
9.3.2.1 Logic Supply Requirements............................................................................................................................... 44
9.3.3. Power Supply EMI Filter..................................................................................................................................... 44
9.3.4. Shunt Braking Resistor Connection .................................................................................................................. 45
9.3.5. Motor Connections............................................................................................................................................. 46
9.3.5.1 3 Phase Brushless............................................................................................................................................... 46
9.3.5.2 DC Motor ............................................................................................................................................................. 47
9.3.5.3 Motor Choke ....................................................................................................................................................... 47
9.3.6. Power Wiring Recommendations...................................................................................................................... 48
9.3.6.1 Cable Selection .................................................................................................................................................. 48
9.3.6.2 Soldering Power Pins......................................................................................................................................... 50
9.4. Safe Torque Off (STO) ........................................................................................................................................ 52
9.4.1. Safety Function Specifications.......................................................................................................................... 52
9.4.2. Integration Requirements ................................................................................................................................. 53
9.4.3. STO External Diagnostic Test ............................................................................................................................ 55
9.4.4. STO Operation States ........................................................................................................................................ 57
9.4.5. Interface and Connections ................................................................................................................................ 58
9.4.6. STO bypass (needed when no STO functionality is implemented) ................................................................. 59
9.5. Brake and Motor Temperature.......................................................................................................................... 61
9.5.1. Motor electromagnetic / electromechanical brake.......................................................................................... 61
9.5.2. External temperature sensor............................................................................................................................. 62
9.6. Feedbacks........................................................................................................................................................... 64
9.6.1. Digital Halls ........................................................................................................................................................ 64
9.6.2. Absolute Encoder 1 ............................................................................................................................................ 66
9.6.3. Absolute Encoder 2 ............................................................................................................................................ 67
9.6.4. Incremental Encoder ......................................................................................................................................... 68
9.6.5. Feedback wiring recommendations ................................................................................................................. 71
9.7. Inputs and Outputs ............................................................................................................................................ 72
9.7.1. Digital Inputs Interface ...................................................................................................................................... 72
9.7.2. Analog Input Interface ....................................................................................................................................... 74
9.7.3. Digital Outputs Interface ................................................................................................................................... 75
9.8. Communications................................................................................................................................................ 77
9.8.1. EVE-XCR-C (CANopen & Ethernet Interface) ..................................................................................................... 77
9.8.1.1 CAN wiring recommendations .......................................................................................................................... 78
9.8.2. EVE-XCR-E (EtherCAT Interface) ........................................................................................................................ 79
9.8.2.1 Recommended EtherCAT cables and connectors ............................................................................................ 80
9.8.2.2 Ethernet over EtherCAT (EoE) Protocol - Used by Motion Lab 3...................................................................... 82
10. Dimensions 84
11. Installation 85
11.1. Unboxing ............................................................................................................................................................ 85
11.2. Installation Safety Requirements...................................................................................................................... 85
11.3. Mounting the Drive to a Heatsink or Cooling Plate .......................................................................................... 85
11.3.1. Back Installation ................................................................................................................................................ 86
11.3.2. Front Installation ............................................................................................................................................... 87
12. Commissioning 89
12.1. Safety first........................................................................................................................................................... 89
12.2. Decommissioning .............................................................................................................................................. 90
13. EMC and Environmental Testing Details 91
14. Service 92
Everest XCR - Product manual | General Information

2. General Information

2.1. Manual revision history

Revision Release Date Changes PDF

v1 01.04.2019 Initial version

v2 21.02.2020 Added safety-related indications, expanded STO

information, added commissioning guide. Reordered
manual structure.

v3 14.09.2020 Changes according to Safe Torque Off (STO)

certification.

v4 14.12.2020 Changed PN from generic to CANopen / EtherCAT

specifics.
For the most up to date information use the online Product manual.

2.2. Disclaimers and limitations of liability

The information contained within this document contains proprietary information belonging to INGENIA-CAT S.L.
Such information is supplied solely for the purpose of assisting users of the product in its installation.
INGENIA-CAT S.L. rejects all liability for errors or omissions in the information or the product or in other documents
mentioned in this document.
The text and graphics included in this document are for the purpose of illustration and reference only. The
specifications on which they are based are subject to change without notice.
This document may contain technical or other types of inaccuracies. The information contained within this
document is subject to change without notice and should not be construed as a commitment by INGENIA-CAT S.L.
INGENIA-CAT S.L. assumes no responsibility for any errors that may appear in this document.
Some countries do not allow the limitation or exclusion of liability for accidental or consequential damages,
meaning that the limits or exclusions stated above may not be valid in some cases.

2.3. Contact
INGENIA-CAT S.L.
C/ Avila 124, 2-B
08018 Barcelona
Spain
Telephone: +34 932 917 682
E-mail: [email protected]
Web site: www.ingeniamc.com

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Everest XCR - Product manual | Safety Information

3. Safety Information

3.1. For your safety

The instructions set out below must be read carefully prior to the initial commissioning or installation in order
to raise awareness of potential risks and hazards, and to prevent injury to personnel and/or damage to property.
To ensure safety when operating this servo drive, it is mandatory to follow the procedures included in this manual.
The information provided is intended to protect users and their working area when using the device, as well as
other hardware that may be connected to it.

3.2. Warnings
Electric servo drives are dangerous: The following statements should be considered to avoid serious injury to
individuals and/or damage to the equipment:
• Do not touch the power terminals of the device (supply and phases) as they can carry dangerously high
voltages > 50 V.
• Never connect or disconnect the device while the power supply is ON to prevent danger to personnel, the
formation of electric arcs, or unwanted electrical contacts.
• Disconnect the drive from all power sources before proceeding with any wiring change.
• The surface of the device may exceed 100 ºC during operation and may cause severe burns to direct touch.
• After turning OFF and disconnecting all power sources from the equipment, wait at least 10 seconds before
touching any parts of the controller, as it can remain electrically charged or hot.

3.3. Precautions
The following statements should be considered to avoid serious injury to those individuals performing the
procedures and/or damage to the equipment:
• Always comply with the connection conditions and technical specifications. Especially regarding wire cross-
section and grounding.
• Some components become electrically charged during and after operation.
• The power supply connected to this controller should comply with the parameters specified in this manual.
• When connecting this drive to an approved power source, do so through a line that is separate from any
possible dangerous voltages, using the necessary insulation in accordance with safety standards.
• High-performance motion control equipment can move rapidly with very high forces. An unexpected motion
may occur especially during product commissioning. Keep clear of any operational machinery and never
touch them while they are working.
• Do not make any connections to any internal circuitry. Only connections to designated connectors are
allowed.
• All service and maintenance must be performed by qualified personnel.
• Before turning on the drive, check that all safety precautions have been followed, as well as the installation
procedures.

3.4. Pour votre sécurité

Les instructions ci-dessous doivent être lues attentivement avant la mise en service ou l'installation initiale afin de
sensibiliser aux risques et dangers potentiels et de prévenir les blessures aux personnes et/ou les dommages aux biens.

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Everest XCR - Product manual | Safety Information

Pour garantir la sécurité lors de l'utilisation de ce servomoteur, il est obligatoire de suivre les procédures incluses dans
ce manuel. Les informations fournies sont destinées à protéger les utilisateurs et leur zone de travail lors de
l'utilisation de l'appareil, ainsi que les autres matériels qui peuvent y être connectés.

3.4.1. Avertissements
Les servo-entraînements électriques sont dangereux : Les déclarations suivantes doivent être prises en compte pour
éviter des blessures graves aux personnes et/ou des dommages à l'équipement :
• Ne pas toucher les bornes d'alimentation de l'appareil (alimentation et phases) car elles peuvent véhiculer des
tensions dangereusement élevées > 50 V.
• Ne jamais connecter ou déconnecter l'appareil lorsque l'alimentation est en marche afin d'éviter tout danger
pour le personnel, la formation d'arcs électriques ou de contacts électriques indésirables.
• Déconnectez l'appareil de toutes les sources d'alimentation avant de procéder à tout changement de câblage.
• La surface de l'appareil peut dépasser 100 ºC pendant le fonctionnement et peut causer de graves brûlures au
contact direct.
• Après avoir éteint et déconnecté toutes les sources d'alimentation de l'appareil, attendez au moins 10 secondes
avant de toucher une partie quelconque de l'appareil, car il peut rester chargé électriquement ou être chaud.

3.4.2. Précautions
Les déclarations suivantes doivent être prises en compte pour éviter des blessures graves aux personnes qui effectuent
les procédures et/ou des dommages à l'équipement :
• Respectez toujours les conditions de connexion et les spécifications techniques. En particulier en ce qui
concerne la section des fils et la mise à la terre.
• Certains composants se chargent électriquement pendant et après le fonctionnement.
• L'alimentation électrique connectée à ce contrôleur doit être conforme aux paramètres spécifiés dans ce
manuel.
• Lorsque vous connectez ce variateur à une source d'alimentation approuvée, faites-le par une ligne séparée de
toute tension dangereuse éventuelle, en utilisant l'isolation nécessaire conformément aux normes de sécurité.
• Les équipements de control de mouvement à haute performance peuvent se déplacer rapidement avec des
forces très élevées. Un mouvement inattendu peut se produire, notamment lors de la mise en service du
produit. Restez à l'écart de toute machine opérationnelle et ne la touchez jamais pendant qu'elle fonctionne.
• N'effectuez aucune connexion à un circuit interne. Seules les connexions à des connecteurs désignés sont
autorisées.
• Tous les travaux d'entretien et de maintenance doivent être effectués par un personnel qualifié.
• Avant de mettre le le contrôleur en marche, vérifiez que toutes les précautions de sécurité ont été prises, ainsi
que les procédures d'installation.

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Everest XCR - Product manual | Product Description

4. Product Description
Everest XCR is a high 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.
Everest XCR is enabled with EtherCAT and CANopen communications.
Main features:
• Ultra-small footprint
• Up to 80 VDC, 45 A continuous
• Up to 98% efficiency
• Up to 50 kHz current loop, 25 kHz servo loops
• 10 kHz ~ 100 kHz PWM frequency
• 16 bit ADC with VGA for current sensing
• Supports Halls, Quadrature encoder, SSI and 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
• Robot end effectors
• Robotic exoskeletons
• Wearable robots
• AGVs
• UAVs
• Industrial highly integrated servomotors
• Smart motors
• Battery-powered and e-Mobility
• Low inductance motors

4.1. Part Numbering

Product Orderin Commu Environ Status Image Label

g part nication ment
number s

Everest XCR EVE-XCR- EtherCAT Industria PRODUC

TION
E l
Ready-to-use servo drive
featuring EtherCAT EVE-XCR- EtherCAT Extende IN
communications. DESIGN
E-X d

Everest XCR EVE-XCR- CANopen Industria PRODUC

TION
C / l
Ready-to-use servo drive
Ethernet
featuring CANopen and
Ethernet communications. EVE-XCR- CANopen Extende IN
DESIGN
C-X / d
Ethernet
For applications requiring a pluggable drive enabled with EtherCAT or CANopen, please see Everest NET.

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Everest XCR - Product manual | Product Description

For applications not requiring CANopen or EtherCAT, please see Everest CORE.

4.2. Specifications

4.2.1. Electrical and Power Specifications

Minimum power supply voltage 8 VDC

Maximum absolute power 80 VDC (continuous)

supply voltage
85 VDC (peak 100 ms)

Working at 80 V will require a stable power supply able to absorb any possible reinjection coming
back from the driver.

Recommended power supply 12 VDC ~ 72 VDC

voltage
This voltage range ensures a safety margin including power supply tolerances and regulation
during acceleration and braking.

Internal drive DC bus 49 µF

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

Logic power supply voltage 8 to 50 VDC

(optional)
Providing the logic supply is optional, as the drive is supplied from the DC bus (single supply) on its
full operating voltage range. When supplied from logic, an intelligent switch will stop consuming
from the DC bus.

Maximum continuous phase 45 A @ 60 ºC

current
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 below.
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. In order to
get 60 A, case temperature should be kept below 35 ºC.

Maximum continuous switch-off • Without heatsink: 4 A @ 25 ºC

rectified current • With heatsink: 3.5 A @ 85 ºC
Notice that maximum current is dependent on temperature and heatsink attached. At higher
temperature, the lower the current. For more information about heatsink applied, see Thermal and
Power Specifications below.

A continuous use of disabled power stage as rectifier is not recommended for thermal limitations.

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Everest XCR - Product manual | Product Description

Maximum continuous output > 3 kW

power How the output power is calculated in an Ingenia drive.

