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ION Digital Drive User`s Manual

1. Termination None CAN Communications Compatibility CAN 2 0b Baud Rates 10k 20k 50k 125k 250k 500k 800k 1M Default baud rate is 20k Isolation Optocoupled Termination External 121 Ohm RJ45 terminator 6 4 ION 500 Protection Circuits Overtemperature User programmable between 0 C and 70 C Overvoltage User programmable between 20 V and 60 V Undervoltage User programmable between 10 V and 56 V Overcurrent Fixed at lt 200 of drive peak rating Short circuit protection Line to line line to power supply and line to case ground 6 5 ION 500 Connectors and Pinouts 6 5 1 High Power Connectors Connector Power Pin Signal Mating connector mfg type Molex MiniFit Jr plug I HV Mating connector P N 3901 4031 2 AuxV Wire range AWG 16 3 Pwr_Gnd Recommended crimp terminal 44476 3112 Connector Motor Pin Signal Mating connector mfg type Molex MiniFit Jr plug Motor Motor A Motor A I Mating connector P N 3901 4051 2 Motor B Motor A Wire range AWG 16 3 Motor Motor C Motor B Recommended crimp terminal 44476 3112 4 Motor B 5 Case Shield ION Digital Drive User s Manual 57 h ION 500 Specifications 6 5 2 Signal Connectors Connector Feedback Pin Signal Mating connector mfg type Molex MicroFit 3 0 plug Shield Mating connector P N 43025 1200 IO Gnd Wire range AWG 20 24 IO 5V 2 3 4 Alternate wire range AWG 26
2. sensor B Figure 2 8 Typical I O High speed wiring capture ION Digital Drive User s Manual 23 Installation 1 Figure 2 9 RS232 485 wiring 24 2 5 8 Serial RS232 485 Connector Pin RS232 RS485 Select float Select low 2 Tx 3 Rx 4 No connect No connect 5 IO_Gnd IO_Gnd 6 Rx 7 Rx 8 Txt 9 Tx This DB9M connector has a combination pinout that supports both RS232 and RS485 serial communications Pin 1 is used to select between the two serial types For RS232 pin 1 must be left floating For RS485 pin 1 must be strapped to IO Gnd For RS485 ION supports both 4 wire and 2 wire configurations To use 2 wire network cabling connect Rx to Tx and Rx to Tx at the ION serial connector ION does not have built in termination for RS485 If a network application requires termination at the ION serial connector the resistors must be added in the network wiring ION Digital Drive User s Manual Installation 2 2 5 9 CAN Ports Pin Signal CAN_H CAN_L CAN_Gnd Reserved AI LULU A HIT Reserved CAN Shield CAN Gnd CAN V Pin 1 Pin 1 CO NI t A Ww N The CAN version of ION has a dual RJ45 connector to allow daisy chaining of IONs in a CANbus network All pins in each port are connected to the corresponding pin the in the other port CAN Shield C
3. 4 T1out Riin Riout V ForceON T2out Tin 1 R2in T2in lt srixmt lon Ke o le le le lu o R2oufNVALID U MAX3223 gt gt SrlRcv MMUN2216 gt gt Select lt RS485DE The Select line shown in the simplified circuit diagram is routed to the Magellan Motion Processor to inform the processor of the selected serial mode ION supports point to point and multi drop networking in RS485 and point to point only in RS232 The Select line is read only once when the ION comes out of powerup reset The communications cable must be connected before power is supplied to the ION module 3 2 2 CAN The CAN version of ION features a dual RJ45 connector and can use standard UTP Ethernet cabling for implementing a daisy chain CANbus network The two jacks are functionally identical A simplified circuit diagram is shown in Figure 3 3 Note that only the signals used internally are shown CAN_V CAN_Shield and the two Reserved pins simply pass through to the other RJ45 jack To minimize ground loops and noise the CAN port is isolated from the rest of the ION module and is powered from an isolated winding of the onboard DC DC converter The small capacitor between the isolated and non isolated grounds is reguired for EMC The transceiver and sign
4. Shield connected to shells at both ends 5 Gnd PI Blk Grounded jumper wire included inside DB9M backshell to use for 6 Rx P3 Grn Select 7 Rx P3 Blk 8 Tx P4 Blu 9 Tx P4 Blk PMD Part Cable RJ45 02 R Pin Signal Pairing Color Description CAN Comm cable I CAN_H PI Org Wht Length 2m 2 CAN_L PI Org Cable 4P 24AWG UTP Cat5 3 CAN_Gnd P2 Grn Wht 4 Reserved P3 Blu 5 Reserved P3 Blu Wht 6 CAN Shield P2 Grn 7 CAN Gnd P4 Brn Wht 8 CAN V P4 Brn PMD Part Cable 1002 02 R Pin Signal Pairing Color Description Feedback stub cable I Drain Length 2m 2 IO_Gnd PI Blk Cable 6P 22AWG foil shield Alpha 2216C or equiv 3 IO 5V PI Red 4 Hall A P5 Brn 5 Hall B P5 Blk 6 Hall C P6 Yel 7 At P2 Wht 8 A P2 Blk 9 B P3 Grn 10 B P3 Blk E Z P4 Blu 12 Z P4 Blk PMD Part Cable 1003 02 R Pin Signal Pairing Color Description Auxiliary stub cable I Drain Length 2m 2 IO_Gnd PI Blk Cable 3P 22AWG foil shield Alpha 2213C or equiv 3 IO 5V PI Red 4 No connect 5 At P2 Wht 6 A P2 Blk 7 B P3 Grn 8 B P3 Blk ION Digital Drive User s Manual 43 Va Options and Accessories PMD Part Cable 1004 02 R Pin Signal Color Description I O stub cable I Drain Length 2m 2 IO_Gnd Blk Cable 13C 22AWG foil shield Alpha 1299C 15 or equiv 3 IO 5V Red 4 IO Gnd Blu 5 lO 5v Red Yel 6 IO Gnd Brn 7 FaultOut Pnk 8 Limit
5. Command Reference Auxilliary DC Input Communications AxisOut FaultOut Main DC Input Enable Axisin EMI Filter DC Bus Monitoring Optional Logic Supply Analog Signal Conditioning 4 CAN 2 0b Isolation Host Communications Options Magellan Motion Processor with Digital Current Loop RS232 485 Interface Digital Signal Conditioning PWM Power Stage Isolation PWM Cmd ry Current Feedback ION Digital Drive User s Manual Y Status LEDs Isolation j Quadrature Signal Conditioning Digital Signal Conditioning Motor Output Figure 3 1 ION block diagram Main Encoder Quad A B Index Auxillary Encoder Quad A B Or Pulse amp Direction Hall Sensors Limits Home High speed Capture 29 ys Operation Figure 3 2 Simplified serial transceiver diagram 30 3 2 Communication Port 3 2 1 RS232 485 The serial version of ION supports both the RS232 and RS485 protocols A simplified transceiver circuit diagram is shown in Figure 3 2 Pin 1 is used to select between RS232 and RS485 operation For RS232 pin 1 can be tied high to 3 3V or simply left floating For RS485 operation pin 1 must be strapped to IO_Gnd X IRS232EN EN ForceOFF 2 C1 Vcc GND
6. SetBusVoltageLimits GetBusVoltage corresponds to a GetBusVoltageLimits voltage of 12 345 counts 1 361 mV counts 16 801V 3 4 5 2 ION 3000 DC Bus Defaults and Limits Parameter Commands Scaling Example Bus Voltage GetBusVoltage 5 349 mV count A value of 12 345 from the command SetBusVoltageLimits GetBusVoltage corresponds to a GetBusVoltageLimits voltage of 12 345 counts 5 349 mV counts 66 033V 3 4 6 Undervoltage and Overvoltage Limits 3 4 6 1 ION 500 DC Bus Defaults and Limits Parameter Default value Limit Undervoltage Limit 9 935V Must be gt 9 935V and lt 56 00V Overvoltage Limit 60 02V Must be lt 60 02V and gt 20 00V 3 4 6 2 ION 3000 DC Bus Defaults and Limits Parameter Default value Limit Undervoltage Limit 20 00V Must be gt 20 00V and lt 195 00V Overvoltage Limit 195 00V Must be lt 195 00V and gt 20 00V 3 5 Trace Buffer Trace capture is a powerful feature of the Magellan Motion Processor that allows various parameters and registers to be continuously captured and stored to an internal memory buffer The captured data may later be downloaded by the host using software commands Data traces are useful for optimizing DC brush and brushless DC performance verifying trajectory behavior capturing sensor data or to assist with any type of monitoring where a precise time based record of the system s behavior is required The ION module features 1 5 kB RAM for trace
7. User s Manual ION 3000 Specifications US Digital outputs Signals AxisOut FaultOut Voltage range 0 24 VDC Output current 4mA source 100 mA sink short circuit protected to 30V RS232 485 Communications Baud Rates 1200 2400 9600 19 2k 57 6k 115k 230k 460k Default is 57 6k 460k support for RS485 only Isolation None Termination None CAN Communications Compatibility CAN 2 0b Baud Rates 10k 20k 50k 125k 250k 500k 800k 1M Default baud rate is 20k Isolation Optocoupled Termination External 121 Ohm RJ45 terminator 7 4 ION 3000 Protection Circuits Overtemperature User programmable between 0 C and 70 C Overvoltage User programmable between 20 V and 195 V Undervoltage User programmable between 20 V and 195 V Overcurrent Fixed at gt 50 A Short circuit protection Line to line line to power supply and line to case ground 7 5 ION 3000 Connectors and Pinouts 7 5 1 High Power Connectors Connector Power Pin Signal Mating connector mfg type Phoenix I HV Mating connector P N 1804917 2 AuxV Wire range AWG 14 3 Pwr_Gnd Connector Motor Pin Signal Mating connector mfg type Phoenix Motor Motor A Motor A I Mating connector P N 1804933 2 Motor Motor B Motor A Wire range AWG 14 3 Motor C Motor B 4 Motor B 5 Case Shield ION Digital Drive User s Manual 65 y ION 3000 Specifications 7 5 2 Signal Connectors Connecto
8. as well as Hall commutation signals These signals are buffered and filtered in the Quadrature Signal Conditioning and Digital Signal Conditioning blocks respectively as shown in the block diagram ION supports incremental quadrature encoders with count rates up to 10 Mcounts per second and for the ION 3000 module Pulse amp Direction input on the auxiliary position input at up to 10 Mpulses per second 5 1 1 Main Encoder Inputs The differential input circuitry for the main encoder A B and Index signals is shown in Figure 5 1 This circuit accepts both differential and single ended signals in the range of 0 5 V For single ended operation the unused input should be left floating Figure 5 1 Main encoder A B Index input circuits A B Index DS26LV32AT For full functionality ION requires a three channel with Index incremental encoder for the main feedback The required index alignment is shown in Figure 5 2 ION qualifies the Index with the A and B quadrature inputs and recognizes an Index event when all signals A B and Index are low ION Digital Drive User s Manual 47 Electrical Signal Interfacing Figure 5 2 Encoder phasing diagram Correct Index phasing and polarity is required for the ION to operate properly The A amp B channels can be swapped and the quadrature signals inverted as required at the differential inputs to achieve the above phasing alignment e While t
9. built in DC DC converter that derives all required internal voltages from the main DC bus A separate logic supply is not required This DC DC converter also ION 3000 provides IO_5V for powering encoders limit switches and other system 1 O 16 ION Digital Drive User s Manual Installation 2 As an additional safety feature ION provides a separate Auxiliary Voltage AuxV input that can be used to power just this DC DC converter without powering the main DC bus and the output stage When the AuxV is not connected power for the DC DC converter comes from the main HV input Figure 2 2 Typical power wiring 2 5 4 Motor Connector Pin DC Brush Brushless DC Step a Motort Motor A U Motor A a 2 Motor ION 3000 Motor B V Motor A PA Wm ar 3 Motor ION 500 Motor C W Motor B i econ mum 4 No connect No connect Motor B a Ld Ld R 5 Case Shield Case Shield Case Shield ION 500 X This connector is used to connect the ION module to the motor Depending on the type of motor being driven up to five connections are required It should be wired with 16 AWG wire ION 500 or 14 AWG wire ION 3000 to minimize voltage drops between the ION drive and the motor The use of shielded cable is recommended to ION 3000 minimize noise ION Digital Drive User s Manual 17 Installation Figure 2 3 Typical motor wiring 18 Soa Motor Case For best performance the ca
