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IONI firmware releases

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This page lists the official firmware releases of the IONI Servo Drive and the change log.

Upgrading firmware

Read instructions from Granity user guide/Uploading a firmware.

Releases

Glossary
  • Firmware release version - a firmware file with .gdf name extension that contains the firmware firmware
  • Version code - the version shown in Granity
  • Change log - the list of changes made since the previous package version.
  • Remarks - Notes
Firmware release version Date Version code Change log Remarks Criticality
1.0.0 15.3.2015 1050
  • Initial version
1.0.1 19.3.2015 1052
  • Address an issue where device may trigger watchdog reset under heavy use
Medium
1.0.2 11.4.2015 1054
  • Fixes
    • Fix Phasing a.k.a. phase search current calculation when Thermal time constantMTC is set below 400 seconds. Avoids too high current flow to motor.
    • Fix overcurrent condition observer (OC fault was not always triggered when it should).
    • Fix incorrect setpoint scaling when using Setpoint smoothingCIS Setpoint smoothing function (before 1.0.2 CIS caused setpoint to incorrectly scale by 1:2)
    • Fix functionality of GPI5 input (homing start)
    • Fix override parameter function (more info: Reading and writing an arbitrary parameter with Granity)
  • Improvements
    • Reduce Phasing a.k.a. phase search current to avoid motor heating at initialization
    • Improve open loop stepping motor performance
    • GPO3 (fault output) will be push-pull instead of open drain when electrical interface is set Standard (for IONICUBE 1X compatibility)
    • IONI Indiegogo campaign drives have 18 Amp maximum current limit instead of 15 A (serial number based)
Important upgrade due to overcurrent protection fix and phasing current calcuation fix. Very high
1.0.3 12.4.2015 1056
  • Fixes
    • Fix clear faults command by Enable signal in IONICUBE electrical interface mode
    • Fix PWM setpoint operation after setpoint source has been changed from pulse/direction to PWM
  • Improvements
    • Stepping motor has automatic current reduction/boost depending on whether motor is standing still or rotating (switch between configured continuous and peak current).
Medium
1.0.4 13.4.2015 1058
  • Fixes
    • Address an issue where Achieved torque readout & graph was showing only zero
  • Improvements
Medium
1.1.0 download 15.4.2015 1060
  • Fixes
    • Fix incorrect (too high) current scale for Brush DC motors
  • New features
  • Improvements
    • Extend the maximum range of resistance and inductance parameters from 32 ohm & mH to above 100 ohm & mH
The new feature requires Granity V 1.6.0 Medium (High for DC motor users)
1.2.0 download 4.5.2015 1062
  • Fixes
    • Address an issue where overspeed fault (parameter Over speed faultFEV) has no effect and not causing fault
  • New features
  • Improvements
    • Increase feed-forward gain sensitivities: velocity FF Velocity feed-forward gainVFF sensitivity is 30 times higher, and acceleration FF Acceleration feed-forward gainAFF is 300 times higher than before
    • Increased Phasing a.k.a. phase search algorithm motor swing to allow successful phasing in the case where motor motion is blocked in one direction
    • Motor inductance & resistance measurement function (introduced V1.1.0) adjusted to be less sensitive to motor motion during the test
The SinCos support requires Granity V 1.7.0

Note: if acceleration or velocity feed-forward gain parameters are non-zero, re-tune the AFF and VFF gains after upgrade!

