IONI user guidebook

This page collect most of the IONI & IONICUBE user guide articles as a single page.

Introduction to IONI

IONI
Device type	Servo & stepping motor drive
Model number	IONI-11K000, IONI-11K200
Supported motors	AC, DC, BLDC, Linear, Stepper
Control modes	Position, Velocity, Torque
Status	Active production, started 2015
Electrical
DC supply voltage	5 - 54 VDC (except 5 - 58 VDC in IONI Pro HC)
Output current range	0.1 - 15A IONI, 0.1 - 18A IONI Pro, 0.1 - 25A IONI Pro HC
Setpoint signals	Pulse and direction, PWM, Analog, SimpleMotion V2
Feedback devices	Quadrature encoder, SinCos encoder
General
Configuration tool	Granity
Web site	Granite Devices IONI
Compliance	CE (EMC & LVD directives)
3D model	IGES & STEP

PDF version of IONI flyer. Download.

IONI is a digital motor drive designed for driving AC/BLDC and DC servo motors and steppers. IONI allows controlling motors in all three operating modes: position control, velocity control and torque control (torque mode only with servo motors). Applications of such control methods include

• Position control, such as CNC, robotics and 3D printing
• Velocity control, such as spindles or feeders
• Force / torque control, such as racing simulator wheel

Commands to IONI drive can be delivered in many formats and from many sources, such as PC, PLC, microcontroller (i.e. Arduino, MBED and OEM boards) or embedded computers like Raspberry Pi. IONI understands several forms of setpoint commands:

• Step & direction digital signals (typical stepper drive interface, good for position control)
• Analog +/-10V signal (good for speed or torque control)
• PWM signal (good for speed or torque control)
• RS485 serial bus (talks SimpleMotion V2 bus protocol, open source library available)

Supported motors

As motor is not included, make sure that you have, or obtain a motor that is compatible with IONI. Learn more about motor types.

Servo motor requirements

• Permanent magnet brush-DC, AC, brushless or linear motor
• Motor voltage rating 12-60 VDC (IONI supply voltage is 5 - 52 VDC)
• Motor current rating 0.1 - 25A (choose drive model accordingly, IONI Pro HC, maximum output is 25A, IONI Pro 18A, and IONI 15A)
• Servo motor must be equipped with an supported feedback device (position sensor / encoder).

See Motor compatibility guide for more details.

Stepping motor requirements

• Two-phase stepping motor with 0.5 - 15A current rating, no feedback device needed. Can be used in position and velocity control mode. Torque mode not possible. Stepper voltage rating is irrelevant, but generally lower voltage & higher current stepper is better.

Unsuitable/non-optimum motors

• Any non-permanent magnet motors: induction AC motor or DC motor with field coil - will not work
• Cheapest grade DC motor, such as one extracted from power drill - might not give satisfying performance
• Motor with very high voltage, such as 200 VAC AC servo motor - it will work if it has incremental encoder feedback, but maximum rotation speed is limited due to drive voltage. Consider Argon servo drive for motors above 100 volts rating.

Features

State of the Art

• High dynamic range torque control
• Wide range motor support, from DC, BLDC, AC and Linear, from 5 W to 500 W
• High functional density and cost efficiency
• 3-level PWM output with reduced motor heating
• Automatically measures motor inductance and resistance for easy setup
• Anticogging / torque ripple compensation

Control

• Input setpoint signals including pulse and direction, quadrature, analog and PWM
• Multidrop & multiaxis capable real-time SimpleMotion V2 field bus for setup & control
• Internal axis homing function with sensorless hard-stop operating mode

Protections & Ruggedness

• Safe torque off
• Prevent machine damage via I²t (motor temperature modeling), blocked motion and tracking error detection
• Industry leading ruggedness: over current, short circuit, over voltage, under voltage and over temperature protections, data/communication error detection
• Warranty 24 months
• Charge pump enable input for safety

Applications

• Industrial servo & stepping motor control
• Robotics
• Industry 4.0 systems
• Testing equipment
• CNC
• Haptics
• Racing & flight simulators
• Pick'n'place machines
• Defense systems

Functionality and specifications

See main article IONI specifications.

Documentation & user guides

See the main article IONI & IONICUBE user guide.

Availability

Shipping worldwide at Granite Devices web shop.

IONI specifications

This page lists official functional, electrical and physical specifications of the IONI Servo Drive.

Device variations

IONI is available in three different models. See also IONI device model comparison.

IONI

Standard model

IONI Pro

Advanced model, additional features and increased current range

IONI Pro HC

Same features as IONI Pro, except higher current and voltage range

Main functionality

Function	Description
Servo/stepping motor drive	Closed loop control of various types of servo motors by sinusoidal field oriented control with dead-time distortion correction and high dynamic range torque control. Synchronous AC & BLDC motors Sinusoidal and trapezoidal commutated SPM (Surface Permanent Magnet) and IPM (Internal Permanent Magnet) types Brush DC motors Linear motors Iron core Ironless (with external inductive filter) Stepping motor, 2 phase (4,6 or 8 wires)
Control modes	Torque control Velocity/speed control Position control
Setpoint types	See setpoint signal / reference inputs list Direct set-point tracking via pulse and direction, PWM, Analog, Quadrature, SimpleMotion V2 Pulse burst positioning Buffered synchronous motion commands via SimpleMotion V2
Closed loop	Cascaded control loops (PIV): Torque / current control, update frequency 20.0 kHz Velocity control, update frequency 2.5 kHz Position control, update frequency 2.5 kHz
Feed-forwards	Feed-forwards working in velocity & position control modes: Acceleration (inertia canceling) feed-forward Velocity (friction canceling) feed-forward
Homing	Integrated homing function for position control mode: Sensorless hard-stop homing Home switch search Index pulse search Soft position limits (eliminate limit switches)
Feedback devices	See feedback devices list
Safety	Safe torque off with 3-way redundancy Charge pump enable input Stopping motor on errors Tracking error (velocity & position) Over speed error Limit switch DC motor runaway prevention on feedback loss Communication error detection
Protections	Over current Short circuit (phase-to-phase) I2t motor thermal protection Over & under voltage Over temperature
Power supply	Externally supplied IONI, IONI Pro 5 – 52 VDC IONI Pro HC 5 - 55 VDC Additionally an external 5 VDC logic supply required. Note: if drive is used with IONICUBE motherboards, then 24 VDC logic supply voltage is needed instead as IONICUBE has on-board 5V regulator.
Motor output current1	AC/BLDC/Stepping/Linear motors (current specified as peak of sine): IONI 0-15 A IONI Pro 0-18 A IONI Pro HC 0-25 A Brush DC motors: IONI 0-19.5 A IONI Pro 0-23.4 A IONI Pro HC 0-30 A
Commissioning	Granity setup software Online user guide
Compliance	CE (LVD & EMC): EN IEC 62368-1:2018, IEC 61000-6-1:2005 and IEC 61000-6-3:2006. SIL2: IEC 61800-5-2:2016-04 Notes: In order to meet EMC standard requirements, a proper installation and wiring is necessary. Refer to user guide for proper installation. Signed Declaration of Conformity will be provided on request.
Reliability	MTBF: 2.99 million hours Failure rate (all delivered units, actual statistic from 2015-2017): 0.36%

¹) Currents achievable continuously only with with sufficient coolant air flow. Without forced cooling, typically 30-45% of the maximum range can be driven continuously. Despite of this, maximum current is available for short periods of time even without cooling. Current is automatically throttled on temperature rise to protect the drive.

Mechanical

Property	Value	Units
Dimensions	70.5 × 37 × 7.5 (W×H×D)	mm
Weight	14.0 ± 0.5	g
Drawings	2D (PDF), 3D (IGES & STEP)
Pinout	IONI connector pinout

Environment

Property	Value	Units
Operating temperature	-10...+75, non condensing	°C
Storage temperature	-30...+90, non condensing	°C
Humidity	0-95 non-condensing	%
Power dissipation	0.3-15¹	W

¹) Power dissipation is output current and input voltage related.

Power supply

Supply2	Input voltage	Input current typ	Input current max
Logic power	5 VDC +/- 10%4	0.1 - 0.3 A	0.2 A
Motor power	5 - 52 VDC3 (IONI, IONI Pro), 5 - 55 VDC 3 (IONI Pro HC)	0 - 23.5 A1	23.5 A1

¹) Estimating true current or power consumption based on this table may be difficult as current demand typically varies greatly and and almost completely depends on motor load conditions.

²) Both logic and motor supplies are required.

³) Possible to use from 5 VDC upwards, however short circuit protection feature is lost below 12 VDC.

⁴) IONICUBE motherboards provide on-board 5V regulator and accepts 24 VDC logic supply voltage. With IONICUBE no 5V supply is needed.

Motor output

Maximum output current throttling vs device temperature. Current is automatically reduced by device to protect from overheating.

Property	Value	Units	Remarks
Supported motors	AC, BLDC, DC, Linear		Permanent magnet motors only
Continuous output current	0-151 (IONI), 0-181 (IONI Pro), 0-251 (IONI Pro HC)	A (peak value of sine)	User settable limit
Peak output current	0-151 (IONI), 0-181 (IONI Pro), 0-251 (IONI Pro HC)	A (peak value of sine)	User settable current limit.
Maximum effective motor phase output voltage	3-phase AC motors: Vsupply*0.671 V RMS (phase-to-phase) DC motors: Vsupply*0.95 VDC		I.e. at 48V supply, the maximum three-phase motor output voltage is 32.2 V RMS phase-to-phase I.e. at 48V supply, the maximum DC motor output voltage is 45.6 V
Switching frequency	20.0	kHz
Maximum modulation depth	95	%	Maximum effective output is 95% of HV DC bus voltage.
Torque control bandwidth (typ.)	1-3.3	kHz	Motor coil dependent
Torque control cycle time	50.0	µs
Position & velocity control cycle time	400	µs
Power conversion efficiency	93-97	%	Under typical conditions
Motor inductance range @ 48 VDC	0.2-25	mH
Motor inductance range @ 24 VDC	0.1-25	mH
Motor power range	0.01 - 0.5	kW
AC commutation frequency	0-400	Hz	Not capped, may achieve up to 2 kHz

¹) Maximum current is obtainable only for short periods without active air cooling. Drive automatically throttles current limit if drive temperature rises beyond 75 Celsius. Output current capacity reduces linearly between 75 and 90 degrees Celsius from the maximum to zero.

Regenerative resistor

IONI has a dedicated 3.3V logic level output for regenerative resistor control. The logic signal can be externally fed to a switch component (such as MOSFET) to drive external regenerative resistor to prevent overvoltage during rapid motor decelerations.

Feedback devices

Status of feedback device support

Feedback device type	Status	Electrical interface
Quadrature incremental encoder	Standard feature	Differential 3-5.5V (RS422), Single ended 3-5.5V (CMOS,TTL,open collector)
Hall sensors	Standard feature	Single ended 3-5.5V (CMOS,TTL,open collector). Differential signals accepted.
Analog SinCos encoder	Standard feature in IONI Pro	1 V p-p signal, user selectable 16X, 64X or 256X resolution interpolation factor (note 1). Automatic signal gain and offset calibration (info about Lissajous tuning).
Serial SSI absolute encoder	Standard feature in IONI Pro, see more info	RS422/RS485
Serial BiSS absolute encoder	Standard feature in IONI Pro, see more info	RS422/RS485

¹) The final resolution will be 4*line_count*interpolation_factor. I.e. with 1000 lines/electrical cycles per revolution SinCos encoder, the supported resolutions are 64000, 256000 and 1024000 counts per revolution. SinCos encoder can be also used without interpolation (4*line_count resolution).