10. connected in parallel CAN V CAN Shield 3 CAN Gnd and the Reserved pins are not connected internally and simply pass the 4 Reserved signals through to the other jack 5 Reali 6 CAN_Shield 7 CAN_Gnd 8 CAN_V 6 6 ION 500 Mechanical Specification Value Dimensions See Figure 6 1 Weight without heatsink 0 6 Ib 0 28 kg with heatsink 1 1 Ib 0 5 kg Enclosure materials Aluminum base and molded plastic cover Mounting options Coldplate panel and DIN rail Recommended mounting screws 6 M3 or M3 5 Protection class IP20 ION Digital Drive User s Manual 59 60 ION 500 Specifications Figure 6 1 ION 500 dimensions 6 7 ION 500 Environmental Specification Value Operating ambient temperature 0 to 60 C Maximum base plate temperature 70C Storage temperature 20 to 85 C Humidity 0 to 9576 non condensing Altitude Up to 2000 meters without derating Contamination Pollution Degree 2 ION Digital Drive User s Manual ION 500 Specifications l 6 8 ION 500 Safety and Compliance Specification Standards CE LVD EN60204 EMC D EN61000 6 1 EN61000 6 3 EN5501 I Electrical safety Designed to UL508c UL840 and EN60204 1 Hazardous materials RoHS compliant Flammability UL 94 V2 or VO Enclosure IP20 6 9 ION 500 Thermal Operating Curves 12 loc lt z Figure 6 2 g ION 500 o Derating curve un 3 for DC brush E mod
11. current limit of 10 00Arms using the SetCurrentFoldback command a value of 10 000mArmg 9152 mArmg count 10 927 should be used DC Brush Continuous DC Current Limit SetCurrentFoldback GetCurrentFoldback 1 121 mApc count To set a continuous current limit of 10 00Apc using the SetCurrentFoldback command a value of 10 000mApc 1 121 mApc count 8 921 should be used Step motor amp Brushless DC It Energy SetCurrentFoldback GetCurrentFoldback 3682 Arms Sec count To set a foldback total energy value of 1 000 0 Arms Sec using the SetCurrentFoldback command a value of 1 000 0 Arms Sec 3682 Arms Sec count 2 716 should be used DC Brush Ik Energy SetCurrentFoldback GetCurrentFoldback 5524 Apc Sec count To set a foldback total energy value of 1 000 0 Apc Sec using the SetCurrentFoldback command a value of 1000 0 Apc Sec 5524 Arms Sec count 1 810 should be used Brushless DC motors used in Hall based commutation should use the Apc scale factors All other Brushless DC motor modes should use the Any scale factors ION Digital Drive User s Manual 33 ys Operation 3 3 4 Power Stage Defaults and Limits To correctly control various ION power stage features via the Magellan Motion Processor it is necessary to know certain drive specific defaults and limits The following tables summarize these values 3 3 4 1 ION 500 Power Stage Defaults and Limits D
12. loads powered from up to 24 VDC to be switched The FET driver is internally protected from shorts up to 30 V Figure 5 10 FaultOut circuit FaultOut When the ION is powered off FaultOut is effectively high impedance and unable to sink current This state should o be interpreted as Fault by the receiving circuit 1 ION Digital Drive User s Manual 53 l Electrical Signal Interfacing This page intentionally left blank 54 ION Digital Drive User s Manual 6 ION 500 Specifications In This Chapter ION 500 Drive Ratings ION 500 Controller Performance ION 500 Electrical ION 500 Protection Circuits ION 500 Connectors and Pinouts ION 500 Mechanical ION 500 Environmental ION 500 Safety and Compliance ION 500 Thermal Operating Curves vvvvvvvvv 6 1 ION 500 Drive Ratings Motor Model Specification DC Brush Brushless DC Step Nominal supply voltage 48 VDC 48 VDC 48 VDC Supply voltage range 12 56 VDC 12 56 VDC 12 56 VDC Output current per phase Continuous DIN rail mount w heat sink free air 25 C 6 ADC 6 Arms 8 5 ADC 5 Arms 7 1 ADC Continuous coldplate mount Tbp lt 50 C 9 8 ADC 8 Arms 11 3 ADC 5 Arms 7 1 ADC Peak 2 sec 21 2 ADC 15 Arms 21 2 ADC 15 Arms 21 2 ADC Maximum continuous output power Coldplate mount Tbp lt 50 C 450 W 500 W 350 W 6 2 ION 500 Controller Performance Supported motor types DC brush brushless DC step motor Commun
13. sink and DIN rail mounting options can be specified in the part number Note that the Serial version of ION supports both RS485 and RS232 serial standards ION Digital Drive User s Manual 11 Installation 12 2 1 1 ION 500 Part Numbers The following table shows the base part number configurations for the ION 500 Note that for ION 500 models it is possible to order units in DIN rail mount and with an optional heat sink See the above part number diagram for details Communications Model Number Motor Type Port DD131S0 056 15 Brushless DC Serial DDI31C0 056 15 Brushless DC CANBus DDI11S0 056 15 DC Brush Serial DDI11C0 056 15 DC Brush CANBus DD141S0 056 15 Step Motor Serial DDI41C0 056 15 Step Motor CANBus 2 1 2 ION 3000 Part Numbers The following table shows the base part number configurations for the ION 3000 Communications Model Number Motor Type Port DD131S0 195 30 Brushless DC Serial DD1I31C0 195 30 Brushless DC CANBus DDI11S0 195 30 DC Brush Serial DDI11C0 195 30 DC Brush CANBus DD141S0 195 30 Step Motor Serial DD141C0 195 30 Step Motor CANBus 2 2 ION Developer s Kits To facilitate initial system development and integration ION is offered in a Developer s Kit version A model number beginning with DK instead of DD specifies the Developer s Kit version The following software and accessory products are included in every ION Developer s Kit e Pro Motion CD and Us
14. use the following connections Connection from Encoder ION Connector Pin ION Pin Pulse amp Direction input Pulse Auxiliary 5 Pulse Pulse Auxiliary 6 Pulse Direction Auxiliary 7 Direction Direction Auxiliary 8 Direction Encoder input optional if ION is controlling step motor Quadrature A Feedback 7 Quad A Quadrature A Feedback 8 Quad A Quadrature B Feedback 9 Quad B Quadrature B Feedback 10 Quad B Index Feedback Il Index Index Feedback 12 Index Hall A Feedback 4 Hall A Hall B Feedback 5 Hall B Hall C Feedback 6 Hall C Brushless DC motors only 22 ION Digital Drive User s Manual Installation 2 2 5 7 I O Connector Pin1 Pin2 Pin Signal Pin Signal I Shield 8 Limit 2 IO_Gnd 9 Limit 3 IO_5V 10 Home 4 IO_Gnd Il High Speed Capture 5 IO_5V 12 Axisln 6 lO Gnd 13 AxisOut 7 FaultOut 14 Enable This connector is used to wire motion specific I O signals such as overtravel limits home reference and High Speed Capture input as well as the general purpose AxisIn and AxisOut signals It also has pins for the master Enable input and FaultOut signals Numerous IO 5V and IO Gnd connections are provided to simplify wiring This connector supports wire gauges from 20 to 30 AWG depending on the crimp terminal used Wiring with 22 AWG shielded cable is recommended Limit switch Limit switch H a ome Out
15. 0Arms Must be lt 15 00Arms Foldback Continuous RMS Current Brushless DC model 1 350Apms sec Must be lt 1 575Apmg sec Foldback Total Energy DC Brush model Foldback 15 00Apc Must be lt 20 00Apc Continuous DC Current DC Brush model Foldback 000Ap sec Must be lt 1 350Apc sec Total Energy Step motor model 5 7 Arms Must be lt 10 6Arms Foldback Continuous RMS Current Step motor model I 575ARMs sec Must be lt 1 735Apms sec Foldback maximum energy For the ION 3000 default values for the Foldback Continuous Current Limit and Foldback Energy Limit are designed to be safe for operation of the drive in its highest output mounting option and at it highest nominal operating voltage See Section 2 4 ION Hardware Configuration and Mounting for information on ION mounting options If the ION 3000 drive is being operated at a lower voltage it may be possible to specify values for Foldback Continuous Current Limit and Foldback Energy Limit that are higher than the default but lower than or equal to the limit since the continuous output current rating of the ION 3000 drive is higher for lower input voltages See Section 7 1 ION 3000 Drive Ratings for drive output specifications For other mounting configurations or for use with motors that have lower current and energy limits it may be useful to set these parameters to values lower than the default values It is the responsibility of the user to
16. 30 5 Hall B 6 7 8 Recommended crimp terminal 43030 0009 Hall A Alternate crimp terminal 43030 0012 Hall C Quad A Quad A 9 Quad Bt 10 Quad B Il Index 12 Index Connector Auxiliary Pin Signal Mating connector mfg type Molex MicroFit 3 0 plug I Shield Mating connector P N 43025 0800 2 IO_Gnd Wire range AWG 20 24 3 IO_5V Recommended crimp terminal 43030 0009 4 No connect Alternate wire range AWG 26 30 5 Quad A Alternate crimp terminal 43030 0012 6 Quad A 7 Quad B 8 Quad B Connector I O Pin Signal Mating connector mfg type Molex MicroFit 3 0 plug I Shield Mating connector P N 43025 1400 2 IO_Gnd Wire range AWG 20 24 3 IO_5V Recommended crimp terminal 43030 0009 4 IO Gnd Alternate wire range AWG 26 30 5 IO_5V Alternate crimp terminal 43030 0012 6 IO Gnd 7 FaultOut 8 Limit 9 Limit 10 Home Il High Speed Capture 12 Axisln 13 AxisOut 14 Enable 58 ION Digital Drive User s Manual ION 500 Specifications l 6 5 3 Communications Connectors Connector RS232 485 Pin Signal Mating connector mfg type Generic DB9M Select 2 Tx RS232 3 Rx RS232 4 No connect 5 IO Gnd 6 Rx RS485 7 Rx RS485 8 Tx RS485 9 Tx RS485 Connector CAN Pin Signal Mating connector mfg type Generic RJ45 8P8C CAN_H 2 CAN_L The dual RJ45 jacks are fully
17. 5 2 6 Software Installation eene nnn 25 2 1 Applying POoWet zeit A eem 26 2 8 Status LEDS ora 26 2 9 Communications Configuration nennen 27 2 10 Checking Operational Status sess 27 3 Operation ue ceres ri EF a 29 33l ION Block Diagram ii ERRARE RERUMS 29 3 2 Communication Port uod Ra Se petras 30 2 3 PWM Power Stage eese tiet tei eive et rote tea fire 31 3 5 DEC BUS erre erret eerie ON 36 3 5 Trace Butler onore tee te Pl iii 37 3 6 Operational and Fault Modes non nonncon non nronnnn non nrrnnrnnnnss 38 4 Options and Accessories cece cece eee cere YH 41 4l Stub Cable Set iii EE e A ER 41 4 2 Development Kit Cable and Plug Specifications sss 43 4 3 Optional Heatsink ION 500 Only i 45 4 4 Optional DIN Rail Adapter ION 500 Only sese 46 5 Electrical Signal Interfacing 0 ccc cece cece eee eees 47 5 l Motor Eeedbackio ooi tera Greer es 47 5 2 Auxiliary Position Input nennen nennen 49 53 Limit and Home Inputs cep csset eee ee nd 50 5 4 Position Capture SourceS escis a ite Ele et lee dee ani 50 5 5 AxisIn and AxisOut Signals enne 51 5 6 Enable and FaultOut Signals sse 53 6 ION 500 Specifications 55 6 1 ION 500 Drive Ratings non non YY serier HYF FFYN 55 6 2 ION 500 Cont
18. AN V and the two Reserved pins are not used by ION but are passed through from one port to the other When the ION module is the last node of a CANbus network the network can be terminated by plugging a RJ45 terminator into the unused port Standard UTP unshielded twisted pair CAT5 Ethernet cabling can be used in most CAN applications For added noise immunity shielded cable can be used with the shield routed through the CAN Shield pins 2 6 Software Installation Each ION developers kit includes a number of powerful software packages for motion system development e Pro Motion an interactive Windows based motion system development tool and performance optimizer e C Motion a C language library designed to simplify integration into C applications e VB Motion an Active X applet providing the features of C Motion to the Microsoft Visual Basic and sim ilar development environments Before applying power to the ION drive locate the Pro Motion CD and install the Pro Motion application on the host computer following the instructions in the Pro Motion Users Guide This software will be used to configure the module and then fully exercise the feature of the ION Digital Drive For more information on developing applications in C Motion and VB Motion refer to the Mage an Motion Processor Programmers Command Reference PDF versions of this manual the Magellan Motion Processor Users Guide and the Magellan Motion Processor Programmers Command Re