Efficiency Up to 98.5%

Maximum DC Bus 98.71% @ 10 kHz

voltage utilization
97.42% @ 20 kHz
93.31% @ 50 kHz
86.79% @ 100 kHz
Note 1: these values assume a Sinusoidal commutation and no load connected.

Standby logic supply 2.4 W ~ 3.2 W (for EtherCAT-enabled version)

consumption
See details and conditions in the section below.

4.2.2. Motion Control Specifications

Supported motor types • Rotary brushless (SVPWM and Trapezoidal)

• Rotary brushed (DC)

Power stage PWM frequency 10 kHz, 20 kHz (default), 50 kHz & 100 kHz
(configurable)
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 4 ranges:

(configurable)
• 2.475 mA/count
• 1.352 mA/count
• 0.570 mA/count
• 0.379 mA/count

Current sense ranges Current ranges for the 4 configurable current gains:
(configurable)
• ±81.1 A
• ±44.3 A
• ±18.7 A
• ±12.4 A

Max. Current loop frequency 50 kHz

Max. servo loops frequency 25 kHz @ 50 kHz current loop

(position, velocity &
commutation)

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Everest XCR - Product manual | Product Description

Feedbacks • Digital Halls (Single-ended)

• Quadrature Incremental encoder (RS-422 or Single-ended)
• Absolute Encoder (RS-422 or Single-ended): up to 2 at the same time,
combining any of the following:
• BiSS-C (up to 2 in daisy chain topology)
• 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

4.2.3. Inputs/Outputs and Protections

General purpose Inputs and 4x non-isolated single-ended digital inputs - 5 V logic level & 3.3 V compatible.
outputs 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 - 5 V logic level (continuous short
circuit capable with 470 Ω series resistance) - 8 mA max. current. Can be
configured as:
• General purpose
• Operation enabled event flag
• External shunt braking resistor driving signal
• Health flag
1x ±10 V, 16 bit, fully differential analog input for load cells or torque sensors.
Can be read by the Master to close a torque loop.

Shunt braking resistor output Configurable over any of the digital outputs (see above).
Enabling this function would require an external transistor or power driver.

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 voltage and power consumption.

Safe Torque OFF inputs 2x dedicated, isolated (> 4 GΩ, 1 kV) STO inputs (from 3.6 V to 30 V).
The STO inputs include a current limiter at ~ 5 mA to minimize
losses. Details: Safe Torque Off (STO).

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Everest XCR - Product manual | Product Description

Motor temperature input 1x dedicated, 5 V, 12-bit, single-ended analog input for motor temperature
(1.65 kΩ pull-up to 5 V included).
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 Phase
• Short-circuit Phase to GND
• 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

4.2.4. Communication for Operation

EtherCAT CANopen over EtherCAT (CoE)

(EVE-XCR-E / EVE-XCR-E-X) File over EtherCAT (FoE)

Ethernet over EtherCAT (EoE)

CANopen / Ethernet CiA-301, CiA-303, CiA-305, CiA-306 and CiA-402 (4.0) compliant.

(EVE-XCR-C / EVE-XCR-C-X) 125 kbps to 1 Mbps (default). Non-isolated. Termination resistor not
included.
Note: Ethernet ports can be used to configure the drive.

4.2.5. Environmental Conditions

Part number → Industrial Extended

(EVE-XCR-E / EVE-XCR-C) (EVE-XCR-E-X / EVE-XCR-C-X)

Environmental test methods IEC 60068-2 MIL-STD-810G

Case temperature (Operating) -20 ºC to +85 ºC -40 ºC to +85 ºC

Check the Current Derating section below. Check the Current Derating section below.

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Everest XCR - Product manual | Product Description

Case temperature (Non- -40 ºC to +100 ºC -50 ºC to +100 ºC

Operating)
Thermal Shock (Operating) 25 ºC to 60 ºC in 25 min -40 ºC to 70 ºC within 3 min

Maximum Humidity (Operating) up to 95%, non-condensing at 60 ºC up to 95%, non-condensing at 70 ºC

Maximum Humidity (Non- up to 95%, non-condensing at 85 ºC up to 95%, non-condensing at 85 ºC

Operating)
Altitude (Operating) -400 m to 2000 m

Vibration (Operating) 5 Hz to 500 Hz, 4/5 g 20 Hz to 2000 Hz, 14.6 g

Mechanical Shock (Operating) ±15g Half-sine 11 msec ±20g Half-sine 11 msec

Mechanical Shock (Non- ±15g Half-sine 11 msec ±40g Half-sine 11 msec

Operating)
Pollution degree and Pollution Degree 2 environment according to IEC 61800-5-1: Normally, only
installation environment non-conductive pollution occurs. Occasionally, a temporary conductivity
caused by condensation is to be expected when the Everest XCR is off.

Minimum index of protection of IP3X: Since Everest XCR has accessible live electrical circuits, it should be
the installation installed on closed electrical operating areas with a minimum protection
rating of IP3X and should be accessed by skilled or instructed persons.

4.2.6. Reliability Specifications

MTBF > 360.000 h

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

Isolation between aluminum Basic insulation according to IEC 61800-5-1.

case (PE) and live circuits
> 200 MΩ. Measured between PE (case) and GND_P and +SUP and phases.
Note: The drive includes 2 nF EMC capacitance between the power supply negative (GND_P) and
the enclosure (PE).

4.2.7. Mechanical Specifications

Aluminum case Yes (interface board not covered). Minimum wall thickness > 0.75 mm.

Dimensions 42 mm x 29 mm x 23.2 mm
Dimensions include mating connectors

Weight 38 gr

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Everest XCR - Product manual | Product Description

4.2.8. Compliance

Part number → Industrial Extended

(EVE-XCR-E / EVE-XCR-C) (EVE-XCR-E-X / EVE-XCR-C-X)

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 • IEC 61800-3:2017

(EMC) Standards • IEC 61000-6-2:2016

Product Safety Standard • UL 61800-5-1: Adjustable Speed Electrical Power Drive Systems - Safety
Requirements - Electrical, Thermal and Energy
• IEC/EN 61800-5-1: Adjustable speed electrical power drive systems -
Safety requirements - Electrical, thermal and energy

Functional Safety Standard Safe Torque Off (STO)

• IEC 61800-5-2:2016 : SIL3
• IEC 61508:2010 : SIL3
• EN ISO 13849-1:2015 : PLe Cat. 3

Environmental Test methods IEC 60068-2: MIL-STD-810G:

• IEC 60068-2-1:2007: Test Ad, Cold • Test Method 501.5: High
• IEC 60068-2-2:2007: Test Be, Dry temperature
Heat • Test Method 502.5: Low
• IEC 60068-2-38:2009: Test Z/AD, Temperature
Composite temperature / • Test Method 503.5: Temperature
humidity cyclic Shock
• IEC 60068-2-78:2012: Test Cab, • Test Method 514.6: Vibration
Damp heat, steady state • Test Method 516.6: Shock
• IEC 60068-2-6:2007: Test Fc: • Test Method 507.5: Humidity
Vibration (sinusoidal)
• IEC 60068-2-27:2008: Test Ea:
Shock

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Everest XCR - Product manual | Product Description

4.3. Product Revisions

Revision Date Notes

1 01.06.2018 Initial prototype

2 01.10.2018 Second prototype. Known issues or pending features:

• Ethernet physical layer is affected by commutation noise

3 20.12.2018 Known issues or pending features:

• Noisy phase current measurement (+/- 150 mA)
• CANopen under development
• Trapezoidal commutation under development
• Halls errors under development
• Efficiency & Bus voltage not yet measured empirically
• STO certification pending

4 14.04.2019 First official product release.

5 24.03.2019 • Added CANopen variant

• Added trapezoidal commutation
• Improved current sensing measurement

6 24.05.2019 • Improvements related to industrialization

7 30.01.2020 • Improvements related to industrialization

8 11.09.2020 • STO certified

4.4. Thermal and Power Specifications

4.4.1. Standby power consumption

The following table shows the standby power consumption of the Everest assuming 1 EtherCAT/Ethernet port is
active and communicating at full speed, no feedbacks or I/Os are connected. When the power stage is enabled,
motor current is set to 0 and housing temperature is kept at 50ºC.

Power Typical total standby power consumption with single supply Power
supply savings by
voltage Power stage disabled Power stage enabled and switching at 0 having dual
current supply with
logic at 12 V*
EtherCAT (1 CANopen 10 kHz 20 kHz 50 kHz 100 kHz
port active)

12 V 2.50 W TBD 2.50 W 2.54 W 2.62 W 2.74 W ~0.0 W

24 V 2.60 W 2.66 W 2.72 W 2.91 W 3.24 W ~0.10 W

48 V 2.85 W 3.07 W 3.26 W 3.80 W 4.70 W ~0.35 W

60 V 2.94 W 3.34 W 3.61 W 4.38 W 5.66 W ~0.44 W

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Everest XCR - Product manual | Product Description

Power Typical total standby power consumption with single supply Power
supply savings by
voltage Power stage disabled Power stage enabled and switching at 0 having dual
current supply with
logic at 12 V*
EtherCAT (1 CANopen 10 kHz 20 kHz 50 kHz 100 kHz
port active)

72 V 3.10 W 3.34 W 3.97 W 5.00 W 6.70 W ~0.60 W

*If minimal standby power consumption is desired working at 48 V or higher it is suggested to have dual supply and
provide 12 V or 24 V to the Logic. This reduces losses by allowing the main DC/DC converter to operate at peak
efficiency.

4.4.2. Thermal model

The following diagram depicts the general dissipation model. The Everest is designed to be mounted on a cooling
plate or heatsink to achieve its maximum ratings. Please see Installation for more details. In order to calculate the
heatsink requirements, the power dissipation can be estimated below.
In some low power applications, the Everest 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. For example, with the drive on standby at 2.6 W losses at 25 ºC air
temperature the internal drive temperature can be 56 ºC. When the Everest is not attached to a heatsink factors like
air cooling, power cable thickness will have a significant effect on its temperature. Typically 7 W can be dissipated
without heatsink, refer to the graph below to know which current can be handled.

4.4.3. 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 can be configured at 10 kHz PWM frequency, however this may not be

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Everest XCR - Product manual | Product Description

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 XCR, the case temperature should be held always below 85 ºC (Tc-
max = 85 ºC).

4.4.4. Heat dissipation and heatsink calculation

Following figure show the total power losses at different operating points. This includes logic supply and considers
a single supply scenario. As can be seen, lower PWM frequency and voltage leads to lower power losses.

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Everest XCR - Product manual | Product Description

Please, use the following procedure to determine the required heatsink:

1. Based on the voltage & continuous (averaged) current required by your application and Current derating
graph determine the Case temperature Tc. Remember that Case temperature must be always below 85 ºC (Tc
< 85 ºC)
a. For example: If the application requires 30 A @ 72 V (20 kHz) the Tc will be 85 ºC
2. Based on the voltage & continuous current required by your application and Power losses graph determine
the generated Power Losses PL to be dissipated.
a. For example: If the application requires 30 A @ 72 V (20 kHz) the PL will be 25 W
3. Determine the Thermal impedance of the used thermal sheet Rth(c-h)
a. For example, a thermal sheet TGX-150-150-0.5-0, which has an estimated thermal impedance of Rth(c-
h) = 0.2 K/W
4. Based on the ambient temperature and using the following formula determine the maximum thermal
impedance to air of the required heatsink Rth(h-a)

a. For example: If the application requires 30 A @ 72 V (20 kHz) working at Ta = 25 ºC and we use a
thermal sheet with Rth(c-h) = 0.2 K/W the required thermal impedance of the heatsink will be Rth(h-a) =
2.6 K/W

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Everest XCR - Product manual | Product Description

4.4.5. Energy efficiency

The following graph shows the 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 > 99% can be achieved at 10 kHz or 20 kHz PWM frequencies.

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Everest XCR - Product manual | EtherCAT specifications

5. EtherCAT specifications

Ports available 2

LED Signals Status LED

Link/Act LED

Supported Mailbox CoE, FoE, EoE

SDO info Supported

Segmented SDO Supported

SDO complete Supported

access

Modes of DS402 drive device profile

Operation
• Voltage mode
• Current mode
• Cyclic Synchronous Current Mode (Note 1)
• Current amplifier mode
• Profile Velocity
• Profile Position
• Homing modes
• Interpolated Position Mode
• Cyclic Synchronous Position Mode (Note 1)
• Cyclic Synchronous Velocity Mode (Note 1)

Synchronization SM synchronous
modes
Distributed clock

Process data Configurable

object
Up to 64 bytes in each direction.
Up to 15 different registers can be mapped in each direction.