Quadrature & SinCos encoder electrical properties

Property	Value	Units	Remarks
Encoder count rate	IONI: 0-4 IONI Pro: 0-18	MHz	After 4x decoding, digitally filtered
SinCos encoder input frequency	IONI Pro: 0-1	MHz	Max theoretical count rate at 256X interpolation becomes 1MHz*4*256 = 1024 MHz, however parameter Over speed faultFEV accepted value range might limit the achievable count rate to 75 MHz.
Supply voltage	4.8-5.2	V	Supplied externally (can share same voltage with drive logic supply)

Setpoint signal / reference inputs

Setpoint signal type	Status	Electrical interface
Analog	Standard feature	Up to +/-10V or any lower voltage range +/-10V (bipolar) and 0-10V with polarity input (unipolar) supported
Pulse and direction	Standard feature	Maximum step rate IONI: 4 MHz IONI Pro: 8 MHz
Quadrature	Standard feature	Maximum quadrature frequency (count rate) IONI: 1 MHz (4 MHz) IONI Pro: 2 MHz (8 MHz)
PWM	Standard feature	1-30 kHz PWM carrier frequency (fPWM), ~3 kHz for optimal operation. Single signal (no polarity input), zero setpoint at 50% duty PWM signal is sampled at 60MHz timer thus reading resolution is 60MHz/fPWM PWM+Polarity input mode
Serial communication	Standard feature	SimpleMotion V2 real-time serial bus with open source SDK. Connect through RS485 or USB.
EtherCAT	Under development	Realized with add-on board, EtherFOX

See also:

• Signal path of motor drive
• Pulse burst positioning

Inputs / outputs

List of I/O's

• Setpoint inputs
  • Two digital channels (pulse/dir, quadrature or PWM)
  • One +/-10V analog channel (differential, 2 wires)
• Digital inputs
  • Switch inputs (3 channels): home switch, positive travel limit switch, negative travel limit switch
  • Status control inputs (3 channels): enable, clear faults, STO
• Feedback inputs
  • Quadrature encoder (3 channels differential, where 2 channels capable of 12 bit analog sampling)
  • Hall sensors (3 channels)
• Digital outputs (3.3V logic level)
  • Regenerative brake control output (external power switch needed, such as MOSFET)
  • Holding brake control output (external power switch needed, such as MOSFET)
  • Status indication outputs (3 channels): fault stop, servo ready, tracking error warning
• Serial comminication interfaces
  • RS485 for SimpleMotion V2

Electrical characteristics

• Digital inputs accept standard signal levels 2.7 - 5.5 VDC, except STO and Enable inputs accept 4 - 26 VDC.
• Digital outputs provide 3.3 VDC signal level
• Analog inputs accept +-/10 VDC (+/- 12 VDC max) referenced to GND

Detailed properties

For detailed pin specific description and electrical ratings, see IONI connector pinout.

Communication

Property	Value	Units
Communication protocol	SimpleMotion V2
Default bitrate	460.8	kBPS
Supported high bit rates	1, 2, 3, 4, 4.5	MBPS
Maximum number of SMV2 devices chained in a single bus	32	pcs
Command throughput	Up to 20000	Commands/s

Safety

Feature	Properties	Remarks
Safe torque off	One dedicated physical STO input Cut gate drive voltage rendering power stage inactive @ STO2 input Disable motor control @ STO2 input (software based) Reaction time from STO2 signal voltage going below 2 volts to de-energized motor is maximum 5 ms.
Control error detection	Tracking error (velocity & position) Over speed error Limit switch DC motor runaway prevention on feedback loss Communication error
Electrical safety	ESD, short circuit, reverse polarity protection on all pins
Overload safety	Over current Short circuit (phase-to-phase) I2t motor thermal protection Over & under voltage Drive over temperature

IONI pinout

IONI card edge connector fits into a standard PCI-Express 8X socket connector. This page lists electrical and functional specifications of each pin.

Pinout

Location of pins B1 to B49. A1 to A49 are on same order except on the opposite side of board.

IONI pin-out

Color
Power pin
Input pin
Output pin
Mixed or other purpose

The pinout of IONI drive is provided in the following table.

I/O and low voltage signals

Pin	Signal name		Pin	Signal name
A1	GND		B1	5V_IN
A2	RS485_A		B2	RS485_B
A3	ADDRSEL1		B3	ADDRSEL2
A4	HSIN1		B4	HSIN2
A5	ANAIN-		B5	ANAIN+
A6	GPI1		B6	GPI2
A7	GPI3		B7	GPI4
A8	GPO1		B8	GPO2
A9	GPO3		B9	GPO4
A10	GPO5		B10	GPI5
A11	REGEN_OUT		B11	MECH_BRAKE_OUT
A12	ENABLE_IN		B12	Reserved/NC
A13	STO2		B13	HALL_W
A14	HALL_V		B14	HALL_U
A15	A-		B15	A+
A16	B-		B16	B+
A17	C-		B17	C+

Power signals

Pin	Signal name		Pin	Signal name
A18-A22	GND		B18	Not connected
A23	Not connected		B19-B22	HV+
A24-A27	PHASE1		B23	Not connected
A28	Not connected		B24-B27	PHASE2
A29-A37	PHASE3		B28	Not connected
A38	Not connected		B29-B37	PHASE4
A39-A43	PHASE1		B38	Not connected
A44	Not connected		B39-B43	PHASE2
A45-A49	GND		B44	Not connected
			B45-B49	HV+

Connection to motor

Signal name	AC/BLDC motor	Brush DC motor	Stepping motor
GND	Connect motor cable shield and motor frame to power GND
PHASE1	U (some motors R)	Armature +	Coil A.1
PHASE2	V (some motors S)	Armature -	Coil A.2
PHASE3	W (some motors T)	Connect to PHASE2	Coil B.1
PHASE4	Not connected	Connect to PHASE1	Coil B.2

Note 1: pins marked as Not connected are left empty for to make larger clearance for high voltage signals. Leave these pins unconnected on motherboard designs.

Note 2: Each power signal is present in two pin groups (internally parallel) and these signals should be wired parallel on motherboard.

Signal assignment

General purpose I/O (GPI/GPO)

The table below summarizes the default functions for GPIO pins.

Signal name	Function	Used for	Remarks
GPI1	Home switch	Homing reference switch (optional), can also disable homing, or use Hard-stop homing without switch	Note 1
GPI2	Enable positive feed	Axis positive direction end limit switch (optional)	Normally closed switch. When switch is open, motion/force in positive direction is prevented. 1
GPI3	Enable negative feed	Axis negative direction end limit switch (optional)	Normally closed switch. When switch is open, motion/force in negative direction is prevented. 1
GPI4	Clear faults	Rising logic edge on this pin will clear fault state of drive	In IONICUBE mode, also rising edge of enable signal will clear faults.
GPI5	Start homing	Rising logic edge on this pin will start homing if homing is enabled
GPO1	Servo ready	Use to indicate controller that drive is ready	Logic 1 when drive has been initialized, enabled and ready to follow setpoint commands. If homing is enabled, then servo ready will be logic 1 after homing is successfully completed.
GPO2	Tracking error warning	Use to indicate controller when drive is having difficulties following the setpoint before a tracking fault occurs	Logic 1 when tracking error (position or velocity, depending on control mode) is greater than 1/8 of configured fault trigger level.
GPO3	Fault state (active low)	Use to indicate controller that drive is stopped due to fault state	In IONICUBE mode GPO3 goes logic 0 after when enable signal is set low (for Mach3 compatibility). GPO3 is open drain type to allow wired and connection.
GPO4	2-way travel allowed	Use to indicate controller when axis is allowed to move in both directions (i.e. any limit switches not hit or axis lies within an optional homing defined limited travel range)	GPO4 will be logic high if both of "Pos feed enable" and "Neg feed enable" as seen in Granity status are true. These Pos/Neg feed enable states are affected by Limit switch polarityLSP. If you see both Pos & Neg feed enables being false, then you probably need to invert the switches with LSP parameter. GPO4 will be also false if limit switch has been configured as home switch and homing is being performed. GPO4 will work also sensorless manner after performing hard-stop homing with active "soft travel limits", in such case GPO4 will indicate whether axis is within the allowed software configured motion range.
GPO5	Reserved		Feel free to request custom signal from Granite Devices support to be added in this output. For example fan control or custom status output. Changes can be made in customer specific firmware.

¹) Connect switch between GND and GPIn pin

See also Drive status & fault bits explained.

Setpoint signals

Setpoint mode is selected by software with parameter Setpoint inputCRI and behavior is affected by parameters Setpoint smoothingCIS, Setpoint multiplierMUL, Setpoint dividerDIV, Setpoint offset nullingCAO and Enable direction inputCED.

Signal name	Function	Used for	Remarks
HSIN1	High speed digital input 1	Depending on setpoint mode, can be either: Step pulse train (in Pulse and direction setpoint mode) Quadrature A channel (in quadrature setpoint mode) PWM input direction (in PWM+Dir setpoint mode)
HSIN2	High speed digital input 2	Depending on setpoint mode, can be either: Direction signal of pulse train (in Pulse and direction setpoint mode) Quadrature B channel (in quadrature setpoint mode) PWM (in PWM and PWM+Dir setpoint modes)
ANAIN-	Differential analog negative input	Used for analog setpoint mode	Setpoint voltage is the voltage difference between ANAIN+ and ANAIN-
ANAIN+	Differential analog positive input	Used for analog setpoint mode

Feedback device signals

Signal name #	Electrical type (in most feedback device modes)	Alternate electrical type (in some feedback device modes)	Connection with various feedback devices
HALL_W	Digital input W		Hall sensor input, phase W
HALL_V	Digital input V		Hall sensor input, phase V
HALL_U	Digital input U		Hall sensor input, phase U
A-	Differential input A-	Analog input A-	Quadrature encoder (A channel)/SinCos A
A+	Differential input A+	Analog input A+
B-	Differential input B-	Analog input B+	Quadrature encoder (B channel)/SinCos B
B+	Differential input B+	Analog input B-
C-	Differential input C-		Quadrature encoder index channel (Z channel)
C+	Differential input C+

Other signals

Signal name	Function	Used for	Remarks
REGEN_OUT	Regenerative resistor control output	Use to control optional regenerative resistor to prevent excessive voltage generation in HV DC bus during motor deceleration.	A buffer circuit is needed for resistor, such as a logic level MOSFET. See example schematic here.
MECH_BRAKE_OUT	Mechanical holding brake control output	Use to control optional holding brake of motor	A buffer circuit is needed to drive a solenoid brake, such as a logic level MOSFET. See example schematic here.
ENABLE_IN	Drive enable input signal (always required)	Use to enable drive and allow motor to initialize and operate	Accepts up to 24V voltage level, but works also with 5V level signal. (1)
STO2	Safe torque off input signal (always required)	Use to allow motor to produce torque (activate power stage)	Accepts up to 24V voltage level, but works also with 5V level signal. STO is inactive (allows torque) when logic high is supplied. (1)

(1) ENABLE_IN and STO2 are not 3.3V compatible, 4.5-26V signal is required to drive logic true state into them.

Electrical ratings

IONI's internal circuity (equivalent schematics, not actual wiring) in feedback device port pins (the pins on D-15 connector on IONICUBEs)

Signal names	Allowed input voltages/output voltage	Internal input/output impedance (Ω)	Internal pull impedance (Ω)
5V_IN	5V +/-10%	-	-
HV+	0 – 55 V	-	-
RS485_A/B	RS485 serial bus, 2.7-5.5V signal level	>10k	-
ADDRSEL1, ADDRSEL2	External address setting pull-down resistors to ground (minimum 1 kΩ). See chapter Selecting device address below.	-	2.2k pull-up to 3.3V
HSIN1, HSIN2	Logic low -0.3-1.0V, logic high 2.7-5.5V	-	2.2k pull-up to 3.3V
ANAIN-, ANAIN+	+/- 11V	8k	-
GPI1...GPI4	Logic low -0.3-1.0V, logic high 2.7-5.5V	-	2.2k pull-up to 3.3V
GPI5	Logic low -0.3-1.0V, logic high 2.7-5.5V	-	Rev 1 drives: ~20-50k pull-up to 3.3V Rev 2 and later: 3.3k pull-up to 5V
GPO1,2,4,5	Logic low 0V, logic high 3.3V	220	-
GPO3	Depends on Electrical interface Electrical interfaceCEI parameter: In IONICUBE mode it is an open drain output, pulled to 0V with 220 ohm impedance or pulled to 3.3V with pull-up (allow wired and connection of multiple drives). In other modes it is push-pull output (like GPO1,2,4,5)	220	~20-50k pull-up to 3.3V
MECH_BRAKE_OUT	Logic low 0V, logic high 3.3V	220	-
REGEN_OUT	Logic low 0V, logic high 3.3V	220	-
ENABLE_IN	Logic low -0.3-2.0V, logic high 4.5-26V	5k	10k pull-down to GND
STO2	Logic low -0.3-2.0V, logic high 4.5-26V	8k	20k pull-down to GND
HALL_U/V/W	Logic low -0.3-1.0V, logic high 2.7-5.5V	-	2.2k pull-up to 5V
A/B/C+	RS422 receiver, 2.7-5.5V signal level	-	2.2k pull-up to 5V
A/B/C-	RS422 receiver, 2.7-5.5V signal level	-	1.9k pull to 1.9V

Electrical interface modes (software selectable)

IONI supports various function mappings to I/O signals and is selectable through Granity CEI Electrical interface parameter. The differences between modes are:

Mode	Description	Effects (change of operation compared to Standard in this mode)
Standard	The default mode	I/O assignments as described in pinout
IONICUBE (CNC applications)	Mode for IONICUBE that is compatible with parallel port CNC controllers such as Mach3 and LinuxCNC software. Not recommended with IONICUBE 1X as GPO3/fault output will not work then.	In addition to rising edge of GPI4, also rising edge on Enable will clear fault state. In standard mode Enable input will not clear faults. GPO3 (fault state) output will go logic low after Enable signal goes low. In standard mode GPO3 stays high until faults are cleared. GPO3 is open drain output to allow Wired and connection of multiple fault outputs of multiple drives
SimuCUBE	Mode for SimuCUBE motherboard for force feedback simulator systems.	STO2 input acts as Enable and Clear faults input. In other words STO2 is the only one needed for all three functions, and Enable and Clear faults can be left unconnected. Regenerative resistor drive has been tuned for SimuCUBE regenerative resistor Power consumption limit has been tuned for simulator use (smoother operation than in other modes) GPO5 is used as temperature controlled fan PWM output

Selecting device address

When accessing drive through SimpleMotion V2 bus, each device in the bus should be assigned to different address between 1 to N. Device address is a sum of hardware setting and software parameter SimpleMotion bus address offsetSMO. The address of device is determined at the moment of logic voltage power on and will become by sum of hardware setting and SMO.