Medium
1.2.1 download 3.6.2015 1064
  • Fixes
    • Address an issue where GPI5 did not start homing
    • Fix signal offset compensation calculation in PWM and Analog setpoint modes (applies when Setpoint offset nullingCAO is non-zero and Enable direction inputCED is enabled)
  • Improvements
    • Reduce sensitivity of gain parameters to suit better for very high resolution feedback devices:
      • Velocity P gainKVP and Position P gainKPP have sensitivty of 1/5 compared to to earlier firmware (to preserve old gain, multiply old gain values by 5 after upgrade)
      • Velocity feed-forward gainVFF has sensitivty of 1/10 compared to to earlier firmware (to preserve old gain, multiply old gain value by 10 after upgrade)
    • Increased maximum value range of gain parameters from 32767 to 300000
Note: adjust KVP, KPP and VFF values after upgrade! See change log for details. Low
1.2.2 download 23.6.2015 1068
  • Fixes
    • Stepper motor mode no longer reduces motor current in steady velocity motion (reduction occurred when a long motion setpoint was commanded via serial command)
    • Target reached status made to work properly
  • Improvements
    • Homing current limit Motor current limit during homingHMT parameter is now effective also in stepper mode
Low
1.2.3 download 15.7.2015 1070
  • Fixes
    • Fix PWM+Dir setpoint mode (was giving only setpoint zero in FW 1.2.1 and 1.2.2)
  • Improvements
    • Drive current limit increased to 18 A in IONI Pro model
Low
1.3.0 download 2.11.2015 1080
  • New features
  • Fixes
    • Avoid overcurrent problem after Phasing a.k.a. phase search with high current motors
    • Allow outputting the 18 A current on IONI Pro (was still limited to 15 A in previous version)
    • Servo ready status updated correctly now
    • Addressed an issue where GPO5 output did not change state
    • Reduced sensitivity to overcurrent fault when using DC motor
  • Improvements
    • Drive current limit increased on DC motor mode on all IONI models:
      • 19.5 A on IONI
      • 23.4 A on IONI Pro
      • 30.0 A on IONI Pro HC
    • Added possibility to disable hard stop detection in homing (set zero to Hard stop detection thresholdHMH)
    • Position mode error recovery motion mode now uses velocity limit Acceleration limitCAL, not Homing acceleration limitHMA
    • Hard-stop homing parameterizing made more logical - now Offset move after homingHMF can be left zero without issues
Requires Granity V 1.9.0 Low
1.3.1 download 25.11.2015 1082
  • Improvements
    • Reduced torque control noise (audible). Noise reduction is active when Torque bandwidth limitTBW is set 680 Hz or less.
Low
1.4.0 download 31.12.2015 1084
  • Improvements
    • IONI Pro HC model maximum output current in AC/BLDC/Stepper modes increased to 25A (was 23A)
    • Re-implemented torque controller using 32 bit floating point arithmetics instead of integer arithmetics (at least theoretical precision improvement)
    • DC motor mode no longer requires parallel connection of drive output phases if current is at most 50% of drive's maximum output current capability (sensitivity of overcurrent fault with Fault ID 440219 is greatly reduced).
  • Fixes
    • Changed limit switch polarity: earlier limit switches needed to be normally open (NO), while drive specifications say that they are normally closed type (NC). Now limit switchers are NC (switch conducting -> motion allowed, switch open -> motion stops).
    • Fix an issue where AC/BLDC motor initialization could become incorrectly phased when Hall sensors are enabled
    • Address an issue where torque was 5% lower than setpoint with TBW parameter value of 4700 Hz
  • Test the upgrade with caution due to significant internal changes
  • If system uses limit switches, they need to be wired differently after upgrade, or disable them with LFS parameter
Medium
1.5.0 download 8.5.2016 1092
  • New features (IONI Pro/Pro HC only):
    • Notch/peaking filter for torque setpoint
    • Torque mode effects added: damping, friction and inertia
    • Homing function that works in all control modes
    • Power consumption limit parameter added (allow setting maximum power driven to motor)
    • SimuCUBE support added in Electrical interfaceCEI. In SimuCUBE mode:
      • STO input acts also as Enable and Clearfaults input
      • Regenerative resistor drive algorithm is tuned for SimuCUBE (tip: use 48 VDC PSU and set Over voltage fault thresholdFOV to 49-50V)
      • Power consumption limit is smoother in SimuCUBE mode than in other modes
  • New features (all models):
    • Support for fast setpoint command added in SimpleMotion V2 protocol
    • In torque mode the Tracking error capture channel now displays the difference between raw unfiltered setpoint and realized actual torque in milliamperes
  • Improvements
    • Smoother multi-axis operation in buffered motion stream mode (SimpleMotion V2)
    • Drive now performs a self-test of the internal RAM of controller at every power-on
  • Fixes
    • Address an issue where fault location 6601 was rarely induced after power-on
  • Test the upgrade with caution due to significant internal changes
  • Use Granity V1.10 or later to access the new features
Low
1.5.1 download 6.6.2016 1094
  • Improvements
    • Operation of regenerative resistor drive enhanced in SimuCUBE Electrical interfaceCEI mode
  • Fixes
    • Address an issue where homing could act erratically (i.e. perform homing twice in a row while one homing is requested)
    • SimpleMotion watchdog/keepalive feature fixed (was broken at 1.5.0)
Medium
1.5.2 4.8.2016 1096
  • New features
    • It is now possible to use torque cogging & ripple compensation parameters for open loop stepping motors to reduce stepper noise and vibration
    • New safety feature: monitoring of actual torque vs target torque. If torque is significantly above torque setpoint (i.e. loss of torque controller stability occurred), then drive will stop in over current fault with Fault location 442001
  • Improvements
    • Eliminated motion glitch during motor initialization
    • Enhanced open loop stepper signal processing: motor will stay quiet at stand still at any angle (note: KVI and KVP values need to changed, see Using stepping motor with IONI for details.
  • Fixes
    • Fixed buffered motion stream glitch that could sometimes cause corruption of instant SimpleMotion command return values while buffered motion is running. Typical symptoms of this glitch are Fault location 480501 and skipping of motion samples.
    • Addressed instability of torque controller with high coil resistance motors
In open loop stepper mode, update KVI and KPP parameters according to page Using stepping motor with IONI Medium
1.5.3 download 11.8.2016 1098
  • Fixes
    • Addressed V1.5.2 velocity feedback bug when using Sin/Cos encoder. Symptoms were instability of velocity and position control mode and instability of torque mode effects.
See also notes of 1.5.2. Medium
1.5.4 download 8.9.2016 1100
  • Improvements
    • General purpose inputs (GPI-pins) of drive are now noise/glitch/debounce filtered. Now digital input state change requires that signals stays stable for 10 milliseconds before it is interpreted as state change.
    • Prevent overloading of regenerative resistor by the means of:
      • Drive will not enable regenerative resistor until HV DC bus voltage has been within valid voltage range with 2% safety margins from Under voltage fault thresholdFUV and Over voltage fault thresholdFOV at least once
      • Pulsing frequency of regenerative resistor has been increased
      • Maximum heat load of regenerative resistor in SimuCUBE mode has been reduced
  • Fixes
    • I²t protection time scale is corrected (earlier versions had wrong scale in Thermal time constantMTC meaning that the protection was bit too conservative, by about 20% difference)
It may be necessary to decrease FUV and/or increase FOV parameter values to make drive initialize as the new changes requires 2% safety headroom for these values versus actual supply voltage.