19. AxisOut AxisIn and AxisOut are versatile I O signals They are not dedicated to any particular motion control function but can be programmed to implement a wide array of system integration functions See the Magellan Motion Processor Users Guide for more information on configuring and programming these signals 52 ION Digital Drive User s Manual Electrical Signal Interfacing 5 6 Enable and FaultOut Signals These dedicated signals are typically used to implement a safety interlock between the ION module and other control portions of the system Enable is an active low input that must be tied or driven low for the ION output stage to be active Similarly FaultOut indicates any serious problem by going high When ION is operating properly FaultOut is low The polarity of these signals is fixed and cannot be changed via software The input buffer for the Enable input is shown in Figure 5 9 This circuit accepts signals in the range of 0 24 V and has TTL compatible Schmidt trigger thresholds It has a pull up to 5V to allow direct interfacing to open collector enable sources without the need for an external pull up resistor and a 1 3 kHz R C low pass filter to reject noise Figure 5 9 Enable input circuit Enable ___ gt The output driver for FaultOut is shown in Figure 5 10 This circuit can continuously sink over 100 mA and source 4mA from a pull up resistor to 5V The diode in series with the pull up resistor allows
20. D Part Description Cable RJ45 02 R RJ45 CANBus Communications Cable TRM RJ45 02 R RJ45 CANBus terminator Cable 1002 02 R Feedback Stub Cable Cable 1003 02 R Aux Stub Cable Cable 1004 02 R I O Stub Cable Cable 1005 02 R ION 500 DC Bus Stub Cable Cable 1006 02 R ION 500 DC Motor Stub Cable ION 3000 Serial Cable PMD Part Description Cable RS232 03 R 9 pin RS232 Communications Cable Cable 1002 02 R Feedback Stub Cable Cable 1003 02 R Aux Stub Cable Cable 1004 02 R I O Stub Cable Plug 1007 01 R ION 3000 DC Bus Plug Plug 1008 01 R ION 3000 DC Motor Plug ION Digital Drive User s Manual 41 Va Options and Accessories ION 3000 CANBus Cable PMD Part Description Cable RJ45 02 R RJ45 CANBus Communications Cable TRM RJ45 02 R RJ45 CANBus terminator Cable 1002 02 R Feedback Stub Cable Cable 1003 02 R Aux Stub Cable Cable 1004 02 R I O Stub Cable Plug 1007 01 R ION 3000 DC Bus Plug Plug 1008 01 R ION 3000 DC Motor Plug 42 ION Digital Drive User s Manual Options and Accessories L 4 2 Development Kit Cable and Plug Specifications PMD Part Cable RS23203 R Pin Signal Pairing Color Description RS232 Comm cable I Select None Blk Length 2m 2 Tx P2 Wht Cable 4P 24AWG foil shield Alpha 5474C or equiv 3 Rx PI Red 4 No connect Notes
21. Diagram 29 brushless DC motors connection 16 drive ratings 55 63 Hall signals 18 48 phase current feedback 31 power stage configuration 31 buffers trace 37 C cable shield See shielded cable CAN cabling 25 CAN Shield pins 25 CANbus network 25 30 communication connection 16 communication rates 30 daisy chain 25 default values 27 electrical specifications 57 65 factory defaults 27 operation 30 pinouts 25 59 67 ports 25 simplified transceiver circuit diagram 31 circuits auxiliary encoder input 49 ION Digital Drive User s Manual 75 A Index AxisIn 51 AxisOut 51 FaultOut 53 Hall input 48 High Speed Capture 50 limit and home input 50 main encoder input 47 protection 57 65 reset 36 simplified CAN transceiver diagram 31 C Motion 25 coldplate cooling method 13 14 Comm connector 24 59 67 Comm ports 30 Comm Status LED 26 communication ports 30 CAN version 30 RS232 485 version 30 communications point to point 30 ports 30 status LED 26 commutation sinusoidal 48 compliance and safety specifications 61 68 conditions hard fault 39 operational and fault 38 configurable loop modes 56 64 connectors auxiliary encoder 19 58 66 by module type 16 CAN 59 67 Comm 24 59 67 communication 24 59 67 DB9M 24 59 67 feedback 18 47 58 66 I O 23 58 66 locator 15 motor 17 57 65 power 16 57 65 RJ45 25 30 RS232 485 24 serial 24 signal 58 66 controller performance specific
22. ION Digital Drive lt PMD Performance Motion Devices Inc 55 Old Bedford Road Lincoln MA 01773 User s Manual Revision 1 4 March 2008 NOTICE This document contains proprietary and confidential information of Performance Motion Devices Inc and is pro tected by federal copyright law The contents of this document may not be disclosed to third parties translated copied or duplicated in any form in whole or in part without the express written permission of PMD The information contained in this document is subject to change without notice No part of this document may be reproduced or transmitted in any form by any means electronic or mechanical for any purpose without the express written permission of PMD Copyright 1998 2008 by Performance Motion Devices Inc Magellan ION Magellan ION Pro Motion C Motion and VB Motion are trademarks of Performance Motion Devices Inc ION Digital Drive User s Manual Warranty PMD warrants performance of its products to the specifications applicable at the time of sale in accordance with PMD s standard warranty Testing and other quality control techniques are utilized to the extent PMD deems necessary to support this warranty Specific testing of all parameters of each device is not necessarily performed except those mandated by government requirements Performance Motion Devices Inc PMD reserves the right to make changes to its products or to discontinu
23. LEDs is shown in Figure 2 1 2 8 1 Module Status LED Upon powerup and or reset the module Status LED should either be solid green or blinking green depending on the state of the Enable input and the internal operating mode If enabled in both Hardware and Software the LED will be solid green The Enable input is active low A Status LED of any other color indicates a fault or unusual condition that must be rectified before going further See Section 3 6 Operational and Fault Modes for complete information on ION Operational and Fault modes and the resulting color and blink rate of the Status LED 2 8 2 Communications Status LED The Comm Status LED indicates successful packets by blinking green and packet errors by blinking red A serious fault in the communications port is indicated with solid red If the LED is solid red check the cabling and then try cycling power and reconfiguring the communications configuration ION Digital Drive User s Manual Installation 2 2 9 Communications Configuration There are a few parameters that must be configured correctly for successful communications between the host computer and the ION module The Pro Motion application contains a wizard to make this setup simple see the Pro Motion Users Guide There are two sets of communications parameters The default set is stored in non volatile memory while the active set is held in RAM At powerup and after every reset the default s
24. Specifications rN 7 9 ION 3000 Thermal Operating Curves Sinusoidal IDC Ej T Hall Commutation ID a T Figure 7 2 7 BLDC output 7 current vs bus voltage at 40 C ambient R Sinusoidal RMS o T fi Continuous current A 40C ambient pl 1 1 Ll fi 1 L L L 20 40 60 80 100 120 140 160 180 200 Bus voltage V Sinusoidal IDC Hall Commutation IDC ES Sinusoidal RMS Figure 7 3 BLDC output current vs temperature with 48V input Continuous current A O 48V 0 il L L i i i Ll i i 20 25 60 65 70 30 35 40 45 50 55 Brushless DC baseplate temperature C ION Digital Drive User s Manual 69 ION 3000 Specifications Figure 7 4 BLDC output current vs temperature with 180V input 70 35 40 45 50 55 6l Brushless DC baseplate temperature C 30 L L L fi 9 a i E 1 Y a uaiquie 20t O V 1 L 2 u co 29c 0 57 1 me op gt OF onsnc o FQ5 20 3 2232 DOS LA 05 co o o eun snonunuo 40 60 80 100 120 140 160 180 Bus voltage V 20 ION Digital Drive User s Manual 70 ION 3000 Specifications rN Continuous current A 48V 30 40 50 60 DC Brush baseplate temperature C 70 Continuous current A 180V ION Digital Drive User s Manual 30 40 50 60 DC Brush baseplate temperature C 70 Fi
25. This will hold up to 384 trace samples Refer to the Magellan Motion Processor Users Guide and the Magellan Motion Processor Programmers Command Reference for complete information on trace configuration and operation ION Digital Drive User s Manual 37 ya Operation 3 6 Operational and Fault Modes The ION is commanded by the host controller to perform various motion control functions During the course of these operations it is possible for the ION to enter various fault states based on operational conditions within the power stage the motor the electrical bus or based on the state of the Enable input signal The following tables summarize the operational and fault modes of the ION Digital Drive More information about these modes can be found in the Magellan Motion Processor User s Guide Output Condition Details Stage FaultOut Module Status LED Enabled Enable low Normal operation in On Low Green solid programmed operating mode Disabled Enable high Off Low Green blinking slow Overvoltage DC bus voltage exceeded programmable Off Program Red blinking fast threshold mable Undervoltage DC bus voltage below programmable threshold It Current Foldback Output stage disabled by I t foldback Off Program Red blinking slow protection mable Overtemperature Power stage temperature exceeded programmable threshold Hard Electrical Output Fault Details Stage FaultOut Module Status LED Over
26. Wht 9 Limit Grn 10 Home Org Il HSI Yel 12 Axisln Vio 13 AxisOut Gry 14 Enable Tan PMD Part Cable 1005 02 R Pin Signal Color Description ION 500 DC bus stub cable I HV Red Length 2m 2 AuxV Wht Cable 3C I6AWG foil shield Alpha 5363C or equiv 3 PGnd Blk Note Drain and PGnd spliced together at Pin 3 PMD Part Cable 1006 02 R Pin Signal Color Description ION 500 Motor stub cable I A U M Wht Length 2m 2 A V Grn Cable 6C 16AWG foil shield Alpha 5366C or equiv 3 B W M Org 4 B Blu Note Drain and PGnd spliced together at Pin 5 5 PGnd Blk PMD Part Plug 1007 01 R Pin Signal Color Description ION 3000 DC bus plug I HV 2 AuxV Cable Phoenix p n 1804917 3 PGnd PMD Part Plug 1008 01 R Pin Signal Color Description ION 3000 Motor Plug I A U M 2 A V M Cable Phoenix p n 1804933 3 B W 4 B 5 PGnd ION Digital Drive User s Manual Options and Accessories 4 3 Optional Heatsink ION 500 Only The optional heatsink available for ION 500 models only can be used to increase the continuous output current and power in applications where the ION module is not cold plate mounted or is operating in high ambient environments It is especially effective when forced air cooling is available See Section 6 9 ION 500 Thermal Operating Curves for the ION specifications with and without the heatsink attached To enhance thermal conductivity the heatsink has a th
27. al isolator used support the high speed CAN communications rates of up to 1 M baud ION Digital Drive User s Manual Operation ISO 3 3V A SN65HVD233 4 I LBK Vdd2 Vdd1 i CANL Vcc Via Voa Figure 3 3 Vob Vib NE Rs GND2 GND Simplified CAN transceiver ADuM1201 circuit diagram 3 3 PWM Power Stage The ION module contains a high efficiency MOSFET power stage with PWM control and phase current feedback A slightly different configuration is used for each motor type DC brush motors are driven with an H Bridge consisting of 4 MOSFETs Brushless DC motors are driven with a 3 phase bridge consisting of 6 MOSFETs Step motors are driven with two H Bridges one for each phase for a total of 8 MOSFETs The use of 3 phase and H Bridge topologies provides full 4 quadrant operation from a single non isolated DC supply ION uses an advanced PWM switching scheme that minimizes the ripple current on the motor windings while maximizing the current loop performance The PWM frequency is selectable between 20 kHz and 40 kHz to cover a broad range of motor inductance The fundamental frequency of the ripple current is at twice the PWM frequency and well out of the audible range in all cases Two channels of phase current feedback are used for brushless DC and step motor current loops In the brushless DC version the third phase is simply calculated as the inverse sum of the other two phase currents For DC brush motors onl