Hardware setting is set by connecting a resistor between ADDRSELx and GND by method defined in article IONI SimpleMotion address selection (ADDRSEL).

Software selecting address

When having more than four devices in the same bus, or for example chaining multiple IONICUBE 1X motherboards (where all of them have address 1), it is necessary to utilize software parameter SimpleMotion bus address offsetSMO. Procedure for setting unique address for each device with SMO:

1. Disconnect or unpower all other devices that the ones with already unique address (i.e. have only one IONICUBE connected to SM bus, or powered on)
2. Connect to drive with Granity
3. Adjust SMO parameter value so that device will receive a desired bus address. I.e. if using IONICUBE 1X, set SMO values 0, 1, 2, 3 to the different drives (drive addresses will become 1, 2, 3, 4). Or when IONICUBE (4 axis) is being used, set SMO values of drives on the first board 0, second board 4, third 8 etc (drive addresses will become 1 - 12).
4. Save settings, disconnect and repeat the procedure for all drives.

Set-up overwies & first connection

This is the official and latest setup guide of IONI Servo Drive and IONICUBE motherboards. Read it through before installing or operating IONI series devices.

Setup process overview

Read trough the guide by following the outline on the top right side of the page and follow the hyper links to subtopics provided in the articles.

Read the page List of things needed for details.

Connect drive to PC with SimpleMotion V2 USB adapter and Granity to test connection, upgrade firmware if necessary and to learn Granity. If you're already familiar with all this, you may skip this step. Read the article Making the first Granity connection.

Carefully do the full wiring of the servo system. Consult an qualified electrician if necessary as dangerous voltages will be present. Before powering up, triple check everything by using multimeter to find short circuits. Read the main article Wiring.

Power-up the system and connect again with Granity. Now set-up the motor to work as intended. See the main article Drive parameterization. If you already have a working configuration to your motor model, you may just load the settings file to the drive.

After motor and drive are fully functional, connect motor to the mechanical load and find the optimum velocity or position control gains. Read the main article Servo motor tuning guide.

Troubleshooting

In case of troubles, refer to the articles in general troubleshooting category and IONI troubleshooting category.

List of items needed

The list of necessary things to build a working servo system with IONI

• IONI drive and a compatible motherboard such as IONICUBE, IONICUBE 1X or a custom board
• SimpleMotion V2 USB adapter
• 1 or more RJ45 Ethernet cables (see details & examples)
• Regulated 24 VDC power supply, output capability at least 0.5A per motherboard
• Regulated or non-regulated 5-52 VDC power supply for motor power. Output capability depends on motor power draw. If unsure, then a good start is a power supply between 150 to 600 Watts for a multiaxis motherboard. As a reference, a typical 3 axis Nema 23 stepping motor system can be fed with a 150-200 W 48 V power supply. See:
  • IONI power supply schemes
  • Estimating power need of motor drive system
• A IONI compatible motor
• Shielded power conductors as motor power cord. Non-shielded will also work but increase EMI and may be source of communication errors.
• Ferrite core EMI filters
• Motion controller. This may be also a software on a computer.
• Windows PC

Optional but highly recommended items

• Emergency stop button (normally closed NC type) or equivalent

Needed for high current motors (>5A average)

• A cooling fan

Tools needed

• Screwdrivers
• Wire cutter

Skills needed

• Qualified electrician skills
• Basic knowledge of servo systems

Making the first Granity connection

Follow the instructions to make the first Granity connection to IONI drive.

Preparations

1. Download and install the Granity software. Latest version can be downloaded from the link: Granity software for windows (approx 18 MB)
2. Make a wiring similar to the image below
   • With IONICUBE 4X revision 008 and lower, make sure that in the pinheader JP10 only position 1 has a jumper as depicted.
   • With IONICUBE 4X revision 009 and higher, make sure that the switch S1 position 1 is ON and position 4 (DFU mode) is OFF.
   • If you use a USB cable to connect (r. 009 and higher), turn also S1 position 2 and 3 ON.
3. Connect IONICUBE to a PC
   • with SimpleMotion V2 USB adapter and a straight Ethernet cable to connector X1, or
   • with an USB cable without any adapters.
4. Power up the 24 VDC power. Leds at the back of the IONI drive should start blinking (more about blinking sequences).
5. Launch Granity software and:
   1. Go to Connect tab
   2. Ensure that "SimpleMotion V2 Adapter" is selected from dropdown menu called Communication interface device. (note 1)
   3. Click Connect to drive
   4. Once list of connected drives pop up, select the one you connected and click Open

Now if everything has gone well, you should see information about the drive model and serial number on the "Connect tab". Connection has been successfully tested and drive may be disconnected to proceed with next setup step.

Note 1) If multiple choices are named as "SimpleMotion V2 Adapter", then try each of them to find the correct one. Also if no adapters are found, try launching Granity software again as the list of adapter choices are updated only at program start-up.

IONICUBE Revision 1-8 (with jumpers)

Minimum connection for Granity

IONICUBE Revision 9 and later (with DIP switch)

SM Bus termination switch position for IONICUBE revision 009 and higher. For typical single IONICUBE wiring, set switches 1-3 to ON position and 4th OFF position.

More information about the termination and biasing of the RS485 serial bus here: Wikipedia:RS-485.

Wiring overwiew

IONICUBE connectors

X1

Dual port RJ45 connector with SimpleMotion V2 interface. For pinout, seeSimpleMotion V2 port.

X2

6 pin wire terminal for logic voltage supply, Safe torque off input, analog output and relay driver outputs.

X3

Two pin wire terminal for HV DC bus supply.

X4

Main control and setpoint signal port consisting Enable input signal, Fault output signal, pulse and direction/quadrature/PWM setpoint inputs and digital outputs for home switch status. X4 is directly wired to conform most common parallel port style pulse & direction CNC controllers.

X5

Second control and setpoint signal port. This port consists analog setpoint signal inputs and additional digital I/O.

X6

These are the feedback device connector for X (lower) and Y (upper) axis motors

X7

These are the power and holding brake output connector for X (lower) and Y (upper) axis motors

X8

These are the feedback device connector for Z (lower) and A (upper) axis motors

X9

These are the power and holding brake output connector for Z (lower) and A (upper) axis motors

X10

A connector for an optional external regenerative resistor. IONICUBE has on-board regenerative resistor that is sufficient for most installations.

IONI_X, IONI_Y, IONI_Z, IONI_A

Card-edge connectors for IONI drives

Front side connectors

Front side connectors consist X6, X7, X8 and X9. These connectors are the interface towards motors (motor power and feedback devices).

Connector layout and naming. View from top of the board.

IONICUBE revision 3 PCB layout. USB connector X11 and Switch S1 to replace the jumper header.

Power and feedback ports of X, Y, Z and A axis. View from plug side of the board.

Names of power and feedback ports. I.e. X9A means upper floor connector of X9 and X9B the lower floor of X9. View from plug side of the board.

Legend

Color
Supply pin
Input pin
Output pin

X7 and X9 pinout

These are the power output and holding brake output connector for motors

Pin number	Signal name	AC/BLDC motor	Brush DC motor	Stepping motor
1	GND	Ground for cable shield and an optional motor holding brake coil
2	PHASE1	U (some motors R)	Armature +	Coil A.1
3	PHASE2	V (some motors S)	Armature -	Coil A.2
4	PHASE3	W (some motors T)	Armature -	Coil B.1
5	PHASE4	Not connected	Armature +	Coil B.2
6	BRAKE	Optional 24V motor holding brake coil

Motor & brake wiring schematics

• 

  Wiring of three phase AC servo motor. Brake is optional.

• 

  Wiring of Brush-DC servo motor. Brake is optional.

• 

  Wiring of two phase stepping motor. Brake can be fitted like in the other examples. Also 6 and 8 wire motors can be wired (the two drive coils connect always to the same PHASE outputs).

X6 and X8 pinout

X6 and X8 are the feedback device connectors of motors

Pin #	Pin name	Electrical type (in most feedback device modes)	Quadrature encoder	SinCos encoder	BiSS-C encoder	SSI encoder	AMS SSI encoder
Shell	GND	Earth/case
1	HALL_W	Hall sensor digital input, phase W			-	-	-
2	HALL_V	Hall sensor digital input, phase V			-	-	-
3	HALL_U	Hall sensor digital input, phase U			-	-	-
4	GND	Encoder supply ground
5	B-	Differential input B-	Channel B-	SinCos input B-	-	-	-
6	B+	Differential input B+	Channel B+	SinCos input B+	-	-	-
7	A-	Differential input A-	Channel A-	SinCos input A-	-	-	-
8	A+	Differential input A+	Channel A+	SinCos input A+	-	-	-
9	5V_OUT	Encoder supply 5V output
10	GND	Encoder supply ground
11	GPI3	Axis negative direction end limit switch (optional). Normally closed (NC) switch is highly recommended for safety reasons. Connect it between this pin and GND pin. Normally open (NO) switch can be used, and the switch polarity can be changed with Limit switch polarityLSP.			Clock/MA-	Clock-	CLK
12	GPI2	Axis positive direction end limit switch (optional).Normally closed (NC) switch is highly recommended for safety reasons. Connect it between this pin and GND pin. Normally open (NO) switch can be used, and the switch polarity can be changed with Limit switch polarityLSP.			Clock/MA+	Clock+	CSn
13	GPI1	Axis home switch switch (optional). Normally closed (NC) switch is highly recommended for safety reasons. Connect it between this pin and GND pin. Normally open (NO) switch can be used, and the switch polarity can be changed with Home switch or hard stop search direction (Home switch polarity)HMS.					DO
14	C-	Differential input C-	Index channel Z-	Index channel Z+	Data/SLO-	Data-	-
15	C+	Differential input C+	Index channel Z+	Index channel Z+	Data/SLO+	Data+	-
Pin layout	Female D-sub 15 connector as it appears from outside of drive. Note: counterpart (male) connector has mirrored pin layout if viewed from pin side, and same layout if viewed from soldering side.

Examples of feedback device and switch wiring

• 

  Fully wired port with differential incremental encoder, hall sensors and switches

• 

  Wiring of differential incremental encoder

• 

  Minimal wiring of incremental encoder (single ended, no index channel)

• 

  Wiring of Hall sensors only (only torque mode possible)

• 

  Illustration of wiring limit and home switches. In addition to this, encoder and/or halls are needed.

Back side connectors

A closeup of X2, X3, X4 and X5

X2 pinout

X2 is 6 pin wire terminal for logic voltage supply, Safe torque off input, analog output and relay driver outputs.

