PMD ION 500 User manual

Performance Motion Devices, Inc.
80 Central Street
Boxborough, MA 01719
ION Digital Drive
User’s Manual
Revision 1.6 May 2010

ii ION Digital Drive User’s Manual
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 1998–2010 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 iii
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 discontinue 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 customer’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
or services might be or are used. PMD’s publication of information regarding any third party’s products or services
does not constitute PMD’s approval, warranty, or endorsement thereof.

iv ION Digital Drive User’s Manual
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
Descriptions 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.

Table of Contents
ION Digital Drive User’s Manual v
Table of Contents
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 ION Digital Drive Overview............................................................................. 9
1.2 ION Features and Functions............................................................................ 10
2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 ION Model Numbering ...................................................................................11
2.2 ION Developer’s Kits ......................................................................................12
2.3 Required Hardware .........................................................................................13
2.4 ION Hardware Configuration and Mounting ..................................................13
2.5 Connector Pinouts and Wiring ........................................................................15
2.6 Software Installation .......................................................................................25
2.7 Applying Power ...............................................................................................26
2.8 Status LEDs .....................................................................................................26
2.9 Communications Configuration ......................................................................27
2.10 Checking Operational Status ...........................................................................27
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1 ION Block Diagram ........................................................................................29
3.2 Communication Port .......................................................................................30
3.3 PWM Power Stage ..........................................................................................31
3.4 DC Bus ............................................................................................................36
3.5 Trace Buffer ....................................................................................................37
3.6 Operational and Fault Modes.......................................................................... 38
4. Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.1 Stub Cable Set ................................................................................................41
4.2 Development Kit Cable and Plug Specifications ............................................43
4.3 Optional Heatsink (ION 500 Only)................................................................. 45
4.4 Optional DIN Rail Adapter (ION 500 Only) ..................................................46
5. Electrical Signal Interfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1 Motor Feedback............................................................................................... 47
5.2 Auxiliary Position Input ..................................................................................49
5.3 Limit and Home Inputs ...................................................................................50
5.4 Position Capture Sources ................................................................................ 50
5.5 AxisIn and AxisOut Signals ............................................................................51
5.6 /Enable and FaultOut Signals ..........................................................................53
6. ION 500 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.1 ION 500 Drive Ratings ................................................................................... 55
6.2 ION 500 Controller Performance.................................................................... 55
6.3 ION 500 Electrical ..........................................................................................56
6.4 ION 500 Protection Circuits............................................................................ 57
6.5 ION 500 Connectors and Pinouts ....................................................................57
6.6 ION 500 Mechanical ......................................................................................59
6.7 ION 500 Environmental.................................................................................. 60
6.8 ION 500 Safety and Compliance ................................................................... 61
6.9 ION 500 Thermal Operating Curves ...............................................................61

Table of Contents
vi ION Digital Drive User’s Manual
7. ION 3000 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.1 ION 3000 Drive Ratings................................................................................. 63
7.2 ION 3000 Controller Performance ................................................................. 63
7.3 ION 3000 Electrical ........................................................................................ 64
7.4 ION 3000 Protection Circuits......................................................................... 65
7.5 ION 3000 Connectors and Pinouts ................................................................. 65
7.6 ION 3000 Mechanical ................................................................................... 67
7.7 ION 3000 Environmental .............................................................................. 68
7.8 ION 3000 Safety and Compliance ................................................................. 68
7.9 ION 3000 Thermal Operating Curves ............................................................ 69
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

List of Figures
ION Digital Drive User’s Manual vii
List of Figures
Connector locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Typical power wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Typical motor wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Recommended feedback wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Recommended auxiliary encoder wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Single Encoder Mode connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Dual Encoder Mode Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Typical I/O wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
RS232/485 wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
ION block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Simplified serial transceiver diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Simplified CAN transceiver circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
ION 500 heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
ION 500 with heatsink attached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Attaching the optional DIN rail adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
ION mounted on DIN rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Main encoder input circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Encoder phasing diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Hall input circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Auxiliary encoder input circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Limit and Home input circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
High Speed Capture circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
AxisIn circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
AxisOut circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
FaultOut circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
/Enable input circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
ION 500 dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
ION 500 Derating curve for DC brush module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
ION 500 Derating curves for brushless DC module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
ION 500 Derating curves for step motor module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
ION 3000 dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
BLDC output current vs bus voltage at 40
o
C ambient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
BLDC output current vs temperature with 48V input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
BLDC output current vs temperature with 180V input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
DC brush output current vs bus voltage at 40
o
C ambient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Microstepping output current vs bus voltage at 40
o
C ambient . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Microstepping output current vs temperature with 180V input . . . . . . . . . . . . . . . . . . . . . . . . . .73

List of Figures
viii ION Digital Drive User’s Manual
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ION Digital Drive User’s Manual 9999
1
1. Introduction
In This Chapter
ION Digital Drive Overview
ION Features and Functions
1.1 ION Digital Drive Overview
The ION 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 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 User’s Guide and the
Magellan Motion Processor Programmer’s Command Reference.