28. al noise problems the metal base of the ION enclosure should be grounded This is usually accomplished automatically when the module is mounted to a metal part of a grounded system When mounted to a DIN rail using the optional DIN rail adapter or when mounted to a non conductive or non grounded surface one of the free mounting holes can be used to attach a ground strap Refer to Section 7 6 ION 3000 Mechanical for information on mounting dimensions and mounting hole sizes for the ION 3000 ION Digital Drive User s Manual Installation 2 2 5 Connector Pinouts and Wiring 2 5 1 Connector Locator Module Status LED Feedback Power Motor Comm Serial connector Figure 2 1 Connector locator Comm Status LED Note Connector location diagrams above are shown for the ION 500 The ION 3000 form factor is somewhat different but with similar overall connection locations The diagrams below show the left connector view for both the ION 3000 and the ION 500 POWER MOTOR B CONE WM TC el el sje s ele T LS To o Jo a a n ola SEI E ES MOn P wER Power Motor Motor Power ION 3000 Left View ION 500 Left View ION Digital Drive User s Manual 15 Installation 2 5 2 Motor Module Type Quick Reference The following table summarizes the recommended conne
29. amily provides an extensive list of motion control functions including e Serial host communications over RS232 RS485 or CANBus e Trajectory generation including trapezoidal and S curve point to point profiling velocity contouring and electronic gearing modes e Advanced PID position loop with integration limit derivative sample time velocity and acceleration feedforward output bias dual biquad filters and support for dual encoder feedback e Two encoder input channels capable of up to 10 Mcounts per second e Sinusoidal and six step Hall brushless DC commutation modes e Microstepping outputs with up to 256 microsteps per step e Digital current loop with choice of standard A B or Field Oriented Control FOC for both brushless DC and step motors e Single phase current loop for DC brush motors e Pulse and direction input ION 3000 only The ION module adds power electronics and signal conditioning circuitry to create a complete digital drive with these key features e High efficiency MOSFET power stages with versions for single phase brush DC motors two phase step motors and three phase brushless DC motors e T current foldback limiting e Selectable 20 kHz and 40 kHz PWM frequencies to support a broad range of motor inductance e Overcurrent short circuit overvoltage undervoltage and overtemperature protection e Single supply operation An onboard DC DC converter supplies all internal circuitry and also provides 5V for en
30. aster in electronic gearing applications or as part of a dual loop filter compensation scheme See the Magellan Motion Processor Users Manual for information on these operational modes Pulse amp direction input available on ION 3000 only is optional and can be used for either general purpose position feedback or as the master in electronic gearing applications To select pulse amp direction as the input format for the auxiliary position input use the Magellan command Set Encoder Source with axis 2 selected See the Magellan Motion Processor Users Manual for more information There is no index pulse input on the auxiliary position input ION Digital Drive User s Manual 49 A Electrical Signal Interfacing 5 3 Limit and Home Inputs The input buffer for the end of travel limit and home signals is shown in Figure 5 5 This circuit accepts signals in the range of 0 24 V and has TTL compatible Schmidt trigger thresholds It has a pull up to 5V to allow direct interfacing to open collector sources without the need for an external pull up resistor and a 1 3 kHz R C low pass filter to reject noise Figure 5 5 Limit and Home input circuits Limit Limit Home gt 5 4 Position Capture Sources The Magellan Motion Processor has the ability to capture the instantaneous position of the main feedback encoder when a trigger is received from a hardware input The ION module supports three trigger sources Encoder Index Home a
31. ation 55 63 convection cooling method 13 14 current foldback See It current foldback 76 ION Digital Drive User s Manual Index Re D daisy chain 30 data traces 37 DB9M connector 24 59 67 DC brush motors connection 16 drive ratings 55 63 phase current feedback 31 power stage configuration 31 DC bus 31 current monitoring 36 overvoltage and undervoltage 36 DC DC converter 16 30 Defaults amp Limits 34 Developer s Kit 25 diagrams Enable input circuit 53 auxiliary encoder input circuits 49 AxisIn circuit 51 AxisOut circuit 52 connector locator 15 dimensions 60 68 encoder phasing 48 FaultOut circuit 53 ION mounted on DIN rail 46 ION with heatsink attached 45 main encoder input circuits 47 optional DIN rail adapter 46 optional heatsink 45 simplified CAN transceiver circuit 31 simplified serial transceiver 30 differential encoder electrical specifications 56 64 outputs 18 19 signals 47 digital inputs and outputs 56 64 dimensions diagram 60 68 DIN rail adapter 46 grounding and 14 installation 46 removing 46 disabled condition 38 drive ratings 55 64 65 67 68 69 ION 3000 63 drive ratings ION 3000 63 65 Dual Encoder connection summary 21 E electrical specifications 56 64 ION Digital Drive User s Manual 77 A Index Enabled condition 38 encoder auxiliary 49 electrical specifications 56 64 incremental quadrature 47 Index 50 main 47 phasing diagram 48 Encoder Connections 20 environmental speci
32. ature A Feedback 8 Quad A Quadrature B Feedback 9 Quad B Quadrature B Feedback 10 Quad B Index Feedback Il Index Index Feedback 12 Index From auxiliary encoder Quadrature A Auxiliary 5 Quad A Quadrature A Auxiliary 6 Quad A Quadrature B Auxiliary 7 Quad B Quadrature B Auxiliary 8 Quad B Index I O Il High Speed Capture Hall A Feedback 4 Hall A Hall B Feedback 5 Hall B Hall C Feedback 6 Hall C For brushless DC motors an Index signal from the auxiliary encoder is recommended when Hall sensors are not available For all other configurations use of the ION s High Speed Capture signal input is optional Brushless DC motors only ION Digital Drive User s Manual 21 Installation 2 5 6 3 Pulse amp Direction Input Connection Summary ION 3000 Only With ION 3000 it is possible to command the position of the drive using pulse amp direction input signals This mode can be used with all motor types DC Brush Brushless DC and step motor and allows the ION to interface to any general purpose motion controller that outputs pulse amp direction position information Operation of the ION in pulse amp direction input mode is software selectable To enter this mode the encoder source for axis 2 should be set to pulse amp direction and the profile mode should be set to electronic gear See the Magellan Motion Processor User s Guide for more information To connect to the ION in this configuration
33. coders and other external I O e Enable input and Fault output safety interlock e Differential or single ended encoder input buffers for all encoder channels e Signal conditioning buffers and analog filters on all I O signals ION comes packaged in a rugged enclosure with flexible mounting options and reliable signal and power connectors ION is fully RoHS compliant and CE marked Additionally ION 3000 is certified by UL Underwriters Laboratories 10 ION Digital Drive User s Manual 2 Installation In This Chapter ION Model Numbering ION Developer s Kits Required Hardware ION HW Configuration and Mounting Connector Pinouts and Wiring Software Installation Applying Power Status LEDs Communications Configuration Checking Operational Status vvvvvvvvvv 2 1 ION Model Numbering D H104 00 000 0 G D 0 0 Axes Voltage Current Version Contact PMD D Digital drive only Communications 056 15 Heatsink R RoHS K Developer s kit S serial RS232 amp RS485 195 30 mounting options G Green C CAN N Not compliant Contact PMD for Motor type availability 1 DC brush 3 brushless DC Green RoHS amp no Sb BR 4 step ION 500 only The ION family consists of versions to drive three motor types DC brush brushless DC and step with the choice of two communications ports CAN or Serial In addition two overall power levels ate available the ION 500 and ION 3000 models For the ION 500 heat
34. ctions for the various motor types and the corresponding ION modules Module Type Connector Required Signals Optional Signals All Power HV Pwr_Gnd AuxV DC brush Motor Motor Motor Case Shield Feedback Main encoder Quad A Quad A Quad IO 5V B Quad B Index Index IO_Gnd Shield Brushless DC Motor Motor A Motor B Motor C Case Shield Feedback Main encoder Quad A Quad A Quad Commutation Hall A Hall B Hall B Quad B Index Index IO Gnd C IO 5V Shield Microstepping Motor Motor A Motor A Motor B Motor B Case Shield Feedback Main encoder Quad A Quad A Quad B Quad B Index Index IO Gnd IO 5V Shield All Auxiliary Auxiliary encoder Quad A Quad A Quad B Quad B lO Gnd IO_5V Shield Pulse and Direction input ION 3000 only Pulse Pulse Direction Direction All 1 10 Enable IO Gnd Limit Limit Home High Speed Capture AxisIn AxisOut FaultOut lO 5V Shield Serial Comm RS232 Tx Rx IO Gnd Select RS485 Select Tx Tx Rx Rx IO Gnd CAN Comm CAN H CAN L CAN Gnd CAN Shield CAN V 2 5 3 Power Connector p A Pin Signal ea TUN I A 7 2 AuxV pl A y 3 Pwr_Gnd ION 500 This connector supplies the main DC power to the ION module To minimize the voltage drop between the DC power supply and the ION power connector ION 3000s should be wired with 14 AWG wire ION 500s should be wired with 16 AWG wire ION has a
35. current Short circuit or overload Off High Red solid Ground Fault Excessive current to ground IO 5V Fault Overloaded out of tolerance Internal Logic Fault Internal hardware failure The hard electrical faults are serious module or system malfunctions that must be rectified before proceeding 38 ION Digital Drive User s Manual Operation 3 6 1 Hard Fault State As an additional safety feature all hard electrical faults put the ION module into the hard fault state In this state the module is completely dormant with even communications disabled A power cycle is required before normal operation can resume The ION module should be disabled and disconnected from its power source before any attempt is made to fix a hard fault condition The following sequence should be used to recover from the hard fault state 1 Unless the failure is clearly caused by external circumstances the ION module should be disconnected from the serial or CANbus network as well as disconnected from all external hardware such as the motor motor encoder power supply etc 2 With all external hardware disconnected restore the module power If the unit is still in the hard fault state as indicated by the red Module Status LED the drive is likely to have sustained an unrecoverable failure and should be considered unusable thereafter A replacement ION module should be used in the application 3 If the Module Status LED indicates tha
36. des Sinusoidal and 6 step Hall commutation Microstepping resolution Up to 256 microsteps per step Maximum encoder rate 10 Mcounts per second PWM frequency 20 kHz or 40 kHz user selectable Loop rates Commutation amp current loop 51 2 usec Position loop amp trajectory generator 102 4 usec to 1 67 sec selectable in multiples of 51 2 usec from n 2 to 2 6 3 ION 500 Electrical AuxV input voltage range 12 56 VDC IO_5V supply output 5V 2 300 mA total max short circuit protected Differential single ended encoder inputs Signals Main encoder A A B B Index Index Auxiliary encoder A A B B Voltage range 0 5 VDC Logic threshold RS422 compatible Max frequency 2 5 MHz Phasing A leads B by 90 20 Index low must align with the A low and B low states and be low for less than 540 total See Figure 3 3 Digital inputs Signals Hall A Hall B Hall C Home Limit Limit AxisIn High speed Capture Enable Voltage range 0 5 VDC Logic threshold TTL compatible Max Hall frequency 400 Hz Digital outputs Signals AxisOut FaultOut Voltage range 0 24 VDC Output current 4mA source 100 mA sink short circuit protected to 30V ION Digital Drive User s Manual ION 500 Specifications l RS232 485 Communications Baud Rates 1200 2400 9600 19 2k 57 6k 115k 230k 460k Default is 57 6k 460k support for RS485 only Isolation None