Pin number	Signal name	Usage
1	GND	Ground
2	24V	24V logic supply
3	STO	Safe torque off input (this pin also available in X1, as defined in SimpleMotion V2 port
4	VFD	0-12V analog output where voltage level is proportional to PWM duty cycle on pin PWM on X4. PWM frequency must be between 100 and 10000 Hz.
5	RL1	Relay coil driver output 1. When RLIN1 on X4 is logic high, RL1 is pulled to GND by an open collector circuit. When RLIN1 is low, RL1 is floating (max 24V). When connecting a relay that has 24VDC coil between RL1 and supplied 24V, no external free-wheeling diode is needed. Output current rating is max 500 mA.
6	RL2	Relay coil driver output 2. When RLIN2 on X4 is logic high, RL2 is pulled to GND by an open collector circuit. When RLIN1 is low, RL2 is floating (max 24V). When connecting a relay that has 24VDC coil between RL2 and supplied 24V, no external free-wheeling diode is needed. Output current rating is max 500 mA.

X3 pinout

X3 is two pin wire terminal for HV DC bus supply.

Pin number	Signal name	Usage
1	GND	Ground
2	HV+	Motor power supply, HV DC bus (see IONI drive voltage range spec)

See also:

• IONI power supply schemes
• Estimating power need of motor drive system

X4 pinout

X4 is main control and setpoint signal port consisting Enable input signal, Fault output signal, pulse and direction/quadrature/PWM setpoint inputs and digital outputs for home switch status. X4 is directly wired to conform most common parallel port style pulse & direction CNC controllers.

Pin number in header	Pin number in D25 cable	Signal name	Typical usage		Pin number in header	Pin number in D25 cable	Signal name	Typical usage
1	1	ENABLE	Enable all axis (with or without chargepump)		2	14	PWM	PWM input for VFD analog output
3	2	HSIN1_X	Pulse/step input X		4	15	GPO4_A	Limit switch output A
5	3	HSIN2_X	Direction input X		6	16	RLIN1	Controls RL1 state
7	4	HSIN1_Y	Pulse/step input Y		8	17	RLIN2	Controls RL2 state
9	5	HSIN2_Y	Direction input Y		10	18	GND	Ground
11	6	HSIN1_Z	Pulse/step input Z		12	19	GND
13	7	HSIN2_Z	Direction input Z		14	20	GND
15	8	HSIN1_A	Pulse/step input A		16	21	GND
17	9	HSIN2_A	Direction input A		18	22	GND
19	10	STOP_OUT	Fault on any axis or E-stop (active low). Note: this is IONI's GPO3 signals connected in parallel between all axis / wired-or configuration.		20	23	GND
21	11	GPO4_X	Limit switch output X		22	24	GND
23	12	GPO4_Y	Limit switch output Y		24	25	GND
25	13	GPO4_Z	Limit switch output Z		26	N/A	Not connected
Pin layout

Alternative setpoint signals

Setpoint mode is selected by software with parameter Setpoint inputCRI and behavior is affected by parameters Setpoint smoothingCIS, Setpoint multiplierMUL, Setpoint dividerDIV, Setpoint offset nullingCAO and Enable direction inputCED.

Signal name	Function	Used for	Remarks
HSIN1	High speed digital input 1	Depending on setpoint mode, can be either: Step pulse train (in Pulse and direction setpoint mode) Quadrature A channel (in quadrature setpoint mode) PWM input direction (in PWM+Dir setpoint mode)
HSIN2	High speed digital input 2	Depending on setpoint mode, can be either: Direction signal of pulse train (in Pulse and direction setpoint mode) Quadrature B channel (in quadrature setpoint mode) PWM (in PWM and PWM+Dir setpoint modes)
ANAIN-	Differential analog negative input	Used for analog setpoint mode	Setpoint voltage is the voltage difference between ANAIN+ and ANAIN-
ANAIN+	Differential analog positive input	Used for analog setpoint mode

X5 pinout

X5 is a second control and setpoint signal port in addition to X4. This port consists analog setpoint signal inputs and additional digital I/O.

Pin number in header	Pin number in D25 cable	Signal name	Typical usage		Pin number in header	Pin number in D25 cable	Signal name	Typical usage
1	1	GND			2	14	+5V_OUT	5V supply from IONICUBE ^2
3	2	ANAIN-_X	+/-10V analog input X		4	15	ANAIN+_X	+/-10V analog input X
5	3	ANAIN-_Y	+/-10V analog input Y		6	16	ANAIN+_Y	+/-10V analog input Y
7	4	ANAIN-_Z	+/-10V analog input Z		8	17	ANAIN+_Z	+/-10V analog input Z
9	5	ANAIN-_A	+/-10V analog input A		10	18	ANAIN+_A	+/-10V analog input A
11	6	GPO1_X	For pin function, refer to IONI connector pinout		12	19	GPI4_X	For pin function, refer to IONI connector pinout
13	7	GPO1_Y			14	20	GPI4_Y
15	8	GPO1_Z			16	21	GPI4_Z
17	9	GPO1_A			18	22	GPI4_A
19	10	GPO5_X			20	23	GPI5_X
21	11	GPO5_Y			22	24	GPI5_Y
23	12	GPO5_Z			24	25	GPI5_Z
25	13	GPO5_A			26	N/A	GPI5_A
Pin layout

Application example

Follwing image shows typical installation schemes for pulse/direction controlled systems, typically found in PC CNC applications.

• 

  A typical connection with parallel port style CNC controller such as Mach3/Mach4/LinuxCNC. A 26 pin ribbon cable may be directly connected to PC parallel port or to equivalent pinout step/dir generator such as SmoothStepper.

IONICUBE 4X wiring

IONICUBE connectors

X1

Dual port RJ45 connector with SimpleMotion V2 interface. For pinout, seeSimpleMotion V2 port.

X2

6 pin wire terminal for logic voltage supply, Safe torque off input, analog output and relay driver outputs.

X3

Two pin wire terminal for HV DC bus supply.

X4

Main control and setpoint signal port consisting Enable input signal, Fault output signal, pulse and direction/quadrature/PWM setpoint inputs and digital outputs for home switch status. X4 is directly wired to conform most common parallel port style pulse & direction CNC controllers.

X5

Second control and setpoint signal port. This port consists analog setpoint signal inputs and additional digital I/O.

X6

These are the feedback device connector for X (lower) and Y (upper) axis motors

X7

These are the power and holding brake output connector for X (lower) and Y (upper) axis motors

X8

These are the feedback device connector for Z (lower) and A (upper) axis motors

X9

These are the power and holding brake output connector for Z (lower) and A (upper) axis motors

X10

A connector for an optional external regenerative resistor. IONICUBE has on-board regenerative resistor that is sufficient for most installations.

IONI_X, IONI_Y, IONI_Z, IONI_A

Card-edge connectors for IONI drives

Front side connectors

Front side connectors consist X6, X7, X8 and X9. These connectors are the interface towards motors (motor power and feedback devices).

Connector layout and naming. View from top of the board.

IONICUBE revision 3 PCB layout. USB connector X11 and Switch S1 to replace the jumper header.

Power and feedback ports of X, Y, Z and A axis. View from plug side of the board.

Names of power and feedback ports. I.e. X9A means upper floor connector of X9 and X9B the lower floor of X9. View from plug side of the board.

Legend

Color
Supply pin
Input pin
Output pin

X7 and X9 pinout

These are the power output and holding brake output connector for motors

Pin number	Signal name	AC/BLDC motor	Brush DC motor	Stepping motor
1	GND	Ground for cable shield and an optional motor holding brake coil
2	PHASE1	U (some motors R)	Armature +	Coil A.1
3	PHASE2	V (some motors S)	Armature -	Coil A.2
4	PHASE3	W (some motors T)	Armature -	Coil B.1
5	PHASE4	Not connected	Armature +	Coil B.2
6	BRAKE	Optional 24V motor holding brake coil

Motor & brake wiring schematics

• 

  Wiring of three phase AC servo motor. Brake is optional.

• 

  Wiring of Brush-DC servo motor. Brake is optional.

• 

  Wiring of two phase stepping motor. Brake can be fitted like in the other examples. Also 6 and 8 wire motors can be wired (the two drive coils connect always to the same PHASE outputs).

X6 and X8 pinout

X6 and X8 are the feedback device connectors of motors

Pin #	Pin name	Electrical type (in most feedback device modes)	Quadrature encoder	SinCos encoder	BiSS-C encoder	SSI encoder	AMS SSI encoder
Shell	GND	Earth/case
1	HALL_W	Hall sensor digital input, phase W			-	-	-
2	HALL_V	Hall sensor digital input, phase V			-	-	-
3	HALL_U	Hall sensor digital input, phase U			-	-	-
4	GND	Encoder supply ground
5	B-	Differential input B-	Channel B-	SinCos input B-	-	-	-
6	B+	Differential input B+	Channel B+	SinCos input B+	-	-	-
7	A-	Differential input A-	Channel A-	SinCos input A-	-	-	-
8	A+	Differential input A+	Channel A+	SinCos input A+	-	-	-
9	5V_OUT	Encoder supply 5V output
10	GND	Encoder supply ground
11	GPI3	Axis negative direction end limit switch (optional). Normally closed (NC) switch is highly recommended for safety reasons. Connect it between this pin and GND pin. Normally open (NO) switch can be used, and the switch polarity can be changed with Limit switch polarityLSP.			Clock/MA-	Clock-	CLK
12	GPI2	Axis positive direction end limit switch (optional).Normally closed (NC) switch is highly recommended for safety reasons. Connect it between this pin and GND pin. Normally open (NO) switch can be used, and the switch polarity can be changed with Limit switch polarityLSP.			Clock/MA+	Clock+	CSn
13	GPI1	Axis home switch switch (optional). Normally closed (NC) switch is highly recommended for safety reasons. Connect it between this pin and GND pin. Normally open (NO) switch can be used, and the switch polarity can be changed with Home switch or hard stop search direction (Home switch polarity)HMS.					DO
14	C-	Differential input C-	Index channel Z-	Index channel Z+	Data/SLO-	Data-	-
15	C+	Differential input C+	Index channel Z+	Index channel Z+	Data/SLO+	Data+	-
Pin layout	Female D-sub 15 connector as it appears from outside of drive. Note: counterpart (male) connector has mirrored pin layout if viewed from pin side, and same layout if viewed from soldering side.

Examples of feedback device and switch wiring

• 

  Fully wired port with differential incremental encoder, hall sensors and switches

• 

  Wiring of differential incremental encoder

• 

  Minimal wiring of incremental encoder (single ended, no index channel)

• 

  Wiring of Hall sensors only (only torque mode possible)

• 

  Illustration of wiring limit and home switches. In addition to this, encoder and/or halls are needed.

Back side connectors

A closeup of X2, X3, X4 and X5

X2 pinout

X2 is 6 pin wire terminal for logic voltage supply, Safe torque off input, analog output and relay driver outputs.

Pin number	Signal name	Usage
1	GND	Ground
2	24V	24V logic supply
3	STO	Safe torque off input (this pin also available in X1, as defined in SimpleMotion V2 port
4	VFD	0-12V analog output where voltage level is proportional to PWM duty cycle on pin PWM on X4. PWM frequency must be between 100 and 10000 Hz.
5	RL1	Relay coil driver output 1. When RLIN1 on X4 is logic high, RL1 is pulled to GND by an open collector circuit. When RLIN1 is low, RL1 is floating (max 24V). When connecting a relay that has 24VDC coil between RL1 and supplied 24V, no external free-wheeling diode is needed. Output current rating is max 500 mA.
6	RL2	Relay coil driver output 2. When RLIN2 on X4 is logic high, RL2 is pulled to GND by an open collector circuit. When RLIN1 is low, RL2 is floating (max 24V). When connecting a relay that has 24VDC coil between RL2 and supplied 24V, no external free-wheeling diode is needed. Output current rating is max 500 mA.

X3 pinout

X3 is two pin wire terminal for HV DC bus supply.

Pin number	Signal name	Usage
1	GND	Ground
2	HV+	Motor power supply, HV DC bus (see IONI drive voltage range spec)

See also:

• IONI power supply schemes
• Estimating power need of motor drive system

X4 pinout

X4 is main control and setpoint signal port consisting Enable input signal, Fault output signal, pulse and direction/quadrature/PWM setpoint inputs and digital outputs for home switch status. X4 is directly wired to conform most common parallel port style pulse & direction CNC controllers.