EtherCAT® is a registered trademark and patented technology, licensed by Beckhoff Automation

GmbH, Germany.
Note 1: Max. Update rate up to 250 μs (4 kHz) to keep a latency of 2-3 cycles
Using PWM ≥ 50 kHz & PDO size 11 bytes

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Everest XCR - Product manual | CANopen Specifications

6. CANopen Specifications

Ports available 1 CAN port

LED Signals CANopen run LED (according to CiA-303)

CANopen error LED (according to CiA-303)

Modes of operation CiA-402 drive device profile

• Voltage mode
• Current mode
• Cyclic synchronous current mode
• Current amplifier mode
• Profile velocity
• Profile position
• Homing modes
• Cyclic synchronous position mode
• Cyclic synchronous velocity mode

Process data object RPDO and TPDO 1 to 4 are available.

(PDO) Up to 32 bytes in each direction (RPDO or TPDO).

Up to 15 different registers can be mapped in each direction (RPDO or TPDO).

Synchronous or asynchronous transmission and reception.

Service data object Supported.

(SDO)

Emergency Supported.
(EMCY)

LSS Device node-ID and baudrate can be configured using this service.

Supported baudrates

1 Mbps

500 kbps

250 kbps

125 kbps

50 kbps

20 kbps

10 kbps

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Everest XCR - Product manual | CANopen Specifications

Fast-scan service is supported.

Life guard protocol Implemented.

Heartbeat Supported heartbeat producer.

Time Stamp Supported time stamp consumer.

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Everest XCR - Product manual | Connectors Guide

7. Connectors Guide

7.1. Connector Overview

7.2. Supply

P1 connector

2.6 mm diameter gold plated solder pads or flying leads option. Pad pitch is 5.08 mm.

Pin Signal Function Warning! Risk of electric shock!

1 POW_SUP Power supply positive

2 GND_P Power supply return

Notes

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Everest XCR - Product manual | Connectors Guide

Warning, power supply and motor terminals can have dangerous voltages in excess to 50 V and cause electric
shock. Never touch them directly while in operation. The end installation must ensure that these terminals are
not accessible.
Recommended section wire is 2.5 mm2 ~ 8.4 mm2 , AWG 13 ~ AWG 8. High-temperature materials are necessary (≥
180 ºC). See Wiring and Connections - Power Supply and Motor Power for more detailed information about the
required wire section. Adapt the cable diameter to the worst-case current needs.
It is recommended to use flexible silicone or Teflon cables with high-temperature ratings ≥ 180 ºC. The diameter
of the cable jacket (insulator) should be less than 5.08 mm to prevent collision between wires.
The cables must always be mechanically secured after soldering.
When using power supply only (no logic supply) it is recommended to connect pins 27 (+LOG_SUP) and 29
(GND_D) of I/O connector J2 together.

7.3. Motor

P2 connector

2.6 mm diameter gold plated solder pads or flying leads option. Pad pitch is 5.08 mm.

Pin Signal Function Warning! Risk of electric shock!

1 PH_A Motor phase A

2 PH_B Motor phase B

3 PH_C Motor phase C

4 PE Protective earth connection, internally connected to standoffs and drive housing.

Notes

Warning, power supply and motor terminals can have dangerous voltages in excess to 50 V and cause electric
shock. Never touch them directly while in operation. The end installation must ensure that these terminals are
not accessible.
Recommended section wire is 2.5 mm2 ~ 8.4 mm2 , AWG 13 ~ AWG 8. High-temperature materials are necessary (≥
180 ºC). See Wiring and Connections - Power Supply and Motor Power for more detailed information about the
required wire section.
The cables must be mechanically secured after soldering.
For long cables, it is essential to use a shielding connected to protective earth at both ends of the cable.

7.4. Feedback Connector

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Everest XCR - Product manual | Connectors Guide

J1 connector

20 pins 2 row Pico-Clasp 1 mm pitch header. Molex 501190-2027

Pin Signal Function

1 +5V_OUT 5 V 200 mA total max. Pins 1, 9, 14 are internally connected.

2 GND_D Digital signal ground

3 ENC_A+/DATA2+ Differential digital incremental encoder: A+ input

Single-ended digital incremental encoder: A input
Absolute encoder 2: Data +

4 ENC_B+ Differential digital incremental encoder: B+ input

Single-ended digital incremental encoder: B input

5 ENC_A-/DATA2- Differential digital incremental encoder: A- input

Single-ended digital incremental encoder: Leave unconnected
Absolute encoder 2: Data -

6 ENC_B- Differential digital incremental encoder: B- input

Single-ended digital incremental encoder: Leave unconnected

7 ENC_Z+/CLK2+ Differential digital incremental encoder: Index+ input

Single-ended digital incremental encoder: Index input
Absolute encoder 2: Clock +

8 ENC_Z-/CLK2- Differential digital incremental encoder: Index- input

Single-ended digital incremental encoder: Leave unconnected
Absolute encoder 2: Clock -

9 +5V_OUT 5 V 200 mA total max. Pins 1, 9, 14 are internally connected.

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Everest XCR - Product manual | Connectors Guide

10 GND_D Digital signal ground

11 HALL_1 Digital hall sensor input 1

12 HALL_2 Digital hall sensor input 2

13 HALL_3 Digital hall sensor input 3

14 +5V_OUT 5 V 200 mA total max. Pins 1, 9, 14 are internally connected.

15 GND_D Digital signal ground

16 DATA1+ Absolute encoder 1 DATA positive signal input

17 CLK1+ Absolute encoder 1 CLK positive signal output

18 DATA1- Absolute encoder 1 DATA negative signal input. For single-ended absolute encoders
with TTL or CMOS levels leave this pin floating and connect the signal to DATA+.

19 CLK1- Absolute encoder 1 CLK negative signal output. For single-ended absolute encoders
with TTL or CMOS levels leave this pin floating and connect the clock to CLK+.

20 PE Protective earth connection, internally connected to standoffs and drive housing.

For systems where the drive is not integrated inside the motor, the PE pin should
typically be connected to the feedback cable shield to protect it against
electromagnetic interferences. To do so it is recommended to use a cable shield
terminator like TE S02-16-R.

7.5. Input / Outputs Connector

J2 connector

30 pins 2 row Pico-Clasp 1 mm pitch header. Molex 501190-3017

Pin Signal Function

1 STO_1 Safe Torque Off input 1 (positive, active from 5 V to 30 V, ISOLATED)

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Everest XCR - Product manual | Connectors Guide

2 PE Protective earth connection, internally connected to standoffs and drive cold plate. Can
be used to connect cable shield. To do so it is recommended to use a cable shield
terminator like TE S02-16-R.

3 STO_RET Safe Torque Off common (optocoupler LEDs cathode, ISOLATED).

4 +5V_OUT +5 V output, can be used for STO circuit.

5 STO_2 Safe Torque Off input 2 (positive, active from 5 V to 36 V, ISOLATED)

6 GND_D Digital signal ground

7 NC Intentionally not connected.

8 +5V_OUT +5 V output, can be used for STO circuit.

9 CAN_H CAN bus line dominant high

10 RESERVED Reserved

11 CAN_L CAN bus line dominant low

12 RESERVED Reserved

13 GND_D Digital signal ground

14 IN1 Digital input 1 (5V levels)

15 IN2 Digital input 2 (5V levels)

16 IN3 Digital input 3 (5V levels)

17 IN4 Digital input 4 (5V levels)

18 OUT1 Digital output 1 (5V levels)

19 OUT2 Digital output 2 (5V levels)

20 OUT3 Digital output 3 (5V levels)

21 OUT4 Digital output 4 (5V levels)

22 AN1+ Analog input 1 positive (±10V range)

23 BRAKE_OUT Brake output (open-drain transistor with PWM capability). A freewheeling diode anode
is connected to this pin.

24 AN1- Analog input 1 negative (±10V range). Connect to GND if a single-ended analog input is
used.

25 BRAKE_DIODE_ The cathode of the freewheeling diode for the brake should be connected to the power
K supply of the brake. The anode of the diode is connected to pin 23 (BRAKE_OUT).

26 GND_D Digital signal ground

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Everest XCR - Product manual | Connectors Guide

27 +LOG_SUP Logic supply positive.

Providing the logic supply is optional as the drive is automatically powered from the DC
bus on its full operating voltage range. Logic supply can be used to keep
communications alive while the power bus is off.
Powering the logic from this input at 12 V or 24 V reduces overall standby losses and
drive self-heating since the main DC/DC converter of the drive has better efficiency at
lower voltages.

28 MOTOR_TEMP Motor temperature sensor input. A 1.65 kΩ pull-up resistor to 5 V is included on the
drive.

29 GND_D Digital signal ground, logic supply negative

30 MOTOR_TEMP_ Motor temperature sensor return (referred to GND_D). Do not use this pin as GND for
RET any other purpose than the negative for motor temperature sensing.

7.6. EtherCAT Connectors

J3 & J4 connectors

5 pins 1 row Pico-Clasp 1 mm pitch header. Molex 501940-0507

Pin Signal Function Suggested Suggested pinout RJ45

pinout M12-4 D-
coded

1 TX_D+ Transmit Data+ line. Colour 1 1

typ.: White - Orange

2 TX_D- Transmit Data- line. Colour 3 2

typ.: Orange

3 RX_D+ Receive Data+ line. Colour 2 3

typ.: White - Green

4 RX_D- Receive Data- line. Colour 4 6

typ.: Green

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Everest XCR - Product manual | Connectors Guide

5 GND_ETH/PE Connection for the EtherCAT cable Housing / Shield Shroud / Shield
shield. This pin is directly
connected to the chassis of the
drive - PE. To do so it is
recommended to use a cable shield
termination like TE S02-16-R.

Note

Both network connectors have the same pinout, thanks to auto-negotiation there is no need to make crossed-
cables. I.e. TX+ of one device can be connected to TX+ of another.
Note that port 0 should be used as EtherCAT IN and port 1 as EtherCAT OUT.

7.7. Mating Connectors

J1 mating connector

Description Molex Pico-Clasp™ 1.0 mm pitch 20 positions dual row receptacle with locking ramp

Image

Part number Molex 501189-2010

J2 mating connector

Description Molex Pico-Clasp™ 1.0 mm pitch 30 positions dual row receptacle with locking ramp

Image

Part number Molex 501189-3010

J3 & J4 mating connectors with latch holder

Description Molex Pico-Clasp™ 1.0 mm pitch 5 positions single row receptacle with Latch Holder.
Provides stronger locking performance and is easy to extract. Use this connector in case the
wiring ensures no strong pull will be performed to the cables, this could cause damage to the
PCB connector.

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Everest XCR - Product manual | Connectors Guide

Image

Part number Molex 501939-0500

J3 & J4 mating connectors with locking ramp

Description Molex Pico-Clasp™ 1.0 mm pitch 5 positions single row receptacle with locking ramp.
Provides less strong locking compared to the latch holder but will avoid breaking the PCB
connector in case of strong pull.

Image

Part number Molex 501330-0500

7.7.1. Common mating terminals and cables for all signal connectors
All signal connectors are of Molex Pico-Clasp™ family. All share the same crimp terminals and jumper wires. Given
the small size of the connectors, crimping must be done with appropriate tools and application guides provided by
Molex. Otherwise, it is strongly recommended to buy pre-crimped jumper wires and connect to your system using
split (or butt) terminals. Spiral wraps are recommended to order and protect the thin wires and make tidy, elegant
wiring.

J1, J2, J3, J4 Crimp terminals

Description Molex Pico-Clasp™ crimp socket 28 AWG ~ 32 AWG selective gold plated

Image

Part number Molex 5011933000

Crimper tool

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Everest XCR - Product manual | Connectors Guide

Description Hand crimper tool 28-32 AWG

Part number Molex 63819-1500

J1, J2, J3, J4 Crimped wires 150 mm

Description Molex Pico-Clasp™ 28 AWG black jumper lead socket to socket 150 mm length. Gold plated.

Image

Part number Molex 079758-1016

J1, J2, J3, J4 Crimped wires 300 mm

Description Molex Pico-Clasp™ 28 AWG black jumper lead socket to socket 300mm length. Gold plated.

Image

Part number Molex 079758-1017

Wiring accessory: Spiral wire wrap

Description Nylon spiral wrap abrasion resistant. Internal diameter:

2.41 mm, 3.18 mm expanded | 5.08 mm, 6.35 mm expanded

Image

Part number Alpha Wire SW20 NA005 | SW21 NA008

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Everest XCR - Product manual | Connectors Guide

Wiring accessory: wire to wire solder sleeve

Description Wire to Wire Solder Sleeve Heat shrinkable. Can be used to reliably connect pre-crimped
wires to a specific sensor, feedback, or other thin wires.