37. ducts or services does not constitute PMD s approval warranty or endorsement thereof ION Digital Drive User s Manual A Related Documents Magellan Motion Processor User s Guide Complete description of the Magellan Motion Processor features and functions with detailed theory of its operation Magellan Motion Processor Programmer s Command Reference Desctiptions of all Magellan Motion Processor commands with coding syntax and examples listed alphabetically for quick reference Pro Motion User s Guide User s guide to Pro Motion the easy to use motion system development tool and performance optimizer Pro Motion is a sophisticated easy to use program which allows all motion parameters to be set and or viewed and allows all features to be exercised Iv ION Digital Drive User s Manual Table of Contents de Table of Contents List of F19ur S e ton orent peche oa e Ns RARUS vii L Introduction si 2 20 lx lI GR IEEE TET pale TR EA e 9 1 1 ION Digital Drive Overview ener enne 9 1 2 ION Features and Functions nono nonnnnrnnnonnrnnrrnn ron FFYN 10 2 Installation 2 0 0 ccc ccc ccc cc cc ce cece eee hh nn 11 2 TON Mod l Numbering us GG ee es 11 2 2 SION Developer s Kits eoe eerte ev eee ee 12 2 3 Required Hardware iia Uh SS tie arci ede 13 2 4 ION Hardware Configuration and Mounting eee 13 2 5 Connector Pinouts and Wiring enne 1
38. e any product or service without notice and advises customers to obtain the latest version of relevant information to verify before placing orders that information being relied on is current and complete All products are sold subject to the terms and conditions of sale supplied at the time of order acknowledgement including those pertaining to warranty patent infringement and limitation of liability Safety Notice Certain applications using semiconductor products may involve potential risks of death personal injury or severe property or environmental damage These products are not designed authorized or warranted to be suitable for use in life support devices or systems or other critical applications Inclusion of PMD products in such applications is un derstood to be fully at the customet s risk In order to minimize risks associated with the customer s applications adequate design and operating safeguards must be provided by the customer to minimize inherent procedural hazards Disclaimer PMD assumes no liability for applications assistance or customer product design PMD does not warrant or represent that any license either express or implied is granted under any patent right copyright mask work right or other in tellectual property right of PMD covering or relating to any combination machine or process in which such products ot services might be or are used PMD s publication of information regarding any third party s pro
39. efault Parameter value Limit Brushless DC model 8 073Arms Must be lt 8 073Arms Foldback Continuous RMS Current Brushless DC model 443 1 Apms sec Must be lt 443 1 Apmgsec Foldback Total Energy DC Brush model Foldback 9 889Apc Must be lt 9 889Apc Continuous DC Current DC Brush model Foldback 6647 Ap sec Must be lt 664 7 Apc sec Total Energy Step motor model 5 052An Ms Must be lt 5 052Apms Foldback Continuous RMS Current Step motor model 443 1 Agmsisec Must be lt 443 1 Apmgsec Foldback maximum energy For the ION 500 default values and limits for the Foldback Continuous Current Limit and Foldback Energy Limit are designed to be safe for operation in the drive s highest output mounting option namely horizontal to cold plate See Section 2 4 ION Hardware Configuration and Mounting for information on ION mounting options For other mounting configurations or for use with motors that have lower current and energy limits it may be useful to set these parameters to values lower than the default values It is the responsibility of the user to set the Foldback Continuous Current and Foldback Energy Limit parameters to values that are safe for the specific ION 500 mounting configuration and motor setup being used 34 ION Digital Drive User s Manual Operation 3 3 4 2 ION 3000 Power Stage Defaults and Limits Default Parameter value Limit Brushless DC model 10 6
40. el ein teh Bi ere e NT el bo eA Rente BWA 17 Typical motor wiring LL 18 Recommended feedback wiring 2 cece cee eee he 19 Recommended auxiliary encoder wiring 20 Single Encoder Mode connections 20 Dual Encoder Mode Connections 0 cee YY FFY FFF FY Y YY uu 21 Typical I O WINE aaae a IO te e Rudd dee Rade ile ses duet ace 23 RS232 485 wiring cui BR ee e Rep exe cr eer Cer e RE PIER IR 24 ION block diagram i ue Lees ere Ret Rete ec cata Ry do 29 Simplified serial transceiver diagram LL 30 SSimplified CAN transceiver circuit diagram 3l ION 500 heatsink urbe epe rr tiere decree d ta 45 ION 500 with heatsink attached 45 Attaching the optional DIN rail adapter LL 46 ION mounted on DIN rail 46 Main encoder input circuits 0 ccc eh 47 Encoder phasing diagram LL 48 Hall input circuits giri esr eye a t e Gee dre re I ees 48 Auxiliary encoder input circuitS Y YY Y FF FF ee 49 Limit and Home input circuits F YY FF IR 50 High Speed Capture circuit se a eraen eicae ei ane obere d d Met eese arl re obe bon 51 AXisIn clteUlt ero ese AAA AAA Roms AA AEN 5l AxisOut circult us uw sn AE a MYD YS medi ted at So ene e 52 FaultOut ircuito ni A A A eer RR pd Rare RM Y EC 53 Enablerinput cir Ultu 2 252 2 casts na Ye aise hei Ur ate gd Wa a RR TR RR yg cwd ny QD SD du hye 53 ION 500 dimensions eiii teme RR hehe epee tee ace Dach cc e RR aas Ro
41. er s Guide e C Motion and VB Motion CD including PDFs of all ION documentation e Communications cable CAN or Serial depending on model ordered e CAN terminator CAN version only e Stub cable set a complete set of cables with matching ION connectors on one end and flying leads on the other For more information on these accessory products refer to Chapter 4 Options and Accessories 2 2 1 Developer s Kit Model Number Examples Comm Model Number Power Motor Type Port DK141S0 056 15 ION 500 Step Motor Serial DK131C0 195 30 ION 3000 Brushless DC CAN ION Digital Drive User s Manual Installation 2 2 3 Required Hardware To install an ION Digital Drive the following hardware is required e A host controller The recommended PC platform is an Intel or compatible processor Pentium or better one available COMM port 30 MB of available disk space 32MB of available RAM and a CD ROM drive The supported PC operating systems are Windows 9X ME NT XP e For RS485 or CAN communications a PCI card PCMCIA card or USB adapter supporting that com munications standard connected to the PC e Mounting screws to attach the ION module to your cabinet or system e Properly sized DC bus power supply e Step DC brush or brushless DC motor with encoder as required by the application e Cables Either the Stub cable set that comes with ION Developer s Kits or custom cables designed for the system e Limit switches and other I O as requi
42. ermal pad permanently attached to its mounting surface The heatsink attaches to the ION enclosure base using the four mounting holes and four 4 M3x10 cross head screws supplied Figure 4 1 ION 500 heatsink M3x0 5 threaded through hole 4 places Figure 4 2 ION 500 with heatsink attached ION Digital Drive User s Manual 45 Va Options and Accessories Figure 4 3 Attaching the optional DIN rail adapter Figure 4 4 ION mounted on DIN rail 46 4 4 Optional DIN Rail Adapter ION 500 Only The optional DIN rail adapter fits on the back of the ION module and allows ION to be mounted to a standard 35mm DIN rail To install the adapter place the tab into the large hole in the enclosure and rotate the adapter clockwise as shown in Figure 4 3 The recommended insertion orientation is indicated When subsequently mounted on a horizon tal DIN rail the Communications connector will be up and the adapter release tab down To remove the adapter pry up the two ends while applying rotation force A flat blade screwdriver may be reguired ION Digital Drive User s Manual 5 Electrical Signal Interfacing Im This Chapter Motor Feedback Auxiliary Position Input Limit and Home Inputs Position Capture Sources AxisIn and AxisOut Signals Enable and FaultOut Signals 5 1 Motor Feedback The Feedback connector contains the main encoder signals
43. et is copied to the active set The active set can be changed at any time with a software command but will revert to the default set at the next powerup or reset The default values for CAN and RS485 parameters can also be changed with a software command Once programmed these new default values will be used at the next powerup or reset Changing the default set does not immediately affect the active parameter set For RS232 communications the situation is deliberately different The active set can be changed with a software command but there is no way to change the defaults Upon powerup or reset the parameters are always reset to the factory defaults This guarantees that RS232 communications cannot be accidentally put into a state that is incompatible with the host 2 9 1 Factory Defaults The following values are pre programmed into non volatile memory at the factory CAN Node ID 0 and Transmission Rate 20k baud RS232 485 57 6k baud no parity 1 stop bit and multi drop networking mode disabled See the Magellan Motion Processor Programmers Command Reference for more information on node ID Transmission Rate and other serial communications parameters 2 9 2 RS232 485 Selection At powerup ION reads the state of the Select pin to decide which protocol to use and automatically loads the appropriate set of default values from non volatile memory Changing the state of the Select pin on the fly is not recommended Doing so
44. ference can be found on the CD included with the ION developer s kit The Adobe Acrobat Reader is required for viewing these files If the Adobe Acrobat Reader is not installed on your computer you may download it at no cost from http www adobe com ION Digital Drive User s Manual 25 26 Installation 2 7 Applying Power Dangerous voltages temperatures and currents exist in all motor drive systems Do not apply power to the ION module until the motor and system wiring is complete and the ION module and motor are securely mounted It is best to leave the motor disconnected from its load until after power is applied for the first time and correct operation is verified The customer must not attempt to service or rewire an ION drive without first shutting down the drive and disconnecting it from its power source Failure to follow this warning may result in fire bodily harm or damage to the product Upon power up ION will be in a reset condition In this condition no motor output will be applied and the motor will remain stationary If the motor does move or jump remove power from the module and re check the wiring If anomalous behavior is still observed call PMD for application assistance Complete PMD contact information is listed on the final page of this manual 2 8 Status LEDs ION has two bi color LEDs to indicate the basic operational status of the module and the communications link The location of these