Pin number in header	Pin number in D25 cable	Signal name	Typical usage		Pin number in header	Pin number in D25 cable	Signal name	Typical usage
1	1	ENABLE	Enable all axis (with or without chargepump)		2	14	PWM	PWM input for VFD analog output
3	2	HSIN1_X	Pulse/step input X		4	15	GPO4_A	Limit switch output A
5	3	HSIN2_X	Direction input X		6	16	RLIN1	Controls RL1 state
7	4	HSIN1_Y	Pulse/step input Y		8	17	RLIN2	Controls RL2 state
9	5	HSIN2_Y	Direction input Y		10	18	GND	Ground
11	6	HSIN1_Z	Pulse/step input Z		12	19	GND
13	7	HSIN2_Z	Direction input Z		14	20	GND
15	8	HSIN1_A	Pulse/step input A		16	21	GND
17	9	HSIN2_A	Direction input A		18	22	GND
19	10	STOP_OUT	Fault on any axis or E-stop (active low). Note: this is IONI's GPO3 signals connected in parallel between all axis / wired-or configuration.		20	23	GND
21	11	GPO4_X	Limit switch output X		22	24	GND
23	12	GPO4_Y	Limit switch output Y		24	25	GND
25	13	GPO4_Z	Limit switch output Z		26	N/A	Not connected
Pin layout

Alternative setpoint signals

Setpoint mode is selected by software with parameter Setpoint inputCRI and behavior is affected by parameters Setpoint smoothingCIS, Setpoint multiplierMUL, Setpoint dividerDIV, Setpoint offset nullingCAO and Enable direction inputCED.

Signal name	Function	Used for	Remarks
HSIN1	High speed digital input 1	Depending on setpoint mode, can be either: Step pulse train (in Pulse and direction setpoint mode) Quadrature A channel (in quadrature setpoint mode) PWM input direction (in PWM+Dir setpoint mode)
HSIN2	High speed digital input 2	Depending on setpoint mode, can be either: Direction signal of pulse train (in Pulse and direction setpoint mode) Quadrature B channel (in quadrature setpoint mode) PWM (in PWM and PWM+Dir setpoint modes)
ANAIN-	Differential analog negative input	Used for analog setpoint mode	Setpoint voltage is the voltage difference between ANAIN+ and ANAIN-
ANAIN+	Differential analog positive input	Used for analog setpoint mode

X5 pinout

X5 is a second control and setpoint signal port in addition to X4. This port consists analog setpoint signal inputs and additional digital I/O.

Pin number in header	Pin number in D25 cable	Signal name	Typical usage		Pin number in header	Pin number in D25 cable	Signal name	Typical usage
1	1	GND			2	14	+5V_OUT	5V supply from IONICUBE ^2
3	2	ANAIN-_X	+/-10V analog input X		4	15	ANAIN+_X	+/-10V analog input X
5	3	ANAIN-_Y	+/-10V analog input Y		6	16	ANAIN+_Y	+/-10V analog input Y
7	4	ANAIN-_Z	+/-10V analog input Z		8	17	ANAIN+_Z	+/-10V analog input Z
9	5	ANAIN-_A	+/-10V analog input A		10	18	ANAIN+_A	+/-10V analog input A
11	6	GPO1_X	For pin function, refer to IONI connector pinout		12	19	GPI4_X	For pin function, refer to IONI connector pinout
13	7	GPO1_Y			14	20	GPI4_Y
15	8	GPO1_Z			16	21	GPI4_Z
17	9	GPO1_A			18	22	GPI4_A
19	10	GPO5_X			20	23	GPI5_X
21	11	GPO5_Y			22	24	GPI5_Y
23	12	GPO5_Z			24	25	GPI5_Z
25	13	GPO5_A			26	N/A	GPI5_A
Pin layout

Application example

Follwing image shows typical installation schemes for pulse/direction controlled systems, typically found in PC CNC applications.

• 

  A typical connection with parallel port style CNC controller such as Mach3/Mach4/LinuxCNC. A 26 pin ribbon cable may be directly connected to PC parallel port or to equivalent pinout step/dir generator such as SmoothStepper.

IONICUBE 1X wiring

IONICUBE 1X connectors

X1.1 and X1.2

RJ45 connector with SimpleMotion V2 interface. For pinout, seeSimpleMotion V2 port.

X2

feedback device connector for motor

X3

9 pin wire terminal for HV DC bus supply, logic voltage supply, regenerative resistor and motor power output.

X4

Control and setpoint signal port. Contains also output for motor solenoid holding brake.

X5

Card-edge connectors for IONI drive

IONICUBE 1X connectors

Connector layout and naming

Wiring overview. R is regenerative resistor and E is encoder. In minimum working connection, wire 5V voltage to ENABLE and STO2 inputs into X4 pins (these two signals allow drive to be operated). Note: STO2 accepts voltage from 4.5 to 25 VDC but other digital inputs, such as ENABLE only between 2.7 to 5.5VDC.

Legend

Color
Supply pin
Input pin
Output pin

X3 pinout

This is a wire terminal connector for power input and output

Pin number	Signal name	Usage
1	GND	Ground
2	HV+	Motor power supply, HV DC bus (see IONI drive voltage range spec)
3	VCC	24V logic supply
4	PH1 (PHASE1)	Motor phase 1 (see wiring table below)
5	PH2 (PHASE2)	Motor phase 2 (see wiring table below)
6	PH3 (PHASE3)	Motor phase 3 (see wiring table below)
7	PH4 (PHASE4)	Motor phase 4 (see wiring table below)
8	REG	Regenerative resistor output
9	GND	Ground

Pin number	Signal name	AC/BLDC motor	Brush DC motor	Stepping motor
1	GND	Ground for cable shield and an optional motor holding brake coil
4	PHASE1	U (some motors R)	Armature +	Coil A.1
5	PHASE2	V (some motors S)	Armature -	Coil A.2
6	PHASE3	W (some motors T)	Armature -	Coil B.1
7	PHASE4	Not connected	Armature +	Coil B.2

Motor & brake wiring schematics

Note: the images below are drawn for IONICUBE 4 axis version. IONICUBE 1X wiring is equivalent except there is no brake output in the X3. Brake output pin is located in X4.

• 

  Wiring of three phase AC servo motor. Brake is optional.

• 

  Wiring of Brush-DC servo motor. Brake is optional.

• 

  Wiring of two phase stepping motor. Brake can be fitted like in the other examples. Also 6 and 8 wire motors can be wired (the two drive coils connect always to the same PHASE outputs).

Regenerative resistor

Regenerative resistor is optional and may be connected between REG and HV+ terminals. The on board transistor is capable of carrying max 10 Amp current on regenerative resistor, so minimum allowed resistance can be calculated from: R_min=HV_voltage/10. I.e. with 48VDC HV supply, the minimum resistance is 48V/10A = 4.8 Ohms. Suggested resistor power capability is 20-100 W.

X2 pinout

X2 is the feedback device connector of motor

Pin #	Pin name	Electrical type (in most feedback device modes)	Quadrature encoder	SinCos encoder	BiSS-C encoder	SSI encoder	AMS SSI encoder
Shell	GND	Earth/case
1	HALL_W	Hall sensor digital input, phase W			-	-	-
2	HALL_V	Hall sensor digital input, phase V			-	-	-
3	HALL_U	Hall sensor digital input, phase U			-	-	-
4	GND	Encoder supply ground
5	B-	Differential input B-	Channel B-	SinCos input B-	-	-	-
6	B+	Differential input B+	Channel B+	SinCos input B+	-	-	-
7	A-	Differential input A-	Channel A-	SinCos input A-	-	-	-
8	A+	Differential input A+	Channel A+	SinCos input A+	-	-	-
9	5V_OUT	Encoder supply 5V output
10	GND	Encoder supply ground
11	GPI3	Axis negative direction end limit switch (optional). Normally closed (NC) switch is highly recommended for safety reasons. Connect it between this pin and GND pin. Normally open (NO) switch can be used, and the switch polarity can be changed with Limit switch polarityLSP.			Clock/MA-	Clock-	CLK
12	GPI2	Axis positive direction end limit switch (optional).Normally closed (NC) switch is highly recommended for safety reasons. Connect it between this pin and GND pin. Normally open (NO) switch can be used, and the switch polarity can be changed with Limit switch polarityLSP.			Clock/MA+	Clock+	CSn
13	GPI1	Axis home switch switch (optional). Normally closed (NC) switch is highly recommended for safety reasons. Connect it between this pin and GND pin. Normally open (NO) switch can be used, and the switch polarity can be changed with Home switch or hard stop search direction (Home switch polarity)HMS.					DO
14	C-	Differential input C-	Index channel Z-	Index channel Z+	Data/SLO-	Data-	-
15	C+	Differential input C+	Index channel Z+	Index channel Z+	Data/SLO+	Data+	-
Pin layout	Female D-sub 15 connector as it appears from outside of drive. Note: counterpart (male) connector has mirrored pin layout if viewed from pin side, and same layout if viewed from soldering side.

Examples of feedback device and switch wiring

• 

  Fully wired port with differential incremental encoder, hall sensors and switches

• 

  Wiring of differential incremental encoder

• 

  Minimal wiring of incremental encoder (single ended, no index channel)

• 

  Wiring of Hall sensors only (only torque mode possible)

• 

  Illustration of wiring limit and home switches. In addition to this, encoder and/or halls are needed.

X4 pinout

X4 is main control and setpoint signal port consisting Enable input signal, Fault output signal, pulse and direction/quadrature/PWM setpoint inputs and digital outputs for home switch status. X4 is directly wired to conform most common parallel port style pulse & direction CNC controllers.

Pin number in header	Signal name	Typical usage		Signal name	Typical usage
1	GND	Ground		2	5V_OUT	5V output for optional external circuity
3	HSIN2	Depending on setpoint mode, can be either: Direction signal of pulse train (in Pulse and direction setpoint mode) Quadrature B channel (in quadrature setpoint mode) PWM (in PWM and PWM+Dir setpoint modes)		4	HSIN1	Depending on setpoint mode, can be either: Step pulse train (in Pulse and direction setpoint mode) Quadrature A channel (in quadrature setpoint mode) PWM input direction (in PWM+Dir setpoint mode)
5	ANAIN+	+/-10V analog setpoint input2		6	ANAIN-	+/-10V analog setpoint input2
7	GPI2	Enable positive feed (also in X2)1		8	GPI1	Home switch input (also in X2)1
9	GPI4	Clear faults1		10	GPI3	Enable negative feed (also in X2)1
11	REGEN_OUT	Regenerative resistor power switch state (redundant, IONICUBE 1X has internal power switch)		12	GPI5	Start homing1
13	MECH_BRAKE_OUT	Mechanical holding brake output3		14	GPO5	Reserved for future use1
15	GPO4	Limit switch output		16	GPO3	Fault on any axis or E-stop (active low)1
17	GPO2	Tracking error warning1		18	GPO1	Servo ready1
19	STO2	Safe torque off input (this pin also present in X14)		20	ENABLE	Enable drive (with or without chargepump) (this pin also present in X14)

1) For detailed pin function and alternative functions in various modes, refer to IONI connector pinout

2) Setpoint voltage is measured from the difference of voltage potentials between ANAIN+ and ANAIN-. Both ANAIN inputs must always lie within +/-12V from GND (meaning that controller's zero voltage reference, i.e. GND must be connected to the GND if drive to prevent voltage potentials from floating.

3) This output can directly drive a 24V solenoid brake (max 500mA) if VCC is supplied by 24 volts. In such case, connect brake wires between MECH_BRAKE_OUT and VCC.

4) The same pin is routed also to X1 connectors. Use ENABLE/STO2 pins of only either X4 or X1, not both.

X1 connector

X1 connectors are for SimpleMotion V2 bus which is used for drive configuration with Granity software and control over a multidrop capable serial data link. For pinout, see SimpleMotion V2 port.

DIP Switch S1 settings

On board switch S1 controls the SM bus termination. Set switch 1 to ON position if the IONICUBE 1X devie is the only device in a SM bus OR if it's the last device in device chain. All other cases, leave it OFF (in other words, if IONICUBE is chained to multiple SM bus devices and it's not the last device of the chain).

Using 24 Volt control signals

As many industrial environments use 24V signaling for logic, interfacing IONICUBE 1X has been designed to accept these voltages with help of external circuits:

• The GPOx outputs are NPN open collector type the pulling pin to GND when output is logic 1. GPO can be loaded up to same voltage level with logic supply voltage.
  • If 24V logic accepts such NPN open collector output, wire directly
  • If push/pull type output is needed, wire a pull-up resistor (i.e. 2200 Ohm or higher) between GPOx and 24V voltage
• Inputs are routed directly to IONI input pins that accept up to 5V directly. To extend the range, add a resistor divider network to reduce the voltage to accepted level. I.e. on each pin:
  • 470 Ohm resistor from GPIx to GND, and
  • 2200 Ohm GPIx to user 24V input signal
  • That two-resistor circuit will reduce 24V level logic 1 to an acceptable ~4.2V level, while logic 0 will be ~0V.