Image

TE B-155-9001

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Everest XCR - Product manual | Signalling LEDs

8. Signalling LEDs

The drive provides information through 6 signalling LEDs:

• EtherCAT / Ethernet 0 link (ECAT 0): LED 6 green
• EtherCAT 1 link (ECAT 1): LED 1 green
• Driver Status: Two LEDs indicate the driver status. Notice that, LED2 & LED3 (one bi-color red/green) are
grouped into a single package.
• EtherCAT / CANopen Status (ECAT Status): Two LEDs indicate the EtherCAT or CANopen status. LED4 &
LED5 (one bi-color red/green) are grouped into a single package.
The meaning of the signaling depends on the product variant.

8.1. LED Signal Definitions

LED signal Description

On The LED is constantly on.

Off The LED is constantly off.

Flickering The LED flickering will have an On and Off sequence with a frequency of approximately 10 Hz: on for
approximately 50 ms and off for approximately 50 ms.

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Everest XCR - Product manual | Signalling LEDs

LED signal Description

Blinking The LED blinking will have an On and Off sequence with a frequency of approximately 2,5 Hz: On for
approximately 200 ms followed by Off for approximately 200 ms.

Single The LED will have a short flash (approximately 200 ms) followed by a long off phase (approximately
flash 1000 ms).

Double The LED will have a sequence of two short flashes (approximately 200 ms), separated by an off
flash phase (approximately 200 ms). The sequence is finished
by a long off phase (approximately 1000 ms).

Triple flash The LED will have a sequence of three short flashes (approximately 200 ms), separated by an off
phase (approximately 200 ms). The sequence is finished
by a long off phase (approximately 1000 ms).

8.2. EtherCAT protocol (EVE-XCR-E)

Identified Group Name Color Meaning

LED2 Driver Status RESERVED Green Reserved

LED3 FAULT Red LED is on when an error event has occurred and the
drive is in the Fault state (CiA-402). In any other state
the LED will remain off.

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Everest XCR - Product manual | Signalling LEDs

Identified Group Name Color Meaning

LED4 EtherCAT / RUN LED Green LED signal EtherCAT slave

CANopen Status status
One Bi-color LED
Off INIT
provides
information about Flickering BOOTSTRAP
the EtherCAT
communication Blinking PRE-OPERATIONAL
status, according
to EtherCAT Single Flash SAFE-
specification. OPERATIONAL

On OPERATIONAL

LED5 ERROR LED Red LED signal EtherCAT slave

status

Off No error

Blinking Invalid
configuration

Single flash Local error

Double flash Watchdog timeout

LED1 & Ethernet Link Status LINK0 & Green LED signal Slave State
LED6 LINK1
Off Port closed

On-Off alternating Port opened (activity on

port)

On Port opened (no activity on

port)

8.2.1. Start-up Sequence

After power on the drive LEDs sequence is the next one:

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Everest XCR - Product manual | Signalling LEDs

EtherCAT 0 EtherCAT 1 Link Drive Ether

Link Status CAT
Status

Standard Standard behaviour • Switch • Sw

behaviour (defined above) off if itc
(defined initializ h
above) ation is off
OK (
• RED if th
an e
error sla
has ve
been wil
detecte l
d sta
during y
initializ in
ation Ini
t
St
at
e
aft
er
po
we
r-
up
un
til
an
Et
he
rC
AT
m
ast
er
for
ce
s it
to
tra
nsi
tio
n
to
an
ot
he
r
sta
te)

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Everest XCR - Product manual | Signalling LEDs

8.3. CANopen protocol (EVE-XCR-C)

Identified Group Name Color Meaning

LED2 Driver Status RESERVED Green Reserved.

LED3 FAULT Red LED is on when an err

state the LED will rem

LED4 EtherCAT / CANopen Status RUN LED Green RUN LED indicates the
signalling. Next table
One Bi-color LED provides
information about the CANopen LED signal
communication status, according
to CiA 303-3 recommendations. Off

Blinking

Single flash

On

LED5 ERROR LED Red ERROR LED indicates

(sync, guard or heartb

LED signal

Off

Single flash

Double flash

Triple flash

On

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Everest XCR - Product manual | Signalling LEDs

Identified Group Name Color Meaning

LED6 Ethernet Link Status LINK0 Green LINK0 indicates the st

connected.

LED signal

Off

On-Off alternating

On

LED1 Ethernet Link Status LINK1 Green LINK1 indicates the st

connected.

LED signal

Off

On-Off alternating

On

8.3.1. Start-up Sequence

After power on the drive LEDs sequence is the next one:

Ethernet Ethernet Drive Status CANopen Status

0 Link 1 Link

Standard Switched • Switch off if initialization is OK 1. Switch off during initialization

behaviour off • RED if an error has been detected 2. PRE-OPERATIONAL signalling when
(defined (unused) during initialization initialization is done
above)

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Everest XCR - Product manual | Wiring and Connections

9. Wiring and Connections

9.1. Everest XCR Connection Diagram

Detailed wiring diagram for each module:

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Everest XCR - Product manual | Wiring and Connections

• Protective Earth
• Power Supply and Motor Power
• Safe Torque Off (STO)
• Brake and Motor Temperature
• Feedbacks
• Inputs and Outputs
• Communications

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Everest XCR - Product manual | Wiring and Connections

9.2. Protective Earth

Connection of Everest XCR Servo Drive and motor housing to Protective Earth (PE) is required for safety and
Electromagnetic Compatibility (EMC) reasons. Electrical faults can electrically charge the housing of the motor or
cabinet, increasing the risk of electrical shocks. A proper connection to PE derives the charge to Earth, activating
the installation safety systems (differential protections) and protecting the users. Please see this technical note to
understand why this is important: Electromagnetic Interference Issues With Servo Drive Systems.

 Reducing EMI susceptibility

Connecting the drive PE terminals and cold plate screws to your system Earth and to the motor
housing solves many noise and EMC problems. The enclosure of the drive and PE terminals are
decoupled to power ground (supply negative, GND_P) through two 1 nF capacitors. This creates a low
impedance preferential path for coupled common-mode noises that otherwise would be coupled to
sensitive electronics like the encoders.
Everest XCR Servo Drive provides the following Protective Earth connection points, which are internally connected
and decoupled to power ground:
• PE terminal in the motor connector P2 pin 4.
• Driver housing
• Threaded M2.5 assembly holes
• Pin 20 of feedback connector J1
• Pin 2 of Inputs/outputs connector J2
The protective earthing conductor must have an area equal or superior to the power cables and always no less than
2.5 mm². Respect the green-yellow color code for PE. Connections must always be done using non-corrosive
bonding points. A diagram of the recommended Protective Earth wiring is shown following.

 Earth plane reference

While some systems will not have a "real Earth" connection, use your machine chassis, the metallic
structure of the device or a good grounding conductive plane as your reference earth.
Some considerations for a proper earth connection are detailed next:
• Connecting PE to GND_P near the power supply can provide an advantage for EMC and electrical safety by
keeping a low voltage. Dis can only be done when the drive is powered with an isolated power supply or
battery. This action, however sometimes can create unwanted effects such as added common mode noise or
electrical safety issues depending on the whole installation layout.
• Switching noise by the phases is coupled to earth through the housing of the motor. This high-frequency
noise creates a common mode current loop between drive and motor. Although the motor housing is
connected to earth through the system chassis, its electrical connection may have a relatively high

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Everest XCR - Product manual | Wiring and Connections

impedance and present a big loop. For this reason, is essential to reduce the common-mode current return
path impedance and its loop area.
• To reduce the return path impedance the motor frame should be directly wired to drive PE
terminals or enclosure.
• PE wiring should be as close as possible to motor power cables.
• In order to avoid ground loops, it is a good practice to have a central earth connection point (or bus) for all
the electronics of the same bench. If multiple drives are supplied from the same power supply or supply PE
to drive PE connection is not practical (not enough connection terminals) connect all PE terminals in a
central connection bus.
• Whenever possible, mount the drive on a metallic conductive surface connected to earth like the
heatsink. Use good quality screws with spring washers that will not oxidize or lose conductivity during the
expected lifetime.
• For achieving low impedance connections, use wires that are short, thick, multi-strand. PE wire section
should be the same as power supply cables. Always minimize PE connection length.
• For best EMC performance Everest XCR should be mounted physically close to the actuator or inside the
enclosure.

In case the Everest XCR is not integrated on the motor or actuator, use shielded cables with isolating
jacket, connecting the shield to PE with a cable clamp to the PE plane. The priorities are:
1. Shield the motor cables, which are the main high-frequency noise source.
2. Shield the feedback signals, which are sensitive signals usually coming from the motor housing. Connect the
shield to one end (drive) to avoid ground loops.
3. Shield I/O signals and communication cables.

The clamp has to be selected according to the shielded cable diameter, ensuring good support and
connection between the cable shield and the clamp. The clamp also offers a mechanical securing of the soldered
wires. Following examples are only suggested for a conceptual purpose:

Description Part number

Cable Clamp, P-Type Silver Fastener 0.187" (4.75 mm) Keystone Electronics 8100

Cable Clamp, Saddle Type Stainless Steel 20 mm RS Pro 471-1300

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Everest XCR - Product manual | Wiring and Connections

9.3. Power Supply and Motor Power

9.3.1. Single Power Supply

The Everest XCR can be powered from a single power supply as shown in the following figure. Since the power
cables are soldered to the board it is essential to provide mechanical fastening to avoid ripping them off.

9.3.1.1 Power Supply Requirements

The choice of a power supply for Everest is mainly determined by the following criteria:
• The power supply must be isolated with a minimum Overvoltage Category of II (Typ ≥ 2500 V isolation). This
does not apply if the Everest is battery-powered and isolated from the electrical grid.
• The voltage should be targeted for the motor and its speed requirements. See How to dimension a power
supply for an Ingenia drive. Ensure it is always within the operating ranges of the Everest specifications. It is
strongly recommended to leave a margin between the nominal voltage and the maximum absolute of the
drive (80 V) to allow some regenerative braking. Working near the limits can cause faults. Note that for
safety-critical applications a ≤50 V power supply has the advantage that all circuits can be considered Safe
Extra Low Voltage (SELV) which simplifies installation protection against electric shock.
• The current should be the one able to provide the electrical power of the application. The conservative
approach is to choose the power supply rated current as your maximum motor current. This conservative
approach, however, can lead to oversized power supplies since the DC current is typically lower than the
motor current. See Understanding why the motor phase current is different than the power supply current.
The power supply current should be determined according to the maximum power point where the product
speed · torque is maximum. See more details here How to dimension a power supply for an Ingenia drive.
Also, consider the simultaneity factor when having various drives in parallel.
• Servo drive systems tend to have large current peaks and regenerate. This can cause overvoltage faults,
under-voltage, or even unstabilize the control loop of the power supply. It is preferred to choose robust
power supplies with current limiting behavior, overvoltage margin from the nominal, and non-latching fault
to prevent shut-down in case of a transient regeneration or overload.
The transformer and rectifier type supplies are simple and reliable. Switch Mode Power Supplies (SMPS) provide
good efficiency, low harmonic distortion. Always choose good quality, EMC compliant power supplies.
To determine if the system may have regenerative braking issues check: Dimensioning a Shunt Resistor for
Regenerative Braking. See shunt wiring next.

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9.3.2. Dual Power Supply

For systems where it is necessary to keep communications alive, or keeping position information with incremental
sensors while power is off, the drive can be powered from a logic supply input on the I/O connector. Choose the
main power supply as indicated above. There are no special power supply sequencing requirements.
Powering the logic supply at a lower voltage than the power will reduce the standby loss by increasing the
efficiency of the main DC/DC converter.

Note GND_P and GND_D are internally connected in the drive. It is not needed or recommended to duplicate this
connection externally.

9.3.2.1 Logic Supply Requirements

The logic supply should meet the following criteria:
• The logic supply must be isolated with a minimum Overvoltage Category of II (Typ ≥ 2500 V isolation) or
battery powered.
• The recommended voltage is range is 8 V to 26.4 V (SELV/PELV). The maximum voltage is 50 V. Lower
voltages reduce standby losses by making the DC/DC converter on a low loss point.
• The power of the logic should be at least 5 W.

9.3.3. Power Supply EMI Filter

In applications that require mitigating conducted and radiated electromagnetic emissions an input EMI filter is
necessary. Depending on the application, motor construction, PWM frequency and specific EMC requirements the
filter should be chosen. It is possible to share a single EMI filter for various servo drives given that the power ratings
are observed.
The connections are shown next, a good PE plane is strongly recommended. Please follow grounding
recommendations. Note that the Everest XCR includes 2 x 1 nF 2 kV capacitors between GND_P and PE (the drive
aluminum enclosure).