45. fications 60 68 F factory defaults 27 FaultOut signal 23 53 faults hard 38 feedback connector 47 pinouts 18 58 66 wiring 18 forced air cooling method 13 14 frequency PWM 31 ripple current 31 G ground fault 36 38 H Hall signals 18 47 48 hard electrical faults 38 hard fault state 39 H Bridge 31 heatsink mounting optional 45 High Speed Capture 23 50 home inputs 50 I I O connector pinouts 23 58 66 signals 52 wiring 23 Pt current foldback 31 energy limit 31 incremental quadrature encoders 47 index alignment 47 event 47 phasing 48 inputs Enable 26 A and B quadrature 47 78 ION Digital Drive User s Manual Index Re auxiliary encoder 49 digital 56 64 Hall 48 High Speed Capture 23 50 limit and home 50 main encoder 47 guadrature 47 installation applying power 26 communications configuration 27 configuration and mounting 13 connector pinouts 15 DIN rail adapter 46 hardware reguirements 13 model numbers 11 software 25 status LEDs 26 wiring 16 Internal Logic Fault 38 IO 5V 23 auxiliary encoder connector 19 fault 38 feedback connector 18 I O connector 23 monitor 36 power connector 16 L LEDs communications Comm status 26 hard electrical faults 38 Module Status 26 operational and fault modes 38 limit inputs 50 loop rates 56 64 M main encoder input circuits 47 main encoder signals 49 mechanical specifications 59 67 microstepping drive connection 16 model numbers 11 modes c
46. g connector mfg type Generic DB9M Select 2 Tx RS232 3 Rx RS232 4 No connect 5 IO Gnd 6 Rx RS485 7 Rx RS485 8 Tx RS485 9 Tx RS485 Connector CAN Pin Signal Mating connector mfg type Generic RJ45 8P8C CAN_H 2 CAN_L The dual RJ45 jacks are fully connected in parallel CAN V CAN Shield 3 CAN Gnd and the Reserved pins are not connected internally and simply pass the 4 Reserved signals through to the other jack 5 Reserved 6 CAN Shield 7 CAN Gnd 8 CAN V 7 6 ION 3000 Mechanical Specification Value Dimensions See Figure 7 1 Weight llb I oz 0 50 kg Enclosure materials Aluminum base and molded plastic cover Mounting options Coldplate and panel Recommended mounting screws 6 M3 or M3 5 Protection class IP20 ION Digital Drive User s Manual 67 ha ION 3000 Specifications Figure 7 1 ION 3000 dimensions 7 7 ION 3000 Environmental Specification Value Operating ambient temperature 0 to 40C Maximum base plate temperature 70C Storage temperature 20 to 85 C Humidity 0 to 95 non condensing Altitude Up to 2000 meters without derating Contamination Pollution Degree 2 7 8 ION 3000 Safety and Compliance Specification Standards CE LVD EN60204 EMC D EN61000 6 EN61000 6 3 EN5501 I safety Designed to UL508C UL840 and EN60204 I Hazardous materials RoHS compliant Flammability UL 94 V2 or VO Enclosure IP20 68 ION Digital Drive User s Manual ION 3000
47. ge Continuous coldplate mount Tbp lt 40 C 15 ADC 10 6 Arms 5 7 Arms Peak 2 sec 30 ADC 30 Arms 30 Arms Max continuous output power at 180V nominal voltage 2700 W 2336 W 1310 W 7 2 ION 3000 Controller Performance Supported motor types DC brush brushless DC step motor Communications options RS232 485 and CANbus Both RS485 and CAN versions are networkable Profile modes S curve point to point Position velocity acceleration deceleration jerk Trapezoidal point to point Position velocity acceleration deceleration Velocity contouring Velocity acceleration deceleration Electronic gearing Using auxiliary encoder or pulse and direction Position loop filter parameters Scalable PID with Velocity and Acceleration feedforward integration limit offset bias dual biquad filter and settable derivative sampling time Also supports dual encoder feedback ION Digital Drive User s Manual 63 ha ION 3000 Specifications 64 Position error tracking Motion error window Allows axis to be stopped upon exceeding programmable window Tracking window Allows flag to be set if axis exceeds a programmable position window Configurable loop modes DC brush and brushless DC motor versions Position torque current and voltage Step motor version Open loop with stall detection current and voltage Digital current loop Filter parameters Scalable PI with integration limit and torque current limit Configuration Sta
48. general purpose auxiliary encoder position feedback master slave electronic gear operation or dual loop servo filter operation See the Magellan Motion Processor User s Guide for more information on these control modes The following diagram and table summarizes the connections for a single encoder Auxiliary Feedback Main Encoder Quad A B Single Encoder Mode Connection from Encoder ION Connector Pin ION Pin Quadrature A Feedback 7 Quad A Quadrature A Feedback 8 Quad A Quadrature B Feedback 9 Quad B Quadrature B Feedback 10 Quad B Index Feedback Il Index Index Feedback 12 Index Hall A Feedback 4 Hall A Hall B Feedback 5 Hall B Hall C Feedback 6 Hall C Brushless DC motors only ION Digital Drive User s Manual Installation 2 5 6 2 Dual Encoder Connection Summary In a two encoder connection one encoder measures the load position and is the primary encoder The second auxiliary encoder is located on the motor shaft measures the motor position and is used for stabilization The following diagram and table shows how to connect two encoders to the ION Auxiliary Encoder Auxiliary Feedback Figure 2 7 Dual Encoder Mode Connections Primary Encoder Dual Encoder Mode Connection from Encoder ION Connector Pin ION Pin From primary encoder Quadrature A Feedback 7 Quad A Quadr
49. gure 7 6 DC brush output current vs temperature with 48V input Figure 7 7 DC brush output current vs temperature with 180V input 71 ION 3000 Specifications Figure 7 8 Microstepping output current vs bus voltage at 40 C ambient Figure 7 9 Microstepping output current vstemperature with 48V input 72 Continuous current A 40C ambient Continuous current A 48V N e i i 100 120 140 160 Bus voltage V Microstepping RMS L Microstepping IDC i fi 25 30 35 40 Microstepping i it 45 50 5 5 60 baseplate temperature C 70 ION Digital Drive User s Manual ION 3000 Specifications rN Microstepping IDC Microstepping RMS i Figure 7 10 Microstepping output current vs temperature with 180V input Continuous current A 180V i i i i i i i 20 25 30 35 40 45 50 55 60 65 70 Microstepping baseplate temperature C ION Digital Drive User s Manual 73 y ION 3000 Specifications This page intentionally left blank 74 ION Digital Drive User s Manual Index Re Index Symbols Enable and FaultOut Signals 53 Enable input 26 Enable signal 53 Numerics 3 3V supply monitor 36 3 phase bridge 31 4 guadrant operation 31 A A and B guadrature inputs 47 auxiliary encoder connector 49 pinouts 19 58 66 wiring 19 Auxiliary Voltage AuxV input 16 AxisIn and AxisOut signals 23 51 B Block
50. he motion processor has the ability to invert the polarity of the A B and Index signals with a software command this command cannot be used to alter the index alignment because the inversion takes effect after index 1 qualification 5 1 2 Hall Inputs The input buffer for the Hall A B and C signals is shown in Figure 5 3 This circuit accepts signals in the range of 0 24 V and has TTL compatible Schmidt trigger thresholds It has a pull up to 5V to allow direct interfacing to open collector sources without the need for an external pull up resistor and a 2 5 kHz R C low pass filter to reject noise Figure 5 3 Hall input circuits Hall A Hall B Hall C 74ACT14 The Hall signals are only used with brushless DC motors They are used to directly commutate the motor in 6 step commutation mode or to provide an absolute phase reference for sinusoidal commutation 48 ION Digital Drive User s Manual Electrical Signal Interfacing 5 2 Auxiliary Position Input The differential input circuitry for the auxiliary position input signals is shown in Figure 5 4 This circuit accepts both differential and single ended signals in the range of 0 5 V For single ended operation the unused input should be left floating Figure 5 4 A B or Pulse Direction Auxiliary A B or Pulse Direction a encoder input DS26LV32AT circuits Auxiliary encoder input is optional and can be used for general purpose position feedback as the m
51. ications options RS232 485 and CANbus Both RS485 and CAN versions are networkable Profile modes S curve point to point Position velocity acceleration deceleration jerk Trapezoidal point to point Position velocity acceleration deceleration Velocity contouring Velocity acceleration deceleration Electronic gearing Using auxiliary encoder Position loop filter parameters Scalable PID with Velocity and Acceleration feedforward integration limit offset bias dual biquad filter and settable derivative sampling time Also supports dual encoder feedback Position error tracking Motion error window Allows axis to be stopped upon exceeding programmable window Tracking window Allows flag to be set if axis exceeds a programmable position window ION Digital Drive User s Manual 55 La ION 500 Specifications 56 Configurable loop modes DC brush and brushless DC motor versions Position torque current and voltage Step motor version Open loop with stall detection current and voltage Digital current loop Filter parameters Scalable PI with integration limit and torque current limit Configuration Standard phase A B control or FOC with state vector PWM user selectable Current feedback scaling 100 full scale equals 21 2 A Current foldback DC brush and brushless DC motor versions Programmable rt peak limiting Step motor version Programmable automatic holding current reduction Brushless DC commutation mo
52. mmended feedback wiring ended Encoder amp Halls The shield drain wire should be connected at the ION module connector end only 1 2 5 6 Auxiliary Connector Pin Signal Shield IO_Gnd IO_5V No connect Quad A or Pulse pulse input available on ION 3000 only Quad A or Pulse pulse input available on ION 3000 only Quad B or Direction direction input available on ION 3000 only 8 Quad B or Direction direction input available on ION 3000 only N OJ A wj N ION provides a second quadrature encoder port for use as a master in master slave and electronic gearing applications ot for the ION 3000 only a pulse and direction input for use in electronic gear applications As on the main encoder port ION supports both single ended and differential signal input This connector supports wire gauges from 20 to 30 AWG depending on the crimp terminal used Wiring with 22 AWG twisted pair shielded cable is recommended ION Digital Drive User s Manual 19 Installation Figure 2 5 Recommended auxiliary encoder wiring Figure 2 6 Single Encoder Mode connections 20 Differential Aux pe The shield drain wire should be connected at the ION module connector end only 2 5 6 1 Single Encoder Connections Summary ION can be connected to feedback encoders in both a single and a dual encoder configuration Dual encoder input may be useful for
53. n Pe aca 60 ION 500 Derating curve for DC brush module 0 LL 61 ION 500 Derating curves for brushless DC module VYFF FF Y Yu 61 ION 500 Derating curves for step motor module 0 LL 62 ION 3000 dimensions iaa a E a 68 BLDC output current vs bus voltage at 40 C ambient ce cee cece ees 69 BLDC output current vs temperature with 48V input 2 cece eee eee Yu 69 BLDC output current vs temperature with 180V input 70 DC brush output current vs bus voltage at 40 C ambient VVVY eee 70 DC brush output current vs temperature with 48V input 71 DC brush output current vs temperature with 180V input 71 Microstepping output current vs temperature with 48V input 0 eee eee Y eee 72 Microstepping output current vs bus voltage at 40 C ambient 00 0 cece eee eee 72 Microstepping output current vs temperature with 180V input eee ee 73 ION Digital Drive User s Manual vii A List of Figures This page intentionally left blank viii ION Digital Drive User s Manual 1 Introduction In This Chapter ION Digital Drive Overview ION Features and Functions 1 1 ION Digital Drive Overview TheION Digital Drives are a family of single axis motion controllers with integrated power electronics and serial network com munications Various models are available to drive DC brush brushless DC and step motors In addition two