Dimensions and mounting

IONICUBE 1X can be mounted by screws to a base or with optional DIN rail clips to a standard DIN rail.

To mount in DIN rail, obtain 2 pcs of Phoenix Contact part number 1201578. Such part is available from many distributors including Digikey 277-2296-ND

Dimensions and mounting hole locations

.

Mating connectors and accessories

This page lists examples of available mating connectors, accessories and spare parts for IONI drive together with IONICUBE four axis motherboard. Most parts or equivalents are available from large number of distributors. You may use http://www.findchips.com/ to search the same or similar parts from alternative distributors.

Recommended shopping list

• Connectors and backshells for X6/X8 unless using a motor with pre-made encoder cables (like Granite Devices servo motors)
• X1 cable (RJ45 cable)
• X4/X5 connectors and flat cable
  • A flat cable to D-Sub 25 connector if direct connection to parallel port based PC CNC software is desired
• EMI filters
• 24 VDC logic power supply
• HV DC bus power supply

See the list of example parts below.

Connectors

X6 & X8 connector

Description	Manufacturer	Part number	Distributors and order codes
PLUG, D, SOLDER, 15WAY	MULTICOMP	5501-15PA-02-F1	Farnell 1084673 DE, US,UK,ES,FR,FI,SE,IT

Accessories

Description	Manufacturer	Part number	Distributors and order codes
D-SUB BACKSHELL, 15WAY	MH CONNECTORS	DPPK15-GREY-K	Farnell 470028 DE, US,UK,ES,FR,FI,SE,IT

X1 connector

Cable assemblies

Cable used for X1 should be shielded (S/FTP or FTP, not UTP) type.

Description	Manufacturer	Part number	Distributors and order codes
Premium patch cable 0.5m	VIDEK	3962-0.5	Farnell 1525999 DE, US,UK,ES,FR,FI,SE,IT
Premium patch cable 1m	VIDEK	3962-1
Premium patch cable 2m	VIDEK	3962-2	Farnell 1525753 DE, US,UK,ES,FR,FI,SE,IT
Premium patch cable 5m	VIDEK	3962-5	Farnell 1525755 DE, US,UK,ES,FR,FI,SE,IT
Premium patch cable 10m	VIDEK	3962-10
Shielded patch cable 0.5m	VIDEK	2992-0.5	Farnell 1517504 DE, US,UK,ES,FR,FI,SE,IT
Shielded patch cable 1m	VIDEK	2992-1
Shielded Patch cable 2m	VIDEK	2992-2	Farnell 1517506 DE, US,UK,ES,FR,FI,SE,IT
Shielded patch cable 5m	VIDEK	2992-5	Farnell 1517509 DE, US,UK,ES,FR,FI,SE,IT
Shielded patch cable 10m	VIDEK	2992-10
Shielded patch cable 0.5m	Assman	A-MCSP-80005/B-R	Digikey A-MCSP-80005/B-R
Shielded patch cable 1m	Assman	A-MCSP-80005/Y-R	Digikey A-MCSP-80010/Y-R
Shielded patch cable 2m	Assman	A-MCSP-80020/Y-R	Digikey A-MCSP-80020/Y-R
Shielded patch cable 3m	Assman	A-MCSP-80050/Y-R	Digikey A-MCSP-80030/Y-R
Shielded patch cable 5m	Assman	A-MCSP-80050/Y-R	Digikey A-MCSP-80050/Y-R
Shielded patch cable 10m	Assman	A-MCSP-80050/Y-R	Digikey A-MCSP-80100/Y-R

Accessories

Description	Manufacturer	Part number	Distributors and order codes
RJ45 break-out board with DIN rail fixture (convert RJ45 to screw terminals). Helpful for wiring STO and Enable wires.	Camden boss	CIM/RJ45	Farnell 2211819 DE, US,UK,ES,FR,FI,SE,IT

X7 and X9 connector

These parts are included with IONICUBE 4 axis product.

Description	Manufacturer	Part number	Distributors and order codes
6 pole 5mm pitch terminal plug	FCI	20020007-G061B01LF	Digikey 609-4182-ND

X4 and X5 connector

Example of DIN rail attachable IDC terminal block/breakout board.

Mating connector type is 0.1" pitch 26 pin IDC ribbon cable socket, see example (pdf).

Description	Manufacturer	Part number	Distributors and order codes
SOCKET, IDC, 2.54MM, 26WAY	AMPHENOL	T812126A100CEU	Farnell 2215239 DE, US,UK,ES,FR,FI,SE,IT
SOCKET, IDC, WITH S/RELIEF, 26WAY	MULTICOMP	MC6FD026-30P1	Farnell 1099240 DE, US,UK,ES,FR,FI,SE,IT
FLAT CABLE 26 WAY	3M	3302/26 300SF	Digikey MC26M-5-ND

Accessories

Description	Manufacturer	Part number	Distributors and order codes
IDC terminal block, 26WAY	Camden boss	CIM/202426W-IDCS	Farnell 2211821 DE, US,UK,ES,FR,FI,SE,IT
FLAT CABLE TO D-SUB 25 CONNECTOR	Sullins	SDS103-PRW2-M25-SN00-211	Digikey S9577-ND

Electromagnetic interference filtering

Description	Manufacturer	Part number	Distributors and order codes
EMI suppression core for low frequency band	Laird	LFB159079-000	Digikey 240-2281-ND
EMI suppression core for medium frequency band	Laird	28B0616-000	Digikey 240-2306-ND

Power supplies

Before making decision on power supplies, see:

• IONI power supply schemes
• Estimating power need of motor drive system

24V low power logic supply

Description	Manufacturer	Part number	Distributors and order codes
24 VDC power supply	TDK-Lambda	LS35-24	Digikey 285-1893-ND
24 VDC DIN rail power supply	CUI Inc	VDRS-20-24	Digikey 102-2152-ND

HV DC high power motor supply

Voltage	Power	Manufacturer	Part number	Distributors and order codes
24 VDC	150 W	Delta Electronics	PMT-24V150W1AA	Digikey 1145-1075-ND
24 VDC	200 W	Delta Electronics	PMT-24V200W1AM	Digikey 1145-1076-ND

Voltage	Power	Notes	! Manufacturer	Part number	Distributors and order codes
48 VDC	150 W		Delta Electronics	PMT-48V150W1AA	Digikey 1145-1109-ND
48 VDC	200 W		TDK-Lambda	LS200-48	Digikey 285-1982-ND
48 VDC	300 W		TDK-Lambda	RWS300B48	Digikey 285-2294-ND
48 VDC	320 W		Mean Well	RSP-320-48	Granite Devices Store RSP-320-48 Findchips RSP-320-48
48 VDC	480 W	DIN rail mounting	Mean Well	NDR-480-48	Granite Devices Store NDR-480-48 Mouser NDR-480-48
48 VDC	480 W	720 W peak output power capability, DIN rail mounting	Mean Well	SDR-480-48	Mouser SDR-480-48
48 VDC	480 W	Requires 3 phase AC power	XP Power	DNR480PS48-I	Digikey 1470-1102-ND Farnell 1372704 DE, US,UK,ES,FR,FI,SE,IT
48 VDC	450 W	Not CE compliant (EU)	Mean Well	SE-450-48	Findchips SE-450-48
48 VDC	480 W		Delta Electronics	DRP048V480W1BN	Digikey 1145-1094-ND
48 VDC	600 W	Not CE compliant (EU)	Mean Well	SE-600-48	Findchips SE-600-48
48 VDC	600 W		TDK-Lambda	RWS600B48	Digikey 285-2298-ND
48 VDC	960 W	Requires 3 phase AC power	XP Power	DNR960TS48-I	Digikey 1470-3050-ND Farnell 1634807 DE, US,UK,ES,FR,FI,SE,IT
48 VDC	1000 W		XP Power	SHP1000PS48	Digikey 1470-2226-ND

Status LED indicators

IONI has two on-board led indicators which have dedicated indicating tasks:

• LED1 Motor control state indicator (green)
• LED2 Fault indicator (orange)

How to read indications

• LED1 and LED2 have programmed blinking sequences. Sequences consists series of short (S) and long (L) light pulses. For example LLS means the led will blink two long flashs and then one short flash. After sequence there will be a pause before the sequence repeats.
• LED1 and LED2 are independent and can show fault and motor state simultaneously. To easier reading sequence, cover one led with a thumb to be able to concentrate to one led.
• LED2 and shows the first fault occurred if multiple fault states are active simultaneously.
• LED1 and LED2 are flashing together if device is in a firmware upgrade mode (DFU).

List of all LED1 and LED2 sequences

To see animated images, view this Wiki page in a web browser with animations enabled. The animations show Argon front panel, but the blinking sequences of IONI are equivalent when LED1=LD4 and LED2=LD3.

Faults

Only LED2 is being controlled by these faults, except in DFU mode when both leds blink together.

Fault reason	LED sequence	LED sequence as text
Hardware		LLSS
Progral or memory		LSLL
Internal comm error (CRC)		LSL
Initialization		LSS
Over current		SLL
Over temperature		LSLS
Over voltage		SLS
Following error		LS
Under voltage		SL
Motion blocked or motor runaway		SSL
Setpoint range exceeded		LSSL
SimpleMotion communication error		LSSS
Other/unknown, possibly configuration error such as motor mode Motor typeMT not selected		SSSL

Motor control states

Only LED1 is being controlled by these states.

Status	LED sequence	LED sequence as text	Motor output powered
Permanent stop (need device reset)		LLS	No
Fault stop (observe LD3 for reason)		Off	Depends on fault
Follow error recovery motion		LS	Yes
Initializing		SL	Yes
Homing		LSS	Yes
Run		On	yes
Drive disabled (enable signal/command missing) OR other/uncategorized (not any of above). For clarity, connect with Granity and see status bits.		LLSS	Yes or No

IONICUBE LED indicators

IONICUBE has four LED indicators that will are dedicated to:

LED1

Power on (24V supplied)

LED2

GPO1_X (LED on when GPO1_X is high)

LED3

Fault stop state (LED on when any of drives has fault stop state on)

LED4

Regenerative resistor is being driven

LED1-4 on IONICUBE

Drive parameterization

This article will describe how to set-up IONI parameters with Granity to make motor operational and ready for servo tuning.

Preparations and connection

As the goal is to parameterize and make motor operational, we should have:

1. The drive and motor fully wired. However it's not required to have controller or braking resistor connected at this point.
2. Be familiar with the operation and parameters of Granity. Make sure you have read Granity user guide.
3. Granity connection working. See IONI & IONICUBE user guide/Making the first Granity connection

Minimum setup for drive & motor configuration stages

Walk-through of initial parametrization

In this chapter we walk-trough all Granity tabs and modify the parameter needed. This guide assumes that the drive is in factory defaults state (not configured before). Restore drive to factory state can be done by uploading a firmware file to the drive.

Connect tab

No other actions than connect to drive needed on this tab. Once connection successful, proceed to the next tab.

Goals tab

The factory defaults (torque control as control mode and serial only as setpoint) as well as the other defaults are the correct ones for beginning.

Machine tab

In this tab we configure the motor and its feedback device.

Axis mechanics

Parameters Axis type & unitsAXT and Axis scaleAXS affect only on the unit conversion of Granity parameters (such as acceleration/velocity limit unit conversions) and has no effect on drive operation.

Choose your axis type and scale, or leave them as defaults.

Motor

Find motor parameters from the motor data sheet/manufacturer specifications.

1. Choose motor type from the drown down list Motor typeMT. If motor is linear type, see configuring linear servo motor. If setting up a stepping motor instead of servo motor, see Using stepping motor with IONI.
2. Set motor Pole countMPC (non-brush DC motors only). If unsure, see Determining motor pole count.
3. Set Maximum speedMMS of the motor, or alternatively the maximum allowed motor speed in the target application
4. Set motor Peak current limitMMC and Peak current limitMMC current values. If non-brush DC motor type has been selected, then these are measured as the peak value of sine. See Motor peak and continuous current limits for description.
5. Set Thermal time constantMTC. Motor thermal time constant value in seconds, used for thermal modeling of motor to avoid motor overheating with Peak current limitMMC. If not available, use formula 200*motor_weight (kg) as approximate, so a 2 kg motor would get a 400 second time constant. There is no guarantee of accuracy of this method.
6. Setting motor Coil resistanceMR and Coil inductanceML values are required for proper drive operation. Do this by using the Granity's measurement function after drive is enabled and operating the first time. If this method fails, perform Tuning torque controller manually after initial parameters are set or find motor inductance & resistance values from your motor data sheet.