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For the lowest EMC, it is recommended to use a 2 stage filter like TE Connectivity 30EMC6.

9.3.4. Shunt Braking Resistor Connection

A shunt braking resistor can be activated from Everest XCR by using an external transistor. Any of the 4 general-
purpose outputs can be configured to turn-on when the dc bus exceeds a certain threshold: Shunt braking resistor.
The digital outputs provide a 0 ~ 5 V output with a 470 Ω in series resistance inside the drive. This will typically be
enough to turn on - off a power MOSFET transistor that can withstand at least 30 A braking current, like
IRLR3110ZTRPBF. Ensure that a transient voltage Zener like MM3Z6V2T1G is placed in parallel with the gate of the
transistor and a pull-down 10 kΩ resistor ensures a safe off state of the transistor in case of disconnection. If the
shunt braking resistor or circuit is inductive a re-circulation diode like V8P10-M3/86A is needed.

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 Shunt resistor calculation tool

Additional information on shunt braking resistor sizing and a calculation tool can be found here.

9.3.5. Motor Connections

9.3.5.1 3 Phase Brushless

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9.3.5.2 DC Motor

9.3.5.3 Motor Choke

In applications where electromagnetic compatibility is needed, the use of an external common mode choke is
necessary for the motor phases. Please see this document to understand why this is relevant Electromagnetic
Interference Issues With Servo Drive Systems.
Note that on applications where the drive is mounted inside the motor or actuator the choke and cable shields may
be removed. While the actuator enclosure will provide shielding against radiated EMC, the need or not of common
mode choke will depend on motor construction, especially capacitive coupling between windings and housing as
well as EMC requirements.
Some choke wiring recommendations are:
• Place the choke as close to the drive as possible. The objective is to cancel the noise close to its source (the
switching power stage).
• Make sure the chosen choke does not saturate at the maximum operating phase current. If this happens,
the choke temperature would increase rapidly.
• Make only 1 or 2 turns of the motor cables. More than 2 reduces its effectiveness as the capacitive coupling
between wires bypasses the choke effect.
• PE conductor should never pass through the choke.
• Avoid contact of the toroid core with a grounding point.
The next table shows recommended chokes for the Everest XCR.

Type Manufacturer Part number Remarks

Wide frequency oval ferrite cable Laird Technology 28B0773-050 Single turn. Preferred option.
core

Wide frequency cylindrical Laird Technology 28B0999-000 Double turn option. Higher
ferrite cable core attenuation.
In case of doing 2 turns, space the phases 120º apart. Start each phase wire in the same rotating direction, wrapping
all phases clockwise or anticlockwise. This will add the common-mode flux and increase its impedance.

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9.3.6. Power Wiring Recommendations

9.3.6.1 Cable Selection

Power cables for the Everest XCR must be designed according to the averaged RMS current of the application.
Please follow the next recommendations:
• The cable insulator must tolerate ≥ 180 ºC. Silicone or Teflon insulation are suggested. PVC or thermoplastic
cables are not recommended due to their low operating temperature.
• Use flexible cables to prevent mechanical stress to the solder joints.
• For an easy and comfortable integration, the diameter of the conductor should not exceed 2.4 mm, the
solder pad has a 2.6 mm in diameter.
The following are recommended wire gauges. The minimum gauge is based on a self-heating to 180 ºC of a Silicone
or Teflon cable. Note that this may not be acceptable in applications that cannot tolerate this cable temperature.

Operating Conductor Minimum Cross- Minimum Conductor Recommended Recommen

RMS current diameter Sectional Area wire diameter Cross-Sectional ded wire
(mm) (CSA mm²) gauge (mm) Area (CSA mm²) gauge

45 ARMS 2.6 mm 5.3 mm² 10 AWG 3.3 mm 8.4 mm² 8 AWG

30 ARMS 1.3 mm 1.3 mm² 16 AWG 2.1 mm 3.3 mm² 12 AWG

18 ARMS 1.0 mm 0.8 mm² 18 AWG 1.3 mm 1.3 mm² 16 AWG

12 ARMS 0.8 mm 0.5 mm² 20 AWG 1.0 mm 0.8 mm² 18 AWG

Protective earth wire must always have an area equal or superior to the power cables and always no less than 2.5
mm² (13 AWG).
For best electromagnetic compatibility (EMC) the power supply cable inductance should be minimized. Wiring
recommendations:
• Minimize the area between positive and negative supply voltages. The best practice is by twisting them as
can be seen in the wiring diagrams.
• Increase cross-section of the cables (Max recommended is 8.4 mm² CSA, 3.3 mm diameter).
• Reduce the distance between the power supply and drive.

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 Using 10 AWG ~ 8 AWG wires recommendations

To reach maximum current capability, 10 - 8 AWG wires must be used. In that case, the conductor diameter
will be wider than the solder pad. 2 soldering options are recommended for best thermal and mechanical
performance:
Option 1: Vertical entry

Option 2: Lateral entry

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9.3.6.2 Soldering Power Pins

The power wires of the Everest-XCR should be soldered appropriately to ensure a reliable and low resistance
connection. The solder holes are 2.6 mm in diameter. ensure the cable diameter does not exceed this. Always use
RoHS compliant solder tin.
Please follow these steps:
1. Cut and peel the power cables in advance with the appropriate length. The peeled length can be around 3
mm. Do not cut them after soldering as it will cause permanent tensions.
2. Pre-tin the stranded wires by applying the solder with flux to the wire using a heated soldering iron tip. This
can be done with a solder bath method. Ensure a minimum solder time of 2 ~ 3 seconds.
a. Solder shall penetrate the inner strands of stranded wire.
b. Solder shall not obscure the wire contour at the termination end of the insulation.
c. Anti‐wicking tools are strongly recommended in order to protect the cable insulation.
3. Apply flux to the pads with a brush to ensure surfaces are clean and there is sufficient flux.
4. Pre-tin the solder pads of the Everest-XCR using Rohs-free solder. Take precautions with the solder balls not
to create any short. Do not fill the hole.
5. Position the wire inside the hole with the desired cable exit direction and solder them with a clean solder tip.
Additional solder may be needed.
6. Clean the flux residues with appropriate solvents like isopropyl alcohol (IPA).
7. Do not cut the wires after soldering as it may cause permanent stress and long term reliability issues.

Further tips on best practices can be found in ESA standard ECSS-Q-ST-70-08C.

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 Danger!
Power and motor pins have live voltages in excess of 50 V which can cause electric shock! It is essential to
perform connection or commissioning procedures without power.
Les broches de l'alimentation et du moteur ont une tension supérieure à 50 V qui peut provoquer un choc
électrique ! Il est essentiel d'effectuer les procédures de connexion ou de mise en service sans alimentation
électrique.

 Motor and power cables must always be mechanically secured

To prevent damage to the solder joint and ensure a long-term reliable connection it is mandatory to
mechanically secure the cables after soldering.
If you use shielded cables, the EMC clamp can provide this mechanical support.
Mechanical clamps must not have sharp edges that could damage the conductor jacket.

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9.4. Safe Torque Off (STO)

The STO is a safety system that prevents motor torque in an emergency event while Everest XCR remains connected
to the power supply. When STO is activated, the power stage is disabled by hardware and the drive power
transistors are disconnected, no matter what control or firmware does. The motor shaft will slow down until it stops
under inertia and frictional forces. Although not common, in the event of a failure of the power stage during an STO
situation, the maximum expected motor movement with torque can be up to 180º electrical degrees. The system
must be designed to avoid any hazard in this situation.
If the STO inputs are not energized or the wires are not connected, the transistors of the power stage are turned
off and an STO fault is notified. In order to activate the power stage, and therefore allow the motor operation, the
two STO inputs must be energized (high level, typically 5V to 24V). STO inputs should not be confused with a digital
input configured as enable input, because enable input is firmware controlled and does not guarantee intrinsic
safety as it can be reconfigured by a user.
In order to ensure redundancy and safety, the Everest XCR includes 2 separate STO inputs that must be activated or
deactivated simultaneously (maximum 1.4 s mismatch). A difference of state between STO1 and STO2 inputs will be
interpreted as an abnormal situation after 1.4 s the drive will be latched in a fault state. A power supply reset is
necessary to remove this STO abnormal error.

9.4.1. Safety Function Specifications

Safety Function Value

Specification
Standards • IEC 61800-5-2:2016
compliance • IEC 61508:2010
• EN ISO 13849-1:2015

Safety function Safe Torque Off (STO)

Safety relevant Safety integrity level SIL3

parameters
according to PFH 1.31 x 10-9 1/h
IEC 61508:2010
SFF > 99 % (High)

Safety relevant PL e
parameters
according to EN Category 3
ISO
13849-1:2015 DC 99% High

MTTFd ≥ 100 years (High)

Safety Function t < 6.3 ms

Reaction Time
The Safety Function Reaction time is measured as the time since one of the STO inputs (STO1
or STO2) goes below 1.1 V and the STO function actuates (power transistors deactivated).

Fault Reaction t< 33 ms

Time
The worst-case fault reaction time is on the event of a 5V DC/DC supply overvoltage.

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Safety Function Value

Specification
High-demand The EUC (Equipment Under Control) is considered as a high-demand or continuous demand
mode mode system.

Mission Time The mission time of the EUC is of 20 years.

Diagnostic In order to guarantee the correct operation of the safety functions, the user has to check the
Time Interval STO function regularly, performing an STO External Diagnostic Test (see further information
below).
The diagnostic test interval is defined as a minimum of 1 activation per 3 months.

9.4.2. Integration Requirements

Integration Value
Requirement
STO Interface Input pins STO1, STO2 and STO_RET
electrical
characteristics Number of 2
independent
channels

Type of Inputs Isolated inputs (STO1, STO2) with common reference (STO_RET).
ESD protected with input current limit to reduce power. See
schematics next.

Maximum input LOW 1.1 V or open (below this value the STO is ACTIVE, no torque can be
level (VIL) applied to the motor)

Minimum Input HIGH 3.6 V (above this value the STO input is inactive, torque can be
level (VIH) applied to the motor)

Maximum absolute 24 V SELV (maximum OVP 26.4V (110%); maximum failure voltage 60
ratings V)

Input current 5 mA typ / 10 mA max

Isolation Level > 4 GΩ, 500 Vrms, 1000 VDC

ESD capability IEC 61000-4-2 (ESD) ± 15 kV (air), ± 8 kV (contact), IEC 61000-4-4 (EFT)
40 A (5/50 ns), IEC 61000-4-5 (Surge) IPPM > 8 A

STO Interface STO activation time t < 6.3 ms

timing (Safety function
characteristics Reaction Time)

STO deactivation time t < 2ms

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Minimum, non- t < 400 µs

detected STO short
The Safety controller can transmit short pulses to STOx inputs for
pulse
diagnostics purposes. These pulses will be ignored by the safety
circuit and will not stop the power stage but can be read from
firmware for system diagnostics, see: Drive protections Register
0x51A.

Abnormal STO ≤ 6.3 ms (Activation STO)

diagnostic time

Abnormal STO 1.4 s ~ 3.4 s (Latching state, permanent activation of STO until power
latching time reset)

Power supply 5 V over-voltage 33 ms, 5 V under-voltage 33 ms

diagnostic time
3.3 V over-voltage 200 ns, 3.3 V under-voltage 8 ms

Logic Supply Logic supply must be provided to the system

Voltage Range 1 24 V SELV (range from 8V to 26.4V; maximum failure voltage 60 V)

Power Supply 48 V SELV (range from 8V to 60V; maximum failure voltage 60 V)

Voltage Range 1

Motor Type STO safety function is only considered when the drive is controlling three-phase permanent
magnet synchronous rotating motors. STO does not apply to DC brush motors.

Uncontrolled
Motor
Movement  Uncontrolled Motor Movement
In the event of a failure in the power stage, the motor shaft may rotate up to 180º
electrical degrees. It is responsibility of the customer to prevent any hazards related
ot this unexpected motor movement.

Environmental Pollution degree Pollution degree 2 with an IP54 enclosure installation.

Conditions for
STO Over- II
voltage category

Altitude < 2000 m above sea level.

Temperature Operating -20ºC to 50 ºC

range for STO 2 Temperature

Storage Temperature -40ºC to 100ºC

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Diagnostics Internal power supply voltage monitors.

Differences between STO1 and STO2 cause abnormal fault. After 1.4 s a hardware latching
condition disables the drive until power cycling.
Status of STO1, STO2, STO_REPORT, ABNORMAL_FAULT, and SUPPLY_FAULT can be read
from the communications.