54. nd High Speed Capture input The choice of trigger source is selectable through software The input circuits for Index and Home are described in sections 5 1 1 and 5 3 respectively 5 4 1 High Speed Capture Input This dedicated input is specifically designed for high speed signals It is similar to the Home input with the exception that the R C low pass filter bandwidth has been increased to 1 2 MHz This value is a compromise between noise rejection and trigger latency 50 ION Digital Drive User s Manual Electrical Signal Interfacing Figure 5 6 High Speed Capture circuit High Speed Capture __ gt LEES 5 5 Axisln and AxisOut Signals The input buffer for the AxisIn signal is shown in Figure 5 7 This circuit accepts signals in the range of 0 24 V and has TTL compatible Schmidt trigger thresholds It has a pull up to 5V to allow direct interfacing to open collector sources without the need for an external pull up resistor and a 13 kHz R C low pass filter to reject noise Figure 5 7 Axisln circuit The output driver for the AxisOut signal is shown in Figure 5 8 This circuit can continuously sink over 100 mA and source 4mA from a pull up resistor to 5V The diode in series with the pull up resistor allows loads powered from up to 24 VDC to be switched The FET driver is internally protected from shorts up to 30 V ION Digital Drive User s Manual 51 A Electrical Signal Interfacing Figure 5 8 AxisOut circuit
55. ndard phase A B control or FOC with state vector PWM user selectable Current feedback scaling 100 full scale equals 42 4 A Current foldback DC brush and brushless DC motor versions Programmable rt peak limiting Step motor version Programmable automatic holding current reduction Brushless DC commutation modes Sinusoidal and 6 step Hall commutation Microstepping resolution Up to 256 microsteps per step Maximum encoder rate 10 Mcounts per second PWM frequency 20 kHz or 40 kHz user selectable Loop rates Commutation amp current loop 51 2 usec Position loop amp trajectory generator 102 4 usec to 1 67 sec selectable in multiples of 51 2 usec from n 2 to dele 7 3 ION 3000 Electrical AuxV input voltage range 20 195 VDC IO 5V supply output 5V 2 300 mA total max short circuit protected Differential single ended encoder inputs Signals Main encoder A A B B Index Index Auxiliary encoder A A B B or Pulse Pulse Direction Direction Voltage range 0 5 VDC Logic threshold RS422 compatible Max frequency 2 5 MHz Phasing A leads B by 90 20 Index low must align with the A low and B low states and be low for less than 540 total Digital inputs Signals Hall A Hall B Hall C Home Limit Limit AxisIn High speed Capture Enable Voltage range 0 5 VDC Logic threshold TTL compatible Max Hall frequency 400 Hz ION Digital Drive
56. onfigurable loop 56 64 fault 38 operational 38 Module Status LED 26 monitor ION Digital Drive User s Manual 79 A Index 3 3V supply 36 IO 5V 36 MOSFET power stages 31 32 motor case wire 18 motor connector applying power 26 pinouts 17 57 65 wiring 17 Motor Feedback 47 motor feedback 47 mounting cooling methods and 13 14 dimensions diagram 59 67 DIN rail adapter 46 mechanical specifications 59 67 optional heatsink 45 recommended surface 13 14 multi drop networking 30 N networking CANbus 25 configurations 24 factory defaults 27 multi drop 30 termination 24 noise CAN Shield pins and 25 minimizing electrical 14 17 R C lowpass filter and 48 shielded cable and 25 O operating temperature 32 orientation recommended 13 14 outputs differential encoder 19 digital 56 65 single ended 18 19 overcurrent fault 38 overtemperature protection 32 overtravel limits 23 overvoltage threshold 36 P packets communications 26 phase current feedback 31 pinouts auxiliary encoder connector 19 58 66 CAN connector 25 59 67 80 ION Digital Drive User s Manual Index Re feedback connector 18 58 66 VO connector 23 58 66 motor connector 17 57 65 power connector 16 57 65 point to point communications 30 polarity Index 48 ports communication 30 Position Capture Sources 50 position error tracking 55 64 power applying 26 overvoltage threshold 36 power connector pinouts 16 57 65 wiring 16 poweru
57. overall power levels are available The ION 500 providing up to 500 watts of power output and the ION 3000 providing up to 3 000 watts of power output ION digital drives are based on PMD s Magellan Motion Processor technology and perform profile generation encoder position feedback position servo compensation step motor stall detection brushless DC motor commutation microstep generation and digital current torque control Network communications options include CANbus RS485 and RS232 All members of the ION family have integrated high power drive stages which fully protect from overcurrent under voltage overvoltage overtemperature and short circuit faults In addition to extensive motion I O capability ION also features Auxiliary Encoder inputs and dedicated Enable input and Fault output safety interlocks ION s flexible mount ing configurations include both a vertical and a horizontal option while ION 500 offers an additional DIN rail mount option with optional heatsink This manual describes the features and functions of the ION family of Digital Drives For more information on the Magellan Motion Processor and its software command set refer to the Magellan Motion Processor Users Guide and the Magellan Motion Processor Programmers Command Reference ION Digital Drive User s Manual hd Introduction 1 2 ION Features and Functions At the heart of ION is the Magellan Motion Processor This enhanced member of the Magellan f
58. p module status LED 26 RS232 485 selection and 27 profile modes 55 63 Pro Motion application CD 25 communications configuration wizard 27 protection circuits 57 65 PWM freguency 31 ripple current 31 switching scheme 31 PWM Power Stage 31 Q quadrature A and B inputs 47 encoders 18 19 incremental encoders 47 R R C lowpass filter bandwidth Enable and FaultOut signals 53 Hall inputs 48 high speed capture input 50 limit and home inputs 50 reset condition 26 RJ45 connector 25 30 RS232 485 connector communication ports 30 electrical specifications 57 65 factory defaults 27 selection 27 wiring 24 ION Digital Drive User s Manual 81 A Index S safety and compliance specifications 61 68 safety interlocks 53 Select pin 27 servo motors 31 shielded cable 17 auxiliary encoder connector 19 CAN ports 25 feedback connector 18 I O connector 23 motor connector 17 signal connectors 58 66 signals Enable 23 53 AxisIn and AxisOut 23 51 FaultOut 23 53 single ended 47 Single Encoder connection summary 21 single ended auxiliary encoder signals 49 encoder inputs 56 64 sinusoidal commutation 48 software installation 25 specifications controller performance 55 63 drive ratings 55 electrical 56 environmental 60 68 mechanical 59 67 safety and compliance 61 68 specifications ION 3000 drive ratings 63 electrical 64 Specificiations ION 3000 63 SPI bus 32 status LEDs 26 step motors automatic holding current red
59. r Feedback Pin Signal Mating connector mfg type Molex MicroFit 3 0 plug Shield Mating connector P N 43025 1200 IO Gnd Wire range AWG 20 24 IO 5V 2 3 4 Alternate wire range AWG 26 30 5 Hall B 6 7 8 Recommended crimp terminal 43030 0009 Hall A Alternate crimp terminal 43030 0012 Hall C Quad A Quad A 9 Quad Bt 10 Quad B Il Index 12 Index Connector Auxiliary Pin Signal Mating connector mfg type Molex MicroFit 3 0 plug Shield Mating connector P N 43025 0800 2 IO Gnd Wire range AWG 2024 3 IO 5V Recommended crimp terminal 43030 0009 4 No connect Alternate wire range AWG 26 30 5 Quad A or Pulse Alternate crimp terminal 43030 0012 6 Quad A or Pulse 7 Quad B or Direction 8 Quad B or Direction Connector I O Pin Signal Mating connector mfg type Molex MicroFit 3 0 plug Shield Mating connector P N 43025 1400 2 IO Gnd Wire range AWG 20 24 3 IO 5V Recommended crimp terminal 43030 0009 4 IO Gnd Alternate wire range AWG 26 30 5 IO 5V Alternate crimp terminal 43030 0012 6 IO Gnd 7 FaultOut 8 Limit 9 Limit 10 Home E High Speed Capture 12 Axisln 13 AxisOut 14 Enable 66 ION Digital Drive User s Manual ION 3000 Specifications rN 7 5 3 Communications Connectors Connector RS232 485 Pin Signal Matin
60. re condition is detected ION shuts down the output stage indicates the fault with the Module Status LED and optionally activates FaultOut The overtemperature threshold is user settable to any value below the maximum rated operating temperature of the output stage See Section 6 4 ION 500 Protection Circuits for the programmable overtemperature range and the Magellan Motion Processor Programmers Command Reference for more information on setting the temperature threshold Refer to the Magellan Motion Processor Users Guide and the Magellan Motion Processor Programmers Command Reference for more information on Operating Modes and on setting up these current foldback parameters 3 3 3 Power Stage Scaling Parameters To correctly control various ION features via the Magellan Motion Processor it is necessary to know certain drive specific scale factors The following tables summarize these values 3 3 3 1 ION 500 Power Stage Scaling Parameters Parameter Commands Scaling Example Current GetCurrentLoopValue 1 296 mA count A value of 12 345 from the command GetFOCValue GetCurrentLoopValue for the ActualCurrent parameter corresponds to a current of 12 345 counts 1 296 mA count 15 999A Step motor amp SetCurrentFoldback 4587 mArmg count To set a continuous current limit of 5 00Agms Brushless DC GetCurrentFoldback using the SetCurrentFoldback command a Continuous RMS value of 5 000mApms 4587 mArmg count serene Limi
61. red for the application 2 4 ION Hardware Configuration and Mounting There are no user settable switches jumpers or potentiometers within the ION module All hardware features are software configurable from the host computer via the communications port The module should be firmly mounted in the desired orientation with adequate space to allow it to be effectively cooled ION is designed to allow maximum mounting flexibility 2 4 1 ION 500 Mounting Options Recommended Recommended Cooling Method Orientation Mounting Surface Mounting Method Coldplate Any Either Horizontal 4 screws Vertical 2 screws Convection Vertical Back small side 2 screws or DIN rail adapter Convection with Vertical Back small side 2 screws or DIN rail adapter Optional Heatsink Forced Air Any Either 2 or 4 screws or DIN rail adapter Forced Air with Any Back small side Horizontal 4 screws Optional Heatsink Vertical 2 screws Refer to Section 6 6 ION 500 Mechanical for information on mounting dimensions and mounting hole sizes for the ION 500 ION Digital Drive User s Manual 13 14 Installation 2 4 2 ION 3000 Mounting Options Recommended Recommended Cooling Method Orientation Mounting Surface Mounting Method Coldplate Any Either Horizontal 4 screws Vertical 2 screws Convection Vertical Back small side 2 screws Forced Air Any Either 2 or 4 screws or DIN rail adapter To minimize electric
62. roller Performance nr nnnn rn YH HR HI I HI HF 55 6 3 ION 500 Electrical nuu GWY FC YF YF iaa 56 6 4 ION 500 Protection Circuits i 57 6 5 ION 500 Connectors and Pimouts non nonncanncnnnos 57 6 6 ION 500 Mechanical _ ener nnne enne 59 6 7 ION S00Environmental er rire eene nennt nennen 60 6 8 ION 500 Safety and Compliance nos 61 6 9 ION 500 Thermal Operating Curves non ncnn non nenn 61 ION Digital Drive User s Manual v A Table of Contents 7 ION 3000 Specifications eese 63 FI ION 3000 Drive Ratin peni IPTE 63 7 2 ION 3000 Controller Performance ii 63 7 3 ION 3000 Ele ctrical cia certi ete eren n tus 64 7 4 ION 3000 Protection Circuits i 65 7 5 ION 3000 Connectors and Pinouts nono nono non HN 65 7 6 TON 3000 Mechanical _ essent enne 67 T ION 3000 Environmentali a tl c etie Te ees 68 7 8 ION 3000 Safety and Compliance non nocononnnnnnonn non HF 68 7 9 ION 3000 Thermal Operating Curves IH III I IH HYN 69 A wee b ee oS eee a oie E ewe eee E 75 vi ION Digital Drive User s Manual List of Figures EN List of Figures Connector locator au or ERR Vd RR EIU DERE CFR AH a 15 Typical power WIFE ines eese aloes alg pe