Feedback device

1. Choose feedback device type from the drop down Feedback deviceFBD
2. Set feedback device resolution. If Feedback deviceFBD is quadrature encoder, then manufacturers typically give resolution as pulses per revolution (PPR) or lines per revolution (LPR) which are the same thing and shall be entered directly into Feedback device resolutionFBR field. Some manufactures also call PPR as CPR.
3. Configure the polarity of feedback device counting direction by Invert feedback directionFBI parameter. Motor and feedback device must have same electrical positive rotation direction to make a stable servo system. If your system shows no stability (instant following error after a motor "jump"), try changing this setting.
4. Leave the Hall sensors Off from parameter Hall sensorsFBH during initial setup. Enable later if necessary (see when).

Tuning

Tuning tab contains feedback gain values for velocity and position control modes as well as torque bandwidth limit setting. Configuring these parameters are documented in Servo motor tuning guide. However, before proceeding into tuning, go through all other settings listed in this article.

Fault limits

Fault limits define the conditions in which drive is willing to operate. If condition is out of the set values, drive will enter into a fault state and stop motor control until errors are cleared.

Drive fault limits

These settings specify drive electrical condition such as supply voltage and over current tolerance.

1. Leave Over current toleranceFOC value as default if no overcurrent faults occur. See Tuning torque controller if overcurrent faults occur.
2. Set Over voltage fault thresholdFOV following way depending on your HV DC bus supply voltage. Set FOV value at least 10% higher than nominal HV DC bus voltage. For detailed guide of understanding FUV and FOV parameters, see page Configuring drive voltage limits FUV and FOV. Examples:
   1. 24 VDC regulated power supply, try value of 32 VDC
   2. 48 VDC regulated power supply, try value of 54 VDC
3. Set Under voltage fault thresholdFUV so that drive will not trigger undervoltage fault during varying load of HV DC bus. Example:
   1. 24 VDC regulated power supply, try value of 19 VDC
   2. 48 VDC regulated power supply, try value of 35 VDC

1. It is important to goal deviation faults (i.e. Goal faults filter timeFFT, Position tracking error thresholdFPT, Velocity tracking error thresholdFVT, Over speed faultFEV) as low as possible. Set them so that faults don't occur during normal operation but any anomaly or unexpected behavior will trigger them.

Goal deviation faults

These faults adjust motor monitoring during operation. Drive will enter into fault state if motor condition deviates more than allowed from the desired condition. See Granity unit conversion before adjusting.

1. Goal Goal faults filter timeFFT sets the time how fast Position tracking error thresholdFPT, Velocity tracking error thresholdFVT, Over speed faultFEV and Motion fault thresholdFMO faults react. Setting higher time value allows drive to continue operation over short deviations thus avoid false triggering. Set this from 0.0 to 0.2 seconds in the beginning.
2. Set Position tracking error thresholdFPT according how much mechanical axis is allowed to deviate from the setpoint position in position control mode.
3. Set Velocity tracking error thresholdFVT according how much motor or axis speed may may deviate from the velocity setpoint. This affects also in position mode as velocity controller is the intermediate step between torque and position controllers.
4. Set Over speed faultFEV according to the maximum speed allowed for the motor or axis. Helps to stop motor if system goes totally out of control and speeds up spuriously.
5. Leave Motion fault thresholdFMO as 0 (0 = disabled) for the beginning. Using nonzero value enables motion fault.
6. Choose Limit switch functionLFS according to your preference. If other than Do nothing option requires that limit switches are installed and connected to J5 port. Note: at the moment Servo stop option is active in the drive firmware and will do nothing until FW upgrade enables it.

Testing tab

These settings does not affect drive operation, so nothing to be changed here at this point. These controls will be used for servo tuning purposes and fault analysis.

Enabling drive

In order to test any configuration you make, you need to set drive in enabled state. This involves that:

1. Drive is powered on (logic & HV DC bus)
2. Enable signal is powered.
   1. If no physical enable signal is wired, you may click Force enable drive from Connect tab to temporarily enable without physical signal. Note that Force enable will release (inactivate) if any of following physical inputs change state: Enable, Limit switches or Home switch.
3. STO2 input is powered
4. Motor typeMT is configured
5. If Require software enableCEN is enabled, then also click Soft enable drive from Connect tab

Servo motor tuning

Tuning a servo motor is a compulsory task to make motor behave as desired and perform well during operation. Follow the Servo motor tuning guide.

Finishing touches

The last step of parameterization is to adapt settings to match the motion controller. Steps:

1. Choose setpoint input Setpoint inputCRI to match your motion controller.
2. If external motion controller with acceleration limit (such as CNC controller) is being used, then it is advised to set Acceleration limitCAL value to maximum of 32767 (unlimited acceleration) after motor tuning to enable motion tracking without delay. Use a limited acceleration value if drive is being used with pulse burst positioning or SimpleMotion V2 controller.
3. If setpoint is too sensitive or not sensitive enough (such as limiting speed), then adjust setpoint scaling factory by adjusting Setpoint multiplierMUL and Setpoint dividerDIV.
4. If setpoint signal is noisy or jittering, try enabling Setpoint smoothingCIS to smoothen it inside drive. However, leave Setpoint smoothingCIS disabled if setpoint tracking without any delay is desired.
5. Set-up homing if required by application

Servo tuning basics

Driving a servo motor is much like driving a car. Driving a car has many similarities including the key concepts of torque, velocity and position control. Most of this happens in the driver's head the same way than a servo drive does with a motor.

For those who are already familiar with the basics, see the principles of real world servo motor drive from article Signal path of motor drive.

Driving (a.k.a servoing) a car

Driving a car to a destination is much like driving a servo motor to it's destination position. The analogies in between are:

Car	Servo axis
Pedal (motor gasoline feed)	Torque setpoint (motor current feed)
Speed limit	Velocity setpoint
Target location	Position setpoint
Speed meter	Velocity feedback
Trip meter	Position feedback
Car driver	Servo drive

The ultimate goal of driver is to get to the target. To achieve this, he follows the road (trajectory) at certain velocity and decelerates once target is being reached. Without knowing, the driver acts as servo controller where he:

• Controls car's velocity based on the speed meter value and speed limit
• Controls car's position based on trip meter's reading or by observing location trough the windshield
• All actions the driver makes, is based on comparing the setpoints and the actual state

Servo controller basics

Controller gains and a PI controller

Controller gain means sensitivity to change output due to tracking error (the difference between setpoint and feedback).

The simplest form of feedback based controller is a proportional gain controller (P controller) where output follows the formula output = Pgain*(setpoint-feedback). The problem of proportional gain controller is that it may never reach the setpoint because output starts approaching zero when the following error is reaching zero.

Because of this, it's better to add in integrating component to the controller (forming PI controller). Integrator accumulates the tracking error to a integrator variable. Integrator variable is like a bucket of water, when you add water, the water level rises and when you take out water, the level lowers. In controller the equation becomes: output = Pgain*(setpoint-feedback) + Igain*IntegralOf(setpoint-feedback).

The characteristics of feedback gain variables:

• P-gain - reacts instantly to the tracking error but can't eliminate tracking error completely
• I-gain - reacts slowly over time, adjusts output until tracking error is zero

When driving a car, human brain closely resembles the operation of a PI controller. For in-depth info about PI controllers and its variants, see the Wikipedia article PID controller.

Tuning the gains

Controller tuning means finding of the optimum gain values for the given system.

The proper gain values always depend on many aspects, especially the target system dynamic properties (such as motor properties, axis transmission ratios, inertias and masses). Change of properties introduces the requirement of tuning the gain values as gain values that work fine in one system may not behave satisfactory on a different system.

In servo drive case, this means that each motor type and mechanical axis need to be tuned separately. However, if axis and motors are identical, then the same gains should work equally.

Gain tuning (car) example

The following series of images illustrate an imaginary car driving scenario where the driver acts as velocity controller of the car. The magnitude of PI gain values equal the driver's aggressivity of controlling the pedal to reach the desired speed.

Low gains - sluggish response

If the gains are set too low, the system response tends to be sluggish and sometimes leave a static tracking error (not reaching setpoint in any time). In this imaginary case we could think PI gains to be P=20 I=10.

Too high gains - oscillation & instability

If the gains are set too high, the system becomes overshooting, oscillating and less stable. Here the comparable PI gains could be P=200 I=100

Optimum gains - only little overshoot

When the gains are tuned correctly, the response shows rapid response with low overshoot and no ringing or oscillations. The comparable gains here P=50 I=25.

Optimum gains with realistic setpoint - optimum response

The response can be improved further by introducing a limit to the slew rate of setpoint signal. The controller behaves optimally when the system is able to follow the setpoint continuously with little tracking error. In this case the gains could be same as before, P=50 I=25.

Real servo motor controller

See the principles of real world servo motor drive from article Signal path of motor drive.

Tuning torque controller

Torque controller tuning means finding the correct gain values for a torque controller inside the servo drive to achieve a proper response from a torque setpoint change.

Direct inductance & resistance setting method

In Granity, there is no dedicated torque control PI gains as the software supports entering motor coil inductance and resistance where the suitable PI gains are calculated from.

Method 1 (preferred)

If you are using a drive model that supports automatic measurement of inductance and resistance, follow the instructions here.

Method 2

If the above measurement function is not available, and your motor comes with coil specifications containing phase-to-phase inductance and resistance values, then the only necessary step is to enter the given values into motor Coil resistanceMR and Coil inductanceML parameter fields. In case of troubles with this method, proceed with manual tuning method.

Manual tuning method

Manual tuning of torque controller is some times done in order to optimize the torque controller response or to find the correct motor Coil resistanceMR and Coil inductanceML parameters if unknown. Manual tuning also usually yields better torque response than the direct method which may help tuning of velocity or position tuning.

In order to change torque tuning, one needs to change motor Coil resistanceMR and Coil inductanceML parameters until the torque response looks satisfactory.

Preparations

Correct torque tuning settings on the Testing tab.

Steps to do to begin torque tuning:

• Ensure that motor is parameterized correctly and working
• Fix the motor shaft so that it cannot rotate under full peak torque of the motor
• Make following parameter changes to Granity and click apply afterwards:
  • Set drive in torque control mode Control modeCM
  • Set Torque bandwidth limitTBW to maximum
  • Choose Serial only setpoint input Control modeCM
  • Untick Setpoint smoothingCIS
  • Set Goals tab Setpoint dividerDIV and Setpoint multiplierMUL to 50
  • Make other necessary adjustments to have drive powered and enabled
• Set-up the test stimulus and capture settings from Testing tab:
  • Set target setpoint 1 TSP1 to 2000-15000 (see the chapter below for finding the optimum test setpoint)
  • Set delay 1 TSD1 to 0.05 seconds
  • Set target setpoint 2 TSP2 to 0
  • Set delay1 TSD2 to 0.5 s
  • Choose sample rate Sample rateTSR of 10000 Hz or more
  • Choose Capture setpoint change ind positive direction from the dropdown
  • Tick Continuously repeating capture
  • Tick Torque setpoint and Torque achieved from signals
  • Tick Start capture to begin continous capture.
  • Tick Enable test stimulusTSE to begin a pulsed torque generation

Once the steps above are done, motor should be generating short torque pulses to a fixed shaft and torque response graphs should appear on the right side of Granity about once in 3-5 seconds.

Finding optimium test current (TSP1)

To find optimum value for TSP1, enable capture channel called "Motor output voltage" to see how much voltage is driven to motor during rising the edge of torque. For optimum TSP1 value the voltage peak should lie within 20% to 80%. If voltage gets saturated (100%), reduce TSP1 value until it stays below 80%. Images below illustrate the wrong case (first image) and correctly set case (second image).

• 

  TSP1 value too high causing output voltage saturation to 100% (A). This will cause torque tuning to look better than it actually is (B).

• 

  TSP1 value set optimally and peak voltage stays at 60% (C). Now the test reveals that present settings are causing some torque overshooting (D) and we can eliminate it by adjusting ML and MR values.

Adjusting MR and ML to for optimum torque control

The task here is to adjust the Coil resistanceMR and Coil inductanceML parameters to achieve near optimum step response for the torque controller. Observe the images below for guidance.

In this case the Coil resistanceMR value has been set too low causing slowly rising achieved torque curve. Such slow response would reduce servo responsiveness.

In the opposite case (too high Coil resistanceMR value) the response shows wavy oscillations and ovesrhoot.

