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