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

Warnings

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