 STO firmware notification

A STO stop is notified to the motion controller and creates a fault that can be read
externally from any communication interface, however, STO operation is totally
independent and decoupled from control or firmware.

EMC To fulfill the EMC requirements it is necessary the use of the following elements is required:
Input EMI filter. Recommended: TE Connectivity 30EMC6 or equivalent.
Motor phases ferrite cable core. Recommended : 28B0773-050 or equivalent.
Properly grounded aluminium enclosure. See grounding recommendations for further
information.

1: Although the drive can operate in a wider range of voltages as can be seen in Product Description, the system
cannot be considered safe outside this range.
2: The drive can operate outside this temperature range as indicated in the Product Description, however, the
system cannot be considered safe as the system reliability and safety margins would not meet the standards.

9.4.3. STO External Diagnostic Test

The operation of the STO diagnostic circuits must be verified at least once per 3 months. The following procedure
details a method to verify the STO diagnostic circuits and the external wiring. If the procedure results are not
the expected ones, safety could be violated and the system cannot be used. Note that it is responsibility of the
customer to prevent any hazards related to motor movement during this proof test.
The procedure requires the Everest XCR to be connected to a brushless motor.

Procedure Action Expected Result

Step

1 Power on the Everest XCR with STO1 = low, -

STO2 = low.

2 Try to perform a "Motor Enable" (using Power stage is not enabled. Check it by software
Motionlab 3 or network commands). (a fault should appear) or by hardware (checking
the Motor phases voltage with a multimeter).
CAUTION: If power stage can be enabled, a
problem on the diagnostics system or in teh
wiring could exist.

3 Provide STO1 = high, STO2 = low. Remain in -

this state more than 3.4 seconds.

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Procedure Action Expected Result

Step

4 Try to perform a "Motor Enable" (using Power stage is not enabled. Check it by software
Motionlab 3 or network commands). (a fault should appear) or by hardware (checking
the Motor phases voltage with a multimeter).
CAUTION: If power stage can be enabled, a
problem on the diagnostics system or in teh
wiring could exist.

5 Provide STO1 = high, STO2 = high. -

6 Try to perform a "Motor Enable" (using Power stage is not enabled. Check it by software
Motionlab 3 or network commands). (a fault should appear) or by hardware (checking
the Motor phases voltage with a multimeter).
CAUTION: If power stage can be enabled, a
problem on the diagnostics system or in teh
wiring could exist.

7 Shut-down Everest XCR supply and remain in -

this state for more than 10 seconds.

8 Power on the Everest XCR with STO1= low, -

STO2 = high. Remain in this state more than
3.4 seconds.

9 Try to perform a "Motor Enable" (using Power stage is not enabled. Check it by software
Motionlab 3 or network commands). (a fault should appear) or by hardware (checking
the Motor phases voltage with a multimeter).
CAUTION: If power stage can be enabled, a
problem on the diagnostics system or in teh
wiring could exist.

10 Provide STO1 = high, STO2 = high. -

11 Try to perform a "Motor Enable" (using Power stage is not enabled. Check it by software
Motionlab 3 or network commands). (a fault should appear) or by hardware (checking
the Motor phases voltage with a multimeter).
CAUTION: If power stage can be enabled, a
problem on the diagnostics system or in teh
wiring could exist.

12 Shut-down Everest XCR supply and remain in -

this state for more than 10 seconds.

13 Power on the Everest XCR with STO1= high, -

STO2 = high.

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Procedure Action Expected Result

Step

14 Try to perform a "Motor Enable" (using Power stage can be enabled, allowing motor
Motionlab 3 or network commands). rotation. Check it by software (system should
enter in motor enable state) or by hardware
(checking the Motor phases voltage with a
multimeter).
If power stage cannot be enabled it could be
caused by other faults not related with STO
(over-voltage, under-voltage, etc.)

9.4.4. STO Operation States

The truth table of the STO inputs is shown next indicating the different states of the system:

Mode State STO1 STO2 Power STO STO State description

status / status / stage report abnorm
level level status bit al fault
status

Norm STO 0 < 1.1 V 0 < 1.1 OFF 0 0 The system logic is powered,
al Enabled V but the STO function is
opera (No torque activated. Therefore, no torque
tion to the can be applied to the motor.
motor)
STO trip is reported to the MCU
and to the safety circuitry. This
is intended safe torque off with
dual-channel operation.

Torque 1 > 3.6 V 1 > 3.6 Can be 1 0 The STO function is

enabled V enable deactivated, and torque can be
d provided to the motor. The
(STO
motor can run under firmware
inactive)
control. This is the normal
operation state.

Abnor 0 < 1.1 V 1 > 3.6 OFF 0 1 If any issue is detected on the
mal Abnormal V dual-channel STO function
opera STO (their state is different for a long
tion 1 > 3.6 V 0 < 1.1 OFF 0 1 period of time), an abnormal
V fault is active can be reported.
This state avoids the
application of torque to the
motor. If this persists for > 1.4 s
~ 3.4 s the STO will lock in
FAULT state. To reset this fault a
power cycle is needed.

Abnormal x - x - OFF NOR 1 After >1.4 s ~ 3.4 s of abnormal

STO (STO1, STO active, the driver will stay
Latched STO2) in this state until the power
supply cycle.

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Mode State STO1 STO2 Power STO STO State description

status / status / stage report abnorm
level level status bit al fault
status

Abnormal x x x x OFF x x If a voltage out of the limits is

Supply detected on the internal logic
voltages, the system is
conducted to a safe state,
similar to power-off. Only if the
safe logic voltages are
recovered (usually after
reparation or restart), the
system can return to any other
state.

9.4.5. Interface and Connections

The wiring of the recommended STO circuit is shown next.

 STO1 and STO2 signals should always change at the same time with a maximum of 1.4 s mismatch. This is
necessary to have 2 channel redundancy and allow diagnostics, as a mismatch will cause an abnormal
fault.
In order to ensure this, do not add big capacitors (> 100 µF) in parallel to the STO inputs as this may cause
faults during activation or deactivation of the STO.
Les signaux STO1 et STO2 doivent toujours changer en même temps avec un décalage maximum de 1,4 s.
Ceci est nécessaire pour avoir une redondance à 2 canaux et permettre le diagnostic, car une discordance
provoquera une anomalie de fonctionnement.
Afin de garantir cela, n'ajoutez pas de gros condensateurs (> 100 µF) en parallèle aux entrées STO, car cela
pourrait provoquer des défauts lors de l'activation ou de la désactivation du STO.

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Wiring for a solution with panic button / emergency stop. When using this circuit ensure the difference between
STO_1 and STO_2 signals changing the state is less than 1.4 s to prevent an abnormal situation. When using various
protective switches connect them in series.

Wiring for a simplified version using the Everest-XCR +5V_out supply is shown next (no need for 24 V supply). Note
that as the 5V_OUT is connected to other circuits like feedbacks and isolation on STO inputs is lost. The example
emphasizes the recommended connection when using various safety elements. Redundant wiring will improve
reliability.

9.4.6. STO bypass (needed when no STO functionality is implemented)

If STO is not be used, it must be overridden with 3 wire jumpers on the I/O connector, otherwise, it will not be
possible to enable the drive. See the following figure:

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9.5. Brake and Motor Temperature

9.5.1. Motor electromagnetic / electromechanical brake

Electromechanical brakes are needed in critical applications where the disconnection of the motor or a lack of
electric braking could be dangerous or harmful (i.e. falling suspended loads). Everest XCR Servo Drive includes
a brake output on the I/O connector J2. The brake output is an N-Channel MOSFET that can be PWM modulated to
reduce effective brake voltage and thus power consumption when energized.
Its operation is usually configured for normally locked electromechanical brakes; that is, brakes that by default
block the movement of the motor shaft when not powered. This kind of brakes increases the safety of the
application because, in a drive power failure, the switch would be opened therefore the brake activated. Main
ratings of the brake switch are detailed in the next table:

Specification Value

Type of output N-Channel MOSFET, open-drain with a recirculation diode

Maximum voltage 50 V (connector limited)

Maximum current 1A (full temperature range)

Delay after enabling the brake 0 ~ 10000 ms (user configurable)

Delay before release brake 0 ~ 10000 ms (user configurable)

Brake PWM frequency 4 kHz ~ 40 kHz

The next figure shows how the typical connection of the brake using a dedicated power supply.

The next figure shows the connection with a single power supply (< 50V systems). Note that it is possible to operate
a 24 V brake with a 48 V power supply by configuring the maximum PWM duty cycle of the brake to 50%. In this case,
configure it carefully before physically connecting the brake.

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9.5.2. External temperature sensor

The Everest XCR motor safety system connector allows the connection of an external temperature sensor based on
changes of resistance (PTC thermistor, bimetal, NTC, PT100, silicon temperature sensors) to measure the motor
temperature. The motion controller includes linearization for various sensors so the motor temperature can be read
directly. Connection of the 2 wire sensors is shown next:

WARNING, the motor can be hot.

The motor may become very hot > 70 ºC during operation. Do not touch it directly to prevent burns!
The use of the temperature sensor is strongly recommended.
ATTENTION, le moteur peut être chaud.
Le moteur peut devenir très chaud > 70 ºC pendant le fonctionnement. Ne le touchez pas directement
pour éviter les brûlures ! L'utilisation de la sonde de température est fortement recommandée.

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CAUTION, motor overload.

The Everest XCR may allow currents that can damage or cause a fire to the motor. Always ensure that
the continuous and peak current ratings of the motor are respected by adjusting during the drive
configuration.
ATTENTION, surcharge du moteur.
L'Everest XCR peut laisser passer des courants qui peuvent endommager ou provoquer un incendie du
moteur. Veillez toujours à ce que les courants nominaux continus et de pointe du moteur soient respectés
en effectuant des réglages lors de la configuration du variateur.

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9.6. Feedbacks
The Everest XCR can be connected to a maximum of 3 feedback devices at the same time that might be used for
commutation and/or velocity/position control purposes. These devices are connected in the J1 connector of the
board in with the following pin definitions:

Feedback port J1 Allowed feedbacks

connector
pins

Digital Halls 9 to 13 Digital Halls, open collector or push-pull.

Absolute encoder 1 14 to 19 SSI absolute encoder, Single BISS-C, Dual BiSS-C in daisy chain
topology (up to 2)

Incremental encoder / 1 to 8 Quadrature incremental encoder (S0S90), SSI absolute encoder.

Absolute encoder 2

 Powering the feedbacks

A 5 V 200 mA overcurrent-protected output is provided to power external circuits, including feedback
sensors.
If it is not used, and the sensor is powered externally, always remember to connect the ground or
reference voltage to the Everest XCR.
Une sortie protégée contre les surintensités de 5 V 200 mA est fournie pour alimenter les circuits externes, y
compris les capteurs de retour.
Si elle n'est pas utilisée et que le capteur est alimenté en externe, n'oubliez pas de connecter la terre ou la
tension de référence à l'Everest XCR.

9.6.1. Digital Halls

The Hall sensors are Hall effect devices that are built into the motor to detect the position of the rotor magnetic
field. Usually, motors include 3 Hall sensors, spaced 120º (electrical degrees) apart that are in phase with the stator
position. Using these 3 signals, the drive is capable to detect the position, direction, and velocity of the rotor. The
Halls effect sensors are a good way to detect the phasing of the motor and avoid "wake and shake"
movements. Everest XCR can use digital Hall sensors alone to drive the motor with trapezoidal commutation, but
not with sinusoidal commutation due to the improper total resolution that the hall effect sensors have in
comparison with other devices such as an incremental encoder.

This interface accepts 0 ~ 5 V level signals. Inputs are pulled up to 5 V with 1 kΩ, so industry-standard open collector
and push-pull output Hall effect sensors can be connected. Next table summarizes digital Halls inputs main
features:

Specification Value

Type of inputs Single ended with pull-up and low pass filter
ESD rugged

Number of inputs 3

ESD capability IEC 61000-4-2 (ESD) ± 30 kV (air), ± 30 kV (contact)

IEC 61000-4-5; tp = 8/20 μs 12 A, 200 W

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Specification Value

Maximum voltage range -0.5 ~ 5.5 V

Maximum recommended working 5 kHz

frequency

1st order filter cutting frequency (-3dB) 16 kHz

Sampling frequency 10 ksps

Type of sensors Open collector

Logic output
Push-pull output

Pull-up resistor value 1 kΩ

Next figures show the typical waveforms of the digital Halls signals.

Next figure illustrates how to connect the digital Halls to Everest XCR and a simplified input schematic.

 Velocity control with Halls

Due to the inherent low resolution of motor mounted Hall sensors, they are not recommended for velocity
feedback in low speed applications.

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9.6.2. Absolute Encoder 1

The Everest XCR servo drive absolute encoder 1 can be used as position, velocity, and commutation feedback
device. This sensor generates digital data that represent the encoder actual position. From the position
information, speed and direction of motion is calculated. The position is not lost even if the encoder is powered
down, which means that it is not necessary to move to a reference position as with incremental type encoders. The
following table shows the absolute encoder inputs electrical specifications.

Specification Value

Type of inputs Differential / Single ended

ESD protected

ESD capability IEC 61000-4-2 (ESD) ± 30 kV (air), ± 30 kV (contact)

IEC 61000-4-5; tp = 8/20 μs 12 A, 200 W

Maximum operating voltage -0.5 ~ 5.5 V

range

Operating frequency 100 kHz to 10 MHz (user configurable)

Receiver hysteresis min 50 mV typ 80 mV (DATA+ - DATA-)

Termination 220 Ω differential on data line

Fail safe bias resistors ENC_x+ (positive input) 500 Ω to 5 V

ENC_x- (negative input) 500 Ω to 2.5 V (equivalent)

Next Figure shows how to connect a single SSI or BISS-C absolute encoder to the Everest XCR servo drive.

For single-ended devices, connect the positive pins of CLK+ and DATA+ and leave the other pins unconnected.

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In the case that the encoder has a current consumption higher than 200 mA (maximum current output of the
+5V_OUT pin of the Everest XCR) or that the encoder has an input supply > 5V, an external power supply will need to
be used in order to power the encoder and in this case some wiring changes need to be taken into account (this
applies to both the differential and single-ended encoders, both incremental and absolute):
• Data and clock connections remain the same between the encoder and the drive
• +5V_OUT pin of the drive is not connected
• The input voltage pin of the encoder is connected to the input voltage of the additional power supply
• The GND of the additional power supply is connected to both GND pins of the encoder and the drive in order
to have a proper reference for the encoder signals

For dual daisy-chain BISS-C use the following connection. Dual BISS-C can be used for redundancy or to read the
position of the rotor before and after a gearbox. Further details on this interface can be found here BiSS-C slave 2
(daisy chain).

9.6.3. Absolute Encoder 2

The Absolute Encoder 2 interface can be used as a position, velocity and commutation feedback device. This
feedback is shared with the incremental encoder input, so you will have to select which one is used by software.

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Specification Value

Type of inputs Differential / Single ended

ESD protected

ESD capability IEC 61000-4-2 (ESD) ± 30 kV (air), ± 30 kV (contact)

IEC 61000-4-5; tp = 8/20 μs 12 A, 200 W

Maximum operating voltage range -0.5 ~ 5.5 V

Operating frequency 100 kHz to 10 MHz (user configurable)

Receiver hysteresis min 50 mV typ 80 mV (DATA+ - DATA-)

Termination 220 Ω differential on data line. Fail safe basing resistors of 1

kΩ, see drawings.

Fail safe bias resistors ENC_x+ (positive input) 1 kΩ to 5 V

ENC_x- (negative input) 1 kΩ to 2.5 V (equivalent)

The next figure shows how to connect a secondary SSI absolute encoder to the Everest XCR servo drive.

9.6.4. Incremental Encoder

Everest XCR can use single-ended or differential digital incremental encoder inputs (also known as quadrature
incremental encoders) for velocity and/or position control, as well as for commutation purposes. The encoder
provides incremental position feedback that can be extrapolated into precise velocity or position information.
Using high-resolution encoders allows Everest XCR to perform sinusoidal commutation. Channel A and channel B

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signals should have a phase shift of 90 degrees, indicating the rotation direction. The drive has an optional index
signal input. Index signal (Z) is a single pulse per revolution signal that can be used to know absolute positions and
for homing operations. The following table illustrates the digital encoder inputs main features.

Specification Value

Type of inputs Non-isolated

Differential or single ended
ESD protected

Number of inputs 3 (A, B and Index)

ESD capability IEC 61000-4-2 (ESD) ± 30 kV (air), ± 30 kV (contact)

IEC 61000-4-5; tp = 8/20 μs 12 A, 200 W

Maximum voltage range -0.5 ~ 5.5 V

Maximum recommended working frequency 10 MHz (differential)

Maximum readable pulse frequency 50 MHz

Termination resistor 220 Ω (between ENC_x+ and ENC_x-).

Fail safe bias resistors ENC_x+ (positive input) 1 kΩ to 5 V

ENC_x- (negative input) 1 kΩ to 2.5 V (equivalent)

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Everest XCR - Product manual | Wiring and Connections

The wiring of a single-ended encoder to the Everest XCR is shown next:

Sometimes encoders require different supply voltages than 5 V or need more than the 200 mA provided by the
drive. In those cases, the connection from the external power source should be as shown next:

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9.6.5. Feedback wiring recommendations

Signal distortion and electrical noise is a common problem in feedback signals. These problems can result in a bad
position or velocity calculation for both digital feedbacks (gain or loss of counts) and analog feedbacks (wrong
voltage levels).To minimize these problems some wiring recommendations are shown:
• Use differential signals whenever is possible. That is, connect both positive and negative signals of
differential feedback sensors. Use a twisted pair for each differential group of signals and another
twisted pair for the +5 V supply and GND. Twisted-pairs help in the elimination of noise because
disturbances induced in twisted pairs
• Twisted-pairs help in elimination of noise due to electromagnetic fields by twisting the two signal leads at
regular intervals. Any induced disturbance in the wire will have the same magnitude and result in error
cancellation.
• Connect the Everest XCR and encoder GND signals even if the encoder supply is not provided by the drive.
• The connection between Everest XCR PE and the motor metallic housing is essential to provide a low
impedance path and minimize noise coupling to the feedback. For further information, see Protective Earth
wiring.
• For better noise immunity, use shielded cables, with the shield connected to PE only in the drive side.
Never use the shield as a conductor carrying a signal, for example as a ground line.
• It is essential to keep feedback wiring as far as possible from motor power, AC power and all other power
wirings.

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9.7. Inputs and Outputs

The Everest XCR Servo Drive provides several inputs and output terminals for parameter observation and drive
control options.
• 4x 5 V non-isolated single ended digital inputs (IN1, IN2, IN3, IN4).
• 1x ±10V differential 16 bit analog input (AN1+, AN1-)
• 4x 5 V non-isolated digital outputs (OUT1, OUT2, OUT3, OUT4).

 Non-isolated I/O
Everest XCR inputs and outputs are not isolated. The reference voltage of the drive (GND_D) and the
ground of the devices connected to I/Os must be the same. Otherwise, inputs or outputs may be damaged.
For electromagnetically noisy environments and for signals that could be user-accessible and cause
electric shock, reinforced isolation is necessary. It is recommended to use isolators like Silicon Labs Si87xx
series, Texas Instruments ISO121x isolators.
Les entrées et sorties de l'Everest XCR ne sont pas isolées. La tension de référence du lecteur (GND_D) et la
masse des dispositifs connectés aux E/S doivent être identiques. Dans le cas contraire, les entrées ou les
sorties peuvent être endommagées.
Pour les environnements à fort bruit électromagnétique et pour les signaux qui pourraient être accessibles à
l'utilisateur et provoquer des chocs électriques, une isolation renforcée est nécessaire. Il est recommandé
d'utiliser des isolateurs comme ceux de la série Si87xx de Silicon Labs, les isolateurs ISO121x de Texas
Instruments.

9.7.1. Digital Inputs Interface

The non-isolated digital inputs are ready for 5 V or 3.3 V digital levels. The following table shows their electrical
specifications.

Specification Value

Number of inputs 4 (IN1, IN2, IN3, IN4)

Type of input Single ended

ESD protected
Low-pass filtered

ESD capability IEC 61000-4-2 (ESD) ± 15 kV (air), ± 8 kV (contact)

Input current 0.2 mA at 5 V (25 kΩ equivalent input resistance)

Maximum input voltage range -2 V ~ +7 V

High level input voltage >3V

Low level input voltage <2V

Minimum hysteresis 200 mV

1st order filter cutting frequency (-3 265 kHz

dB)

Next figure shows an example of how to wire digital inputs with various input options. For higher voltage systems
like 12 V or 24 V a series resistance should be connected to the input.

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The interface for 3 wire NPN and PNP sensors is shown next.

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Everest XCR - Product manual | Wiring and Connections

9.7.2. Analog Input Interface

The Everest XCR has a high accuracy fully differential 16-bit analog input AN1. See the specifications next:

Specification Value

Type of input Differential

ESD protected

ESD capability IEC 61000-4-2 (ESD) ± 15 kV (air), ± 8 kV (contact)

Input voltage range ±10 V differential (AN1+ - AN1-)

Analog input resolution 16 bits, 0.305 mV / ADC coun

(Theoretical values: +10 V → 65535 counts, -10 V → 0 counts)

Accuracy ±0.05% from -9.8 V to + 9.8 V. 0.5% full range

Maximum absolute voltage on any pin (AN1+ ±15 V

or AN1-)

1st order filter cutting frequency (-3 dB) 10 kHz

Input impedance 5 kΩ typ

Next figure shows how to connect the analog input. Note that for single-ended inputs it is recommended to connect
the negative AN1- to GND_D.
Also, for long distances, twisted pair, shielded cables are preferred. Connecting the shield to GND will improve the
signal to noise ratio. However, take precautions not to connect the shield to PE as this could actually increase the
noise of the signals.

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Everest XCR - Product manual | Wiring and Connections

9.7.3. Digital Outputs Interface

Everest XCR Servo Drive has 4 non-isolated digital outputs. These outputs can be used to drive optocouplers, LEDs
or other digital circuits.

Specification Value

Number of outputs 4

Type of output Push-pull output at 5 V

ESD protected.
Overload, short circuit protected

ESD capability IEC 61000-4-2 (ESD) ± 15 kV (air), ± 8 kV (contact)

Maximum sink/source current ±10 mA

Unloaded output high voltage 4.5 ~ 5 V

Unloaded output low voltage 0 ~ 0.5 V

The wiring of the digital outputs is shown next:

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Everest XCR - Product manual | Wiring and Connections

9.8. Communications
The Everest XCR provides the following network communication interfaces for configuration and operation.

Part Communicatio J4 connector (ECAT 0) J3 connector (ECAT 1) J2 (I/O) connector pins

number n Option functionality functionality 9, 11

EVE-XCR- CANopen / EtherNET standard port EtherNET standard port CANopen interface
C Ethernet (default address (default address CAN_H and CAN_L.
192.168.2.22). 192.168.2.22).
Allows configuration and Allows configuration and
tuning using Motion Lab 3. tuning using Motion Lab 3.

EVE-XCR- EtherCAT EtherCAT INPUT port 0. EtherCAT OUTPUT port 1 Not used.
E
Motion Lab 3 can be
accessed via Beckhoff
Twincat tool from a PC.

9.8.1. EVE-XCR-C (CANopen & Ethernet Interface)

Everest XCR Servo Drive supports the CANopen interface, a multi-terminal communication protocol based on CAN
(Controller Area Network) bus. J4 connector ETH Port 0 and J3 connector ETH Port 1 could be used with a standard
Ethernet port for configuration. The Everest XCR CAN interface is not isolated. If your computer has no Ethernet
port, you can use an Ethernet - USB adapter, like TeckNet HU043.
It is possible to control a servo drive from a CAN Master or from a computer with a CAN transceiver. Some USB to
CAN transceivers that work with Everest XCR are indicated here: Kvaser Leaf SemiPro HS (EAN: 73-30130-00242-5),
Kvaser Leaf Professional Rugged HS (EAN: 73-30130-00509-9), Peak Systems PCAN-USB (IPEH-002021), Peak
Systems PCAN-USB opto-decoupled (IPEH-002022). Always ensure to have the drivers installed prior to connection.
An example of the required wiring for the CANopen interface is shown in the next figure.

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9.8.1.1 CAN wiring recommendations

• Build CAN network using cables with 2-pairs of twisted wires (2 wires/pair) as follows: one pair for CAN_H
with CAN_L and the other pair for GND.
• Do not make a 2 wire only interface. Not connecting the CAN GND may result in loss of data and poor EMC
performance.
• Cable impedance should have an impedance of 100 to 140 Ω (120 Ω typical) and a capacitance below 30 pF/
meter.
• Whenever possible, use bus links between the CAN nodes. Avoid using stubs (a "T" connection, where a
derivation is taken from the main bus). If stubs cannot be avoided, keep them as short as possible. For
maximum speed (1 Mbps), use a stub length lower than 0.3 meters.
• For a total CAN bus length over 40 meters, it is mandatory to use shielded twisted cables. Connect the
cable shield to protective earth at both ends. Ensure that the cable shield is connected to the connector
shield, as the connection to host protective earth is usually soldered inside the connector.