63. se wire should run within the cable shield If the motor does not come with a case wire or other dedicated case connection a lug under a motor mounting screw can be used The shield drain wire should be connected at the ION module connector end only 2 5 5 Feedback Connector Pin DC Brush Brushless DC Step I Shield Shield Shield 2 IO_Gnd IO_Gnd IO_Gnd 3 IO_5V IO_5V IO_5V 4 Not used Hall A Not used 5 Not used Hall B Not used 6 Not used Hall C Not used 7 Quad A Quad A Quad A 8 Quad A Quad A Quad A 9 Quad B Quad B Quad B 10 Quad B Quad B Quad B Il Index Index Index 12 Index Index Index This connector is used to wire the signals from the main feedback encoder to the ION module For brushless DC motors it also connects the Hall Effect signals typically used to commutate the motor The Halls are not used with DC brush or step motors ION directly supports quadrature encoders with single ended or differential outputs IO 5V and IO Gnd are provided to power the encoder and Hall Effect transducers This connector supports wire gauges from 20 to 30 AWG depending on the crimp terminal used Wiring with 22 AWG shielded cable is recommended For differential encoders twisted pair cable should be used ION Digital Drive User s Manual Installation 2 Differential Encoder amp Halls Figure 2 4 Reco
64. set the Foldback Continuous Current and Foldback Energy Limit parameters to values that are safe for the specific ION 3000 input voltage ION mounting configuration and motor setup being used ION Digital Drive User s Manual 35 ys Operation 3 4 DC Bus 3 4 1 DC Bus Current Monitoring ION monitors both the positive and negative DC bus current to detect overcurrent conditions including line to line line to power supply and line to case ground short circuits Both hard short circuits and excessive current conditions are detected ION can even detect some ground fault conditions caused by a partial winding short circuit between winding and case within a motor When an overcurrent condition occurs the output stage is shut down and the ION module goes into the hard fault state See Section 3 6 1 Hard Fault State for a description of this state 3 4 2 DC Bus Overvoltage and Undervoltage ION monitors the main DC bus voltage for overvoltage and undervoltage conditions These thresholds are user settable within the voltage operating range of the drive When the DC bus voltage drops below the undervoltage threshold ION shuts down the output stage indicates the fault with the Module Status LED and optionally activates FaultOut There are two ways for the DC bus to exceed the overvoltage threshold 1 The supplied DC power is too high There is little the ION module can do about this ION simply turns off the output s
65. t 10 900 should be used DC Brush SetCurrentFoldback 5619 mApc count To set a continuous current limit of 5 00Apc Continuous DC GetCurrentFoldback using the SetCurrentFoldback command a Current Limit value of 5 000mApc 5619 mApc count 8 898 should be used Step motor amp SetCurrentFoldback 0923 Arms Sec count To set a foldback total energy value of 100 0 Brushless DC Pt GetCurrentFoldback Arms Sec using the SetCurrentFoldback Energy command a value of 100 0 Arms Sec 0923 Arms Sec count 1 083 should be used DC Brush SetCurrentFoldback 385 Apc Sec count To set a foldback total energy value of 100 0 Yt Energy GetCurrentFoldback Apc Sec using the SetCurrentFoldback command a value of 100 0 Apc Sec 1385 Arms Sec count 722 should be used Brushless DC motors used in Hall based commutation should use the Apc scale factors All other Brushless DC motor modes should use the Any scale factors 32 ION Digital Drive User s Manual Operation 3 3 3 2 ION 3000 Power Stage Scaling Parameters Parameter Commands Scaling Example Current GetCurrentLoopValue 2 588 mA count GetFOCValue A value of 12 345 from the command GetCurrentLoopValue for the Actual Current parameter corresponds to a current of 12 345 counts 2 588 mA count 31 949A Step motor amp Brushless DC Continuous RMS Current Limit SetCurrentFoldback GetCurrentFoldback 9152 mArms count To set a continuous
66. t a fault is no longer present the cause can be determined by recon necting the communications cable cycling power again and reading the Drive Fault Status from the ION module See the Magellan Motion Processor Users Guide for more information on reading the Drive Fault Status 4 Once the nature of the fault is known it must be corrected It is always the responsibility of the user to main tain safe operating conditions of the ION module as well as all associated electronics or hardware 5 With the source of the problem corrected the ION module can be reinstalled and reconnected It should now function normally ION Digital Drive User s Manual 39 y Operation This page intentionally left blank 40 ION Digital Drive User s Manual 4 Options and Accessories In This Chapter Stub Cable Set Development Kit Cable and Plug Specifications Optional Heatsink ION 500 Only Optional DIN Rail Adapter ION 500 only 4 1 Stub Cable Set The following tables summarize the cables and other accessories that come with each ION Developer s Kit See the next section for detailed information on each cable type ION 500 Serial Cable PMD Part Description Cable RS232 03 R 9 pin RS232 Communications Cable Cable 1002 02 R Feedback Stub Cable Cable 1003 02 R Aux Stub Cable Cable 1004 02 R I O Stub Cable Cable 1005 02 R ION 500 DC Bus Stub Cable Cable 1006 02 R ION 500 Motor Stub Cable ION 500 CANBus Cable PM
67. tage indicates the fault with the Module Status LED and optionally activates FaultOut 2 The motor is decelerating at a rate too high for the DC power supply to absorb the regenerated energy and the DC bus pumps up ION will protect itself by turning off the output stage It also indicates the fault with the Module Status LED and optionally activates FaultOut In either case the DC bus voltage must then fall below the threshold before the module exits this fault state and can be re enabled 3 4 3 IO 5V Monitor ION features a separate 5V supply for powering external encoders Hall sensors and other I O devices This supply is monitored to detect overloading or out of tolerance operation and if either condition occurs ION goes into the hard fault state See Section 3 6 1 Hard Fault State for a description of this state 3 4 4 Motion Processor 3 3V Supply Monitor and Reset Circuit The 3 3V supply for the motion processor automatically forces the processor into the reset state if the supply voltage falls out of regulation 36 ION Digital Drive User s Manual Operation 3 4 5 DC Bus Scaling Parameters To correctly control ION DC Bus features via the Magellan Motion Processor it is necessary to know the DC Bus scale factor The following tables summarize this value 3 4 5 1 ION 500 DC Bus Scaling Parameters Parameter Commands Scaling Example Bus Voltage GetBusVoltage 1 361 mV count A value of 12 345 from the command
68. uction 31 drive ratings 55 63 phase current feedback 31 power stage configuration 31 stub cable 41 T temperature sensors 32 termination CAN 57 65 RS485 24 82 ION Digital Drive User s Manual Index Re Thermal Operating Curves ION 3000 69 Trace Buffer 37 trace buffer 37 trace capture 37 trigger latency 50 trigger sources 50 U undervoltage condition and threshold 36 38 V VB Motion 25 W wiring applying power 26 auxiliary encoder connector 19 feedback connector 18 I O connector 23 motor connector 17 power connector 16 recommended auxiliary encoder 19 recommended feedback 19 typical I O 23 typical motor 18 typical power 17 Z Pulse amp Direction input connection summary 22 ION Digital Drive User s Manual 83 A Index This page intentionally left blank 34 ION Digital Drive User s Manual For additional information or for technical assistance please contact PMD at 781 674 9860 You may also e mail your request to support pmdcorp com Visit our website at http www pmdcorp com PM D Performance Motion Devices 55 Old Bedford Rd Lincoln MA 01773 ION Digital Drive User s Manual 85
69. ule c o 0 i i i i 20 30 40 50 60 70 DC brush baseplate temperature 9C 12 Sinusoidal loc 10 Hall Commutation loc Sinusoidal RMS e 8 D Figure 6 3 3 ION 500 6 3 Derating 2 curves for E 4r brushless DC module DL o i i 20 30 40 50 60 70 Brushless DC baseplate temperature C Note Ipc 1 414 IRms ION Digital Drive User s Manual 61 La ION 500 Specifications 8 T 1 T r Microstepping loc 7 Me 7 Microstepping RMS Figure 6 4 5 ION 500 S Derating 3 4 curves for step Z3 motor module E EMEN S 2 1 o i i i i 20 30 40 50 60 70 Step motor baseplate temperature 9C Note Ipc 1 414 RMs 62 ION Digital Drive User s Manual 7 ION 3000 Specifications In This Chapter ION 3000 Drive Ratings ION 3000 Controller Performance ION 3000 Electrical ION 3000 Protection Circuits ION 3000 Connectors and Pinouts ION 3000 Mechanical ION 3000 Environmental ION 3000 Safety and Compliance ION 3000 Thermal Operating Curves vvvvvvvvv 7 1 ION 3000 Drive Ratings Motor Model Specification DC Brush Brushless DC Step Supply voltage range 20 195 VDC 20 195 VDC 20 195 VDC Output current per phase at 48V nominal voltage Continuous coldplate mount Tbp lt 40 C 20 ADC 15 Arms 10 6 Arms Peak 2 sec 30 ADC 30 Arms 30 Arms Maximum continuous output power at 48V nominal voltage 960 W 882 W 650 W Output current per phase at 180V nominal volta
70. will change the hardware configuration without changing the active set of communication parameters and will most likely result in loss of communications 2 10 Checking Operational Status Once communications have been established the ION module is ready for operation Refer to the Pro Motion Users Guide for a step by step system configuration procedure ION Digital Drive User s Manual 27 Installation This page intentionally left blank 28 ION Digital Drive User s Manual 3 Operation A In This Chapter vvvvvvvv ION Block Diagram PWM Power Stage Communications Ports Internal Protection and Control Signals Operational and Fault Modes Trace Buffer Operational Scaling Parameters Operational Defaults and Limits 3 1 ION Block Diagram ION combines the function of a motion controller and amplifier It directly interfaces to a host computer using a serial or CANBus interlace and connects to all power and feedback signals required to drive a postioning DC Brush Brushless DC or step motor In addition to the Magellan Motion Processor ION incorporates several major subsytems including a communications system a high performance MOSFET based power stage a DC Bus conditioning system and a trace buffer The following sections describe these major sections of the ION Digital Drive For a complete description of the Magellan Motion Processor see the Magellan Motion Processor User s Guide and the Magellan Programmers
71. y one phase current feedback is used By monitoring the DC bus voltage the DC bus current and the output phase currents the ION Digital Drive s output stage is fully protected from overcurrent overvoltage and undervoltage faults and line to line line to power supply and line to earth case ground short circuits The Magellan Motion Processor also implements rt peak current foldback and automatic holding current reduction for step motors 3 3 1 1 t Current Foldback Protection ION uses the current feedback to implement I t current limiting This feature protects the drive by controlling its ability to operate above continuous current ratings This protection feature is active in all operating modes When the current loop is enabled and the rt energy limit is exceeded ION will automatically fold back the phase currents to a user programmable continuous current limit value Alternatively ION can be configured to fault and disable the output stage when the rt energy limit is exceeded When the current loop is disabled ION is operating in voltage control mode only and the re energy limit is exceeded ION will always fault and disable the output stage ION Digital Drive User s Manual 31 ys Operation 3 3 2 Overtemperature Protection ION uses digital temperature sensors to monitor the operating temperature of the output stage power MOSFETs The motion processor communicates with the sensors over the built in SPI bus If an overtemperatu

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