Introduction
10 ION Digital Drive User’s Manual
1
1.2 ION Features and Functions
At the heart of ION is the Magellan Motion Processor. This enhanced member of the Magellan family provides an
extensive list of motion control functions including:
Serial host communications over RS232, RS485, or CANBus
Trajectory generation, including trapezoidal and S-curve point-to-point profiling, velocity contouring, and
electronic gearing modes
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
Two encoder input channels capable of up to 10 Mcounts per second
Sinusoidal and six-step (Hall) brushless DC commutation modes
Microstepping outputs with up to 256 microsteps per step
Digital current loop with choice of standard A/B or Field Oriented Control (FOC) for both brushless DC
and step motors
Single phase current loop for DC brush motors
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:
High-efficiency MOSFET power stages with versions for single-phase brush DC motors, two-phase step
motors, and three-phase brushless DC motors
I
2
t current foldback limiting
Selectable 20 kHz and 40 kHz PWM frequencies to support a broad range of motor inductance
Overcurrent, short circuit, overvoltage, undervoltage, and overtemperature protection
Single supply operation. An onboard DC/DC converter supplies all internal circuitry and also provides 5V
for encoders and other external I/O.
Enable input and Fault output safety interlock
Differential or single-ended encoder input buffers for all encoder channels
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).
Introduction

ION Digital Drive User’s Manual 11
2
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
2.1 ION Model Numbering
.
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 are available, the ION 500 and ION
3000 models. For the ION 500, heat 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 500 only

Installation
12 ION Digital Drive User’s Manual
2
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.
2.1.2 ION 3000 Part Numbers
The following table shows the base part number configurations for the ION 3000.
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:
Pro-Motion CD and User’s Guide
C-Motion and VB-Motion CD including PDFs of all ION documentation
Communications cable (CAN or Serial, depending on model ordered)
CAN terminator (CAN version only)
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
Model Number Motor Type
Communications
Port
DD131S0-056/15 Brushless DC Serial
DD131C0-056/15 Brushless DC CANBus
DD111S0-056/15 DC Brush Serial
DD111C0-056/15 DC Brush CANBus
DD141S0-056/15 Step Motor Serial
DD141C0-056/15 Step Motor CANBus
Model Number Motor Type
Communications
Port
DD131S0-195/30 Brushless DC Serial
DD131C0-195/30 Brushless DC CANBus
DD111S0-195/30 DC Brush Serial
DD111C0-195/30 DC Brush CANBus
DD141S0-195/30 Step Motor Serial
DD141C0-195/30 Step Motor CANBus
Model Number Power Motor Type
Comm
Port
DK141S0-056/15 ION 500 Step Motor Serial
DK131C0-195/30 ION 3000 Brushless DC CAN

Installation
ION Digital Drive User’s Manual 13
2
2.3 Required Hardware
To install an ION Digital Drive, the following hardware is required:
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.
For RS485 or CAN communications, a PCI card, PCMCIA card, or USB adapter (supporting that com-
munications standard) connected to the PC
Mounting screws to attach the ION module to your cabinet or system
Properly sized DC bus power supply
Step, DC brush, or brushless DC motor, with encoder as required by the application
Cables. Either the Stub cable set that comes with ION Developer’s Kits or custom cables designed for the
system
Limit switches and other I/O as required 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
Refer to Section 6.6, ION 500 Mechanical, for information on mounting dimensions and mounting hole sizes for the
ION 500.
Cooling Method
Recommended
Orientation
Recommended
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
Optional Heatsink
Vertical Back (small side) 2 screws or DIN rail adapter
Forced Air Any Either 2 or 4 screws, or DIN rail adapter
Forced Air with
Optional Heatsink
Any Back (small side) Horizontal - 4 screws
Vertical - 2 screws

Installation
14 ION Digital Drive User’s Manual
2
2.4.2 ION 3000 Mounting Options
Refer to Section 7.6, ION 3000 Mechanical, for information on mounting dimensions and mounting hole sizes for the
ION 3000.
Cooling Method
Recommended
Orientation
Recommended
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 electrical 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.