 Drive ID
When installing CANopen communication, ensure that each servo drive is allocated a unique ID.
Otherwise, CANopen network may hang.
Lors de l'installation de la communication CANopen, assurez-vous que chaque servomoteur se voit attribuer
un identifiant unique. Sinon, le réseau CANopen risque de se bloquer.

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9.8.2. EVE-XCR-E (EtherCAT Interface)

Everest XCR Servo Drive provides access to the EtherCAT field bus system. EtherCAT is an isolated bus suitable for
hard and soft real-time requirements in automation technology, test and measurement, and many other
applications. The drive can be accessed and configured using any EtherCAT master over EtherCAT connecting the
PC to the port 0 (in).
The next figure shows how to connect the Everest XCR in an EtherCAT bus. It is recommended to follow the
standard IEC 61918-2013 for best practices.

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9.8.2.1 Recommended EtherCAT cables and connectors

The following table shows the recommended connectors and cable colors for EtherCAT according to IEC 61918
Appendix H.

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Signal Function Correspondin Pin for RJ45 M12-4 M8-4 Cable colour as Cable colour
g pin on per TIA-568B as per
Everest XCR D coded D coded EN61918

TX_D+ Transmit 1 1 1 1 White / Orange Yellow

data +

TX_D- Transmit 2 2 3 4 Orange Orange

data -

RX_D+ Receive data 3 3 2 2 White / Green White

+

RX_D- Receive data 4 6 4 3 Green Blue

-

- Not used, - 4 - - Blue

leave these
- wires - 5 - - White / Blue
unconnected
- - 7 - - White / Brown
.
- - 6 - - Brown

Screen Screening 5 Housing Housing Housing Metal Metal

Image of the connector

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9.8.2.2 Ethernet over EtherCAT (EoE) Protocol - Used by Motion Lab 3

Everest XCR Servo Drive supports Ethernet over EtherCAT protocol. This protocol encapsulates Ethernet frames into
EtherCAT packets allowing to establish a communication between standard Ethernet clients and EtherCAT devices
over an EtherCAT network in a transparent way.
Thanks to this protocol is possible to configure a specific Everest XCR of the network using Motion Lab without
requiring to modify the wiring of the installation.
The next figure shows how to connect the Everest XCR in an EtherCAT bus and how to establish communication
with Motion Lab 3 to configure the drive. EtherCAT controller/master needs to provide EoE capability and include
two different Network Interfaces Cards (NIC). If your computer has no Ethernet port, you can use an Ethernet - USB
adapter, like TeckNet HU043.

It is also possible to install Motion Lab 3 and EtherCAT Controller (i.e. Beckhoff TwinCAT) in the same PC reducing
the number of needed NIC.

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 EoE and TwinCAT

You can find more information on how to configure EoE on Beckhoff TwinCAT in the following link: http://
doc.ingeniamc.com/summit/manuals/reference-manual/tricks-and-tips/setting-up-ethernet-over-
ethercat-eoe

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Everest XCR - Product manual | Dimensions

10. Dimensions
All dimensions are in mm. All tolerances ≤ ±0.2 mm. Assembly instructions are indicated here: Installation.

 3D Model
For further detail, download the STEP model.

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Everest XCR - Product manual | Installation

11. Installation

11.1. Unboxing
When unboxing the drive please ensure the following:
• Remove it from the bag carefully.
• Check that there is no visible physical damage. If any, report it immediately to the carrier.
• Check the part number of the drive on the side label.

11.2. Installation Safety Requirements

The drive has live circuits that can be touched and entail a risk of electric shock (Protective Class 0), as well as a
risk of thermal injury. It must be mounted on a closed electrical operating area to which access is restricted to
skilled or instructed personnel. This enclosure, cabinet, protection, or case should have a minimum Index of
Protection of IP3X. To ensure electrical safety it is also important that the environment is clean from conductive
pollution or condensation when the drive is powered (Pollution degree 2).

WARNING HOT SURFACES!

The drive and motor can become hot and cause severe burns.
If any of the user-accessible surfaces exceeds 70ºC, a hot-surface signal must be added. This
is the responsibility of the installer.

ATTENTION, le moteur peut être chaud.

Le moteur peut devenir très chaud > 70ºC pendant le fonctionnement. Ne le touchez pas
directement pour éviter les brûlures ! L'utilisation de la sonde de température est fortement
recommandée.

DANGER, ELECTRIC SHOCK!

Power and motor pins have live voltages which can exceed 50 V which can cause electric
shock!
Perform installation procedures without voltage. Ensure the drive is mounted on a closed
electrical operating area which protects against direct contact.

ATTENTION, surcharge du moteur.

L'Everest XCR peut laisser passer des courants qui peuvent endommager ou provoquer un
incendie du moteur. Veillez toujours à ce que les courants nominaux continus et de pointe du
moteur soient respectés en effectuant des réglages lors de la configuration du variateur.

The drive may be operated without enclosure and protection against electric shock when it is supplied at Extra Low
Voltage (ELV), ≤ 50 V.

11.3. Mounting the Drive to a Heatsink or Cooling Plate

The drive has 4x M2.5 threaded holes with a max. thread depth of 6.4 mm for assembling the Everest XCR to a
cooling plate or heatsink. See Dimensions section for further details. Assembling the drive correctly is essential to:
1. Provide a conduction heat dissipation path. Please see the Thermal and Power Specifications section in
the Product Description chapter to determine your heat dissipation needs.
2. Ensure electrical conduction between the drive and Protective Earth, chassis, or the motor enclosure. This is
strongly recommended for EMC and electrical safety.

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3. Secure the drive in place to prevent any damage.

11.3.1. Back Installation

The preferred way to assemble the drive is from the back using a thermal interface tape and 4 x M2.5 screws.
Thermal tapes and materials offer a clean and repetitive way to improve the heat transfer from the drive to the heat
sink. There are several thermal interface alternatives, some suggested part numbers are T-Global Technology
LI98-1140-27-0.25, Berquist Bond-Ply 100 series, t-Global Technology GT30S, or copper conductive
tape CCH-18-101-0100. To install the drive, follow these steps:
1. Ensure the bottom surface of the drive and the heatsink are clean and dry. Isopropyl alcohol (isopropanol)
applied with a lint-free wipe or swab should be adequate for removing surface contamination such as dust
or fingerprints. Do not use “denatured alcohol” or glass cleaners which often contain oily components. Allow
the surface to dry for some minutes before applying the tape. More aggressive solvents (such as acetone,
methyl ethyl ketone (MEK) or toluene) may be required to remove heavier contamination (grease, machine
oils, solder flux, etc.) but should be followed by a final isopropanol wipe as described above. Note:- Be sure
to read and follow the manufacturers’ precautions and directions when using primers and solvents.
2. Cut a 34 mm x 27 mm piece of the thermal tape.
3. Apply the tape to the bottom of the drive at a modest angle with the use of a squeegee, rubber roller, or
finger pressure to help reduce the potential for air entrapment under the tape during its application. The
liner can be removed after positioning the tape onto the first substrate.
4. Assemble the drive to the heatsink ensuring alignment to the holes by applying compression to ensure good
wetting of the substrate surfaces with the tape. Proper application of pressure ~ 5 kg and time (> 5 s) is
crucial for the best thermal performance as the surface adhesive will have better wetting. A twisting motion
during assembly will improve wetting. This should be a back and forth twisting motion during the
application of compression. Moderate heat (<85ºC) can be employed to increase the wetting percentage and
wetting rate of the substrates and to build room temperature bond strength.
5. Screw the 4 x M2.5 screws applying between 0.17 and 0.3 Nm of torque. Note that the M2.5 thread should be
handled gently. The threads may penetrate the thermal interface material if the corners have not been
trimmed.

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For best power and thermal performance (high current and voltage application), thermal grease, pastes, or
silicone are recommended. The best thermal material tested is ARCTIC MX-4. Chemtronics CW7250 (white paste
non-conductive) and Chemtronics CW7100 (silver-based, conductive) also offer good results.
Mounting the drive without a thermal interface material is also acceptable for low power applications since any
imperfection on the heatsink or case surfaces will create air bubbles that would reduce the heat transfer.

11.3.2. Front Installation

Front installation can be done using a Flat heatsink together with the thermal tape and 4 x M2.5 x 8 DIN965 screws.
1. Assemble the drive to the flat heatsink following the Back Installation process.
2. Use appropriate thermal interface material between the previously cleaned Flat Heatsink and the other
surface.
3. Screw using M3 screws with appropriate torque according to the base material.

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Everest XCR - Product manual | Commissioning

12. Commissioning

12.1. Safety first

Always keep the recommendations of Safety Information in mind. Spending some extra minutes on safety, keeping
the workspace clean and ordered can save several days or weeks in case of malfunction or damage!

DANGER

ROTATING PARTS can cause serious injury.

Keep hands clear. Before starting motors, ensure that all moving parts are reliably
secured and assembled. High speed moving parts are very dangerous. Never try to
brake the motor with your hands.

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Everest XCR - Product manual | Commissioning

Initial Commissioning
Once the Everest has been installed as described in Installation, wired according to the Wiring and Connections and
Pinout, the initial commissioning can be performed following the Quick Start guide:

• Wire the drive

• Switch on the power supply
• Connect PC and servo drive
• Configure parameters and tuning

12.2. Decommissioning
Before decommissioning, ensure the power supply is off (wait a minimum of 5 s for capacitors to discharge), and the
drive is cool.
First, disconnect all the cables and connectors.
Then, removing the Everest from the plate or heatsink carefully following this sequence:
1. Remove the 4x M2.5 screws.
2. Separate the Everest from the heatsink by prying off, torquing, or peeling. Make sure the forces are applied
to the Everest enclosure and not to the PCB or connectors.
3. The thermal tape will be destroyed upon separation. The surfaces should be re-cleaned according to the
recommendations mentioned above. Do not try to reuse the thermal tape.
4. Heating the substrates can reduce the adhesion level and make removal easier

If you need disposing of the Everest, please:

• Be sure to comply with local disposal regulations.
• Separate the housing part made of aluminum.
• Dispose of the parts following the applicable legal regulations regarding electronic waste.
• Dispose of the packaging material following the applicable legal regulations.

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Everest XCR - Product manual | EMC and Environmental Testing Details

13. EMC and Environmental Testing Details

Testing Type Compliance Details

EMC Compliance IEC 61800-3:2017: Adjustable speed electrical power drive

systems. Part 3: EMC requirements and specific test methods
• CISPR 16-1-2:2014 + CISPR 11:2015 + A1:2016: Conducted
emissions: EN 61800-3 Category C2
• CISPR 22:2015: Conducted emissions for Ethernet fieldbus
standard: EN 55022 Class B
• CISPR 16-1-4:2010 + CISPR 11:2015 + A1:2016: Electromagnetic
radiation emissions: EN 55032 Class B, EN 61800-3 Category
C3
IEC 61000-6-2:2016: Electromagnetic compatibility (EMC) - Part
6-2: Generic standards - Immunity standard for industrial
environments
• IEC 61000-4-2:2008: ESD (electrostatic discharge)
disturbances: Performance criterion B.
• IEC 61000-4-3:2006: Radio-frequency electromagnetic field
disturbances, amplitude modulated 80 MHz to 2,7
GHz: Performance criterion A.
• IEC 61000-4-4:2012: Fast transients
disturbances: Performance criterion B.
• IEC 61000-4-6:2013: Conducted radio frequency disturbances
common mode 150 kHz to 80 MHz: Performance criterion A.
IEC 61800-5-2:2016: Adjustable speed electrical power drive
systems. Part 5-2: Safety requirements – Functional, Clause 9.3
(Immunity Testing)
• IEC 61000-4-2:2008: ESD (electrostatic discharge)
disturbances: Performance criterion Functional Safe.
• IEC 61000-4-3:2006 + AMD1:2007 + AMD2:2010: Radio-
frequency electromagnetic field disturbances,
amplitude modulated 80 MHz to 2,7 GHz: Performance
criterion Functional Safe.
• IEC 61000-4-4:2012: Fast transients
disturbances: Performance criterion Functional Safe.
• IEC 61000-4-6:2013: Conducted radio frequency disturbances
common mode 150 kHz to 80 MHz: Performance criterion
Functional Safe.

Environmental Testing Compliance 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

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