I.e. for 48.0V supply voltage, the FUV value should be less than 48*0.98=47V and FOV should be greater than 48/0.98=49V.

In practice, make allowed voltage range at least 0.5V wider to allow supply voltage variation, like FUV=46.5V and FOV=49.5V or greater.

For more information, see Configuring drive voltage limits FUV and FOV

Medium
1.5.5 download 19.12.2016 1102
  • Improvements
    • Support changing limit switch polarity (requires Granity 1.10.2)
    • Limit switch polarity default setting changed. Now default setting assumes normally closed switches, instead of normally open type.
    • Added soft current ramp-up for open loop stepping motors
    • Tracking error warning flag is now controlled also in torque mode (of torque error is greater than 25% of peak current parameter MMC, the tracking error warning flag goes logic true)
    • SimpleMotion bus baud rate now resets to the default if connection watchdog timeout occurs
  • Fixes
    • Address an issue where I²t protection did not react (in some cases allow motor overheating)
Medium
1.5.6 download 16.1.2017 1104
  • Improvements
    • Overcurrent fault with Fault location 402001 can not occur any more if Over current toleranceFOC is set to Maximum
    • Increased error tolerance for Fault location ID 250101
  • Fixes
    • Address an issue where SimpleMotion bus connection may get interfered by usage of bus watchdog feature
Maximum FOC setting is still safe value for drive. Low
1.5.8 download 14.2.2017 1108
  • Improvements
    • Support for new production run IONI drives (a requirement for drives manufactured after 1.2017)
    • Support for custom 7 axis motherboard added (similar to IONICUBE but customer design)
This, or later version is required for drives manufactured after 1.2017 due to minor hardware change. Installing older FW version on such device will cause update error and requires re-update. Low
1.6.0 download 3.8.2017 10600
  • New/improved features
    • Support for serial feedback devices have been added. These include:
    • Scope capture feature improvements:
      • Scope allows setting pre-trigger delay to capture events that occur before the selected trigger
      • New trigger source: external trigger. This is triggered by state change of clear faults and home switch physical inputs.
      • Scope setup is now saved in drive flash
      • Offline scope feature introduced: saved scope settings allow downloading rarely occurring events when Granity is not connected (see Downloading offline scope capture in Granity)
    • Homing feature now supports optional second home switch/hard stop approach motion from user defined direction to improve homing repeatability when home switch has significant hysteresis or when high homing velocity is being used.
    • Added automatic single-click configuration of optional motor Hall sensors. By using this method, Hall sensors and motor phases may be wired in any order and still achieve working configuration. The benefit of utilizing Hall sensors is the elimination Phasing a.k.a. phase search during initialization of AC/BDDC motors and ability to start motor under any mechanical load.
    • Added support for Hall sensor angle offset calibration to maximize motor torque sensitivity even with inperfectly aligned Hall sensors.
    • Added optional audible status change notification beeps (motor plays sound when initialization is complete)
    • Error detection against excessively fast toggling Direction input in pulse & direction setpoint mode (i.e. incorrectly wired pulse/dir signals)
    • Increased torque ripple compensation range to sin/cos 50x from 12x (TRF1/TRF2 params)
    • Reduced time delay from enable signal to motor becoming active
    • Support for SimuCUBE revision 2 boards added. GPO2 output will be always logic 0 if Electrical interfaceCEI is set to SimuCUBE in order to enable SimuCUBE revision 2 fan output
  • Fixes
    • Fix clearfaults issue when faulted/disabled motor is located out of HHL/HLL bounds after homing and CRV=0 (unable to clear fault because setpoint was inside limits and motor beyond follow error threshold). Now motor is driven to nearest HHL/HLL limit at homing velocity.
    • Avoid resetting devices faults & status registers
    • If device restart happens due to insufficient logic voltage or firmware watchdog trigger, drive will now requires software enable command to initialize for safety reasons
    • Status