Installation
ION Digital Drive User’s Manual 15
2
2.5 Connector Pinouts and Wiring
2.5.1 Connector Locator
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
Power/Motor
Module Status LED
I/O
Auxiliary
Feedback
Comm (Serial connector)
Comm Status LED
ION 3000 Left View ION 500 Left View
the left connector view for both the ION 3000 and the ION 500.
Power Motor Motor Power
Figure 2-1:
Connector
locator

Installation
16 ION Digital Drive User’s Manual
2
2.5.2 Motor/Module Type Quick Reference
The following table summarizes the recommended connections for the various motor types and the corresponding
ION modules:
2.5.3 Power Connector
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 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
provides IO_5V for powering encoders, limit switches, and other system
I/O.
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.
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
B+, Quad B-, Index+, Index-), IO_Gnd,
Shield
IO_5V
Brushless DC Motor Motor A, Motor B, Motor C, Case/Shield
Feedback Main encoder (Quad A+, Quad A-, Quad
B+, Quad B-, Index+, Index-), IO_Gnd,
Shield
Commutation (Hall A, Hall B, Hall
C), IO_5V
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-)
IO_Gnd IO_5V, Shield
Pulse and Direction input (ION
3000 only; Pulse+, Pulse-,
Direction+, Direction-)
All I/O /Enable, IO_Gnd +Limit, -Limit, Home, High Speed
Capture, AxisIn, AxisOut, FaultOut,
IO_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
Pin Signal
1+HV
2 AuxV
3 Pwr_Gnd
ION 500
ION 3000
Pin 1

Installation
ION Digital Drive User’s Manual 17
2
A (transformer) isolated power supply should be used for powering ION. The return of this power supply should be
grounded. The size of the power supply has to meet the load requirement. If a regulated power supply is used, care
should be taken to make sure the power supply can sustain the regenerated power. If a diode is used, the input
capacitor should be able to hold the regenerated power without triggering ION into overvoltage protection.
2.5.4 Motor Connector
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
minimize noise.
Pin 3 of the power connector (Pwr_Gnd) should be connected to earth ground as shown in Figure 2-2.
Pin DC Brush Brushless DC Step
1 Motor+ Motor A (U) Motor A+
2 Motor- (ION 3000) Motor B (V) Motor A-
3 Motor- (ION 500) Motor C (W) Motor B+
4 No connect No connect Motor B-
5 Case/Shield Case/Shield Case/Shield
Figure 2-2:
Typical power
wiring
1
2
3
+
HV
-
+
AuxV
-
ION 3000
ION 500
Pin 1

Installation
18 ION Digital Drive User’s Manual
2
2.5.5 Feedback Connector
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.
For best performance, the case 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.
Pin DC Brush Brushless DC Step
1 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-
11 Index+ Index+ Index+
12 Index- Index- Index-
Motor
Case
1
2
3
4
5
Figure 2-3:
Ty p i c a l m o t o r
wiring
Pin 1 Pin 2
Pin 12

Installation
ION Digital Drive User’s Manual 19
2
2.5.6 Auxiliary Connector
ION provides a second quadrature encoder port for use as a master in master-slave and electronic gearing applications
or, 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.
The shield drain wire should be connected at the ION module connector end only.
Pin Signal
1 Shield
2IO_Gnd
3 IO_5V
4 No connect
5 Quad A+ or Pulse+ (pulse input available on ION 3000 only)
6 Quad A- or Pulse- (pulse input available on ION 3000 only)
7 Quad B+ or Direction+ (direction input available on ION 3000
only)
8 Quad B- or Direction- (direction input available on ION 3000
only)
Differential
Encoder
& Halls
3
2
7
8
9
10
11
12
4
5
6
1
5V
G
A+
A-
B+
B-
I+
I-
HA
HB
HC
Single-
ended
Encoder
& Halls
5V
G
A
B
I
HA
HB
HC
3
2
7
8
9
10
11
12
4
5
6
1
Differential
Encoder
& Halls
3
2
7
8
9
10
11
12
4
5
6
1
5V
G
A+
A-
B+
B-
I+
I-
HA
HB
HC
Single-
ended
Encoder
& Halls
5V
G
A
B
I
HA
HB
HC
3
2
7
8
9
10
11
12
4
5
6
1
Figure 2-4:
Recommended
feedback
wiring

Installation
20 ION Digital Drive User’s Manual
2
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 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.
*Brushless DC motors only
The shield drain wire should be connected at the ION module connector end only.
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 11 Index+
Index- Feedback 12 Index-
Hall A* Feedback 4 Hall A
Hall B* Feedback 5 Hall B
Hall C* Feedback 6 Hall C
Figure 2-5:
Recommended
auxiliary
encoder wiring
Differential
Aux
Encoder
3
2
5
6
7
8
4
1
5V
G
A+
A-
B+
B-
ION
I/O Auxiliary Feedback
Main
Encoder
Index
Quad A/B
Single Encoder
Mode
Figure 2-6:
Single Encoder
Mode
connections