Same kind of phenomenon will be seen if motor Coil inductanceML value is too low. Finding oscillation free tuning is finding the correct balance between the MR and ML as both affect each other.

Too high Coil inductanceML will cause sharp overshooting and high frequency oscillations. Motor may produce audible noise if oscillations are continuous (occurs with way too high ML).

The above image shows near optimum torque response with fast rising edge combined to minimal overshoot.

The above image shows what may happen if motor shaft is not fixed properly (allowed to rotate). This is with the same optimum settings like the previous image.

Steps to do after manual tuning finished

• Stop test stimulus by unticking Enable test stimulusTSE
• Stop scope catpure by unticking Continuously repeating capture
• Undo all temporary changes made to settings (such as Torque bandwidth limitTBW, Control modeCM, Setpoint dividerDIV, Setpoint multiplierMUL) but leave the optimized Coil resistanceMR and Coil inductanceML values active
• Save settings to drive memory by clicking Save settings on drive non-volatile memory button

Using drive in torque mode

If torque mode is the final desired operating mode, set-up the setpoint signal source from Granity Goals tab. Also see Signal path of motor drive for explanation of torque setpoint scale.

Tuning velocity controller

Velocity controller tuning means finding the correct drive settings and feedback gain values to achieve a proper Servo stiffness and response to a velocity setpoint change.

This tuning guide is for you if the final application uses the motor in velocity control mode such as spindle or as position mode with external closed loop position controller such as LinuxCNC.

Velocity control tuning method

Preparations

An example of Testing tab settings for velocity controller tuning. Different settings should be experimented during the process to observe the stability and behavior of the settings.

Initial settings on Goals tab before beginning the example in this tuning guide.

Steps to do to begin position tuning:

• Ensure that motor is parameterized correctly and working and torque control tuning has been properly done.
• Attach motor to the target load and ensure it can rotate in both directions infinitely
• Make following parameter changes to Granity and click apply afterwards:
  • Set drive in velocity control mode Control modeCM
  • Choose Serial only setpoint input Control modeCM
  • Make other necessary adjustments to have drive powered and enabled
  • Untick Setpoint smoothingCIS
  • Set Goals tab Setpoint dividerDIV and Setpoint multiplierMUL to 50
  • Set Acceleration limitCAL & Velocity limitCVL reasonably to the levels that motor is expected to handle
• Set-up the test stimulus and capture settings from Testing tab (an example, may be varied):
  • Set target setpoint 1 TSP1 between 1000 and 16383 (16383 equals the max speed that is configured via Velocity limitCVL)
  • Set delay 1 TSD1 to 0.25 seconds
  • Set target setpoint 2 TSP2 to same, but negative, value of TSP1
  • Set delay1 STD2 to 0.25 s
  • Choose Sample rateTSR of 500 to 2500 Hz
  • Choose Capture setpoint change in positive direction from the dropdown
  • Tick Continuously repeating capture
  • Tick Velocity setpoint and Velocity achieved from signals
  • Tick Start capture to begin continous capture.
  • Tick Enable test stimulusTSE to begin a continuous position back and forth spinning motion generation

Once the steps above are done, motor should be generating direction reversing spinning and velocity response graphs should appear on the right side of Granity about once in 3-5 seconds.

Finding velocity control gain values

Tuning protocol

Tuning is begun with low or medium target speeds (TSP1 & 2 values below 5000).

Initial velocity response with the default settings. As seen from the achieved velocity graph, it follows the setpoint velocity lazily and exhibits overshooting. In such state motor servo stiffness is low can be easily decelerated by adding load to the shaft.

Begin tuning by increasing Velocity P gainKVP. This makes motor follow velocity setpoint much better.

To try different gains, go to Tuning tab, change value and click the Apply settings button.

When Velocity P gainKVP has been increased too much, the system becomes unstable and may start oscillating. In such case, you may hit Esc button to disable drive, reduce the gain and enable drive again.

Tip: torque bandwidth has significant effect on the behavior of KVP value and the point where it goes unstable. One may experiment different Torque bandwidth limitTBW settings to find the optimum.

Once a maximum perfectly stable Velocity P gainKVP value has been found, start increasing Velocity I gainKVI gain by a similar fashion. The higher KVI value is, the better servo stiffness.

If Velocity P gainKVP is increased too much, the result is overshooting and even sustained oscillation. The cure is similar to the too high Velocity P gainKVP as described earlier.

Once stable and stiff gains has been found, increase setpoint values (TSP1 & 2) to test the settings with higher speeds. If necessary adjust the gains experimentally to find the optimum tuning that works satisfactory on all needed speeds.

Advanced tuning: Feed-forwards

Feed-forward parameters may be used to boost motor responsiveness to setpoint change. Velocity feed-forward gainVFF and Acceleration feed-forward gainAFF essentially compensate system friction and mass limiting the dynamic performance.

The recommended way to tune FF gains, is to start increasing Velocity feed-forward gainVFF until the optimum level has been found. After that, increase Acceleration feed-forward gainAFF until the optimum point has been reached.

In the image above a sharp response has been achieved even with low feedback gains as feed-forward gains help motor to accelerate as demanded.

The image above shows similar response without feed-forwards but using high feedback gain values (optimally tuned according to the previous chapter).

Problem cases

Current/torque saturation

In the following test we run motor with higher speeds (TSPn > 10000) to illustrate a typical problem case.

The image above shows acceleration limited by insufficient torque produced by the motor. In this example the acceleration limit is set too high to be accelerated with the given motor torque limits (or current limits).

To verify if the problem happens due to torque limit, tick also Torque achieved and Torque setpoint signals from the Testing tab settings. In such way also motor currents will be displayed simultaneously with the position response curves. If the torque curve is limited to the set Peak current limitMMC, then the problem is insufficient torque. In the image above we can see that the torque curves are saturated/clipping at 5A and -5A levels which matches the configured Peak current limitMMC value of 5A in this demonstration.

To help this, try:

• Increasing current limits Peak current limitMMC and Continuous current limitMCC if possible
• Reducing Acceleration limitCAL and/or Velocity limitCVL limits

Oscillation

The above example shows instability and oscillation with high speeds even when the system was stable at lower speeds with the same parameters. In such case tune the system again at the most unfavorable conditions and speeds to achieve stability over all required operating conditions.

Low resolution velocity feedback

The above example shows another kind of problem: low resolution of velocity graph. This happens if feedback device resolution is low, and/or test velocity setpoint is low. However tuning is still possible. Tune KVP up until you find instability (you can hear it), and then take it down for 30-50% from that. Then adjust KVI up until graph looks best (no overshooting or oscillations). You may do this procedure with several torque bandwidths (TBW param) to see which gives best result.

Steps to do after tuning finished

• Stop test stimulus by unticking Enable test stimulusTSE
• Stop scope capture by unticking Continuously repeating capture
• Undo all temporary changes made to settings
• Save settings to drive memory by clicking Save settings on drive non-volatile memory button
• Set preferred setpoint source Setpoint inputCRI, also consider the use of Setpoint smoothingCIS
• If setpoint signal scaling is needed, adjust Setpoint multiplierMUL and Setpoint dividerDIV values

Using drive in velocity control mode

If velocity control mode is the final desired operating mode, set-up the setpoint signal source from Granity Goals tab. Also see Signal path of motor drive for explanation of velocity setpoint scale.

Tuning position controller

Position controller tuning means finding the correct drive settings and feedback gain values to achieve a proper Servo stiffness and response to a position setpoint change.

Position control tuning method

This article describes a practical approach for finding proper drive parameters to achieve a stable and stiff position control.

Preparations

An example of Testing tab settings for position controller tuning. Different settings should be experimented during the process to observe the stability and behavior of the settings.

Steps to do to begin position tuning:

• Ensure that motor is parameterized correctly and working and torque control tuning has been properly done.
• Attach motor to the target machine in a position where it can rotate in both directions
• Make following parameter changes to Granity and click apply afterwards:
  • Set drive in position control mode Control modeCM
  • Choose Serial only setpoint input Control modeCM
  • Make other necessary adjustments to have drive powered and enabled
  • Untick Setpoint smoothingCIS
  • Set Goals tab Setpoint dividerDIV and Setpoint multiplierMUL to 50
  • Set Acceleration limitCAL & Velocity limitCVL limits reasonably to the levels that motor is expected to handle
• Set-up the test stimulus and capture settings from Testing tab (an example, may be varied):
  • Set target setpoint 1 TSP1 to 100
  • Set delay 1 TSD1 to 0.25 seconds
  • Set target setpoint 2 TSP2 to -100
  • Set delay1 TSD2 to 0.25 s
  • Choose Sample rateTSR of 500 to 2500 Hz
  • Choose Capture setpoint change in positive direction from the dropdown
  • Tick Continuously repeating capture
  • Tick Position setpoint and Position achieved from signals
  • Tick Start capture to begin continous capture.
  • Tick Enable test stimulusTSE to begin a continuous position back and forth motion generation

Once the steps above are done, motor should be generating short distance back and forth motion motion and position response graphs should appear on the right side of Granity about once in 3-5 seconds.

Finding velocity & position control gain values

---

The task here is to adjust the Coil resistanceMR and Coil inductanceML parameters to achieve near optimum step response for the torque controller. Observe the images below for guidance.

The image above represents the initial position step response with low feedback gains. As seen, motor reaction is sluggish, lagging and has overshooting.

The next step is to increase Velocity P gainKVP gain as much as possible. The graph may start looking acceptable but it motor still has low stiffness thus it will get lag once mechanical load increases.

To try different gains, go to Tuning tab, change value and click the Apply settings button.

When Velocity P gainKVP has been increased too much, the system becomes unstable and may start oscillating. In such case, you may hit Esc button to disable drive, reduce the gain and enable drive again.

Tip: torque bandwidth has significant effect on the behavior of KVP value and the point where it goes unstable. One may experiment different Torque bandwidth limitTBW settings to find the optimum.

Once a maximum perfectly stable Velocity P gainKVP value has been found, start increasing Velocity I gainKVI gain by a similar fashion. The higher KVI value is, the better servo stiffness.

If Velocity P gainKVP is increased too much, the result is instability and oscillation. The cure is similar to the too high Velocity P gainKVP gain as described earlier.

Once both Velocity P gainKVP and Velocity I gainKVI has been optimized, the next step is to increase Position P gainKPP gain the same way. Increasing Position P gainKPP gives better servo stiffness but may also increase overshooting. Overshoot less than 10 feedback device counts is generally considered good.

Finally after playing little bit with all of Velocity P gainKVP, Velocity I gainKVI and Position P gainKPP experimentally, we find a less overshooting response without losing much stiffness.

Curing tracking error and overshoot

If servo overshoots too much, or can't follow the trajectory precisely, several cures may be tried.

Reducing Acceleration limitCAL and/or Velocity limitCVL limits makes the trajectory easier to follow and reduces tracking error and overshooting.

The same may be also achieved by utilizing Feed-forward Velocity feed-forward gainVFF and Acceleration feed-forward gainAFF which essentially compensate system friction and mass limiting the dynamic performance.

The recommended way to tune FF gains, is to start increasing Velocity feed-forward gainVFF until the optimum level has been found. After that, increase Acceleration feed-forward gainAFF until the optimum point has been reached.

If following the tuning procedure does not result in satisfactory tracking performance, the problem may be asking too much from the motor. In the example above the acceleration limit is set too high to be accelerated with the given motor torque limits (or current limits).

To verify if the problem happens due to torque limit, tick also Torque achieved and Torque setpoint signals from the Testing tab settings. In such way also motor currents will be displayed simultaneously with the position response curves. If the torque curve is limited to the set, Peak current limitMMC, then the problem is insufficient torque. In the image above we can see that the torque curves are saturated at 4A and -4A levels which matches the configured Peak current limitMMC value of 4A in this demonstration.

To help this, try:

• Increasing Peak current limitMMC and Continuous current limitMCC if possible
• Reducing Acceleration limitCAL and/or Velocity limitCVL limits

Steps to do after tuning finished

• Stop test stimulus by unticking Enable test stimulusTSE
• Stop scope capture by unticking Continuously repeating capture
• Undo all temporary changes made to settings
• Save settings to drive memory by clicking Save settings on drive non-volatile memory button
• Set preferred setpoint source Setpoint inputCRI, also consider the use of Setpoint smoothingCIS
• If setpoint signal scaling is needed, adjust Setpoint multiplierMUL and Setpoint dividerDIV values. See Signal path of motor drive for explanation of velocity setpoint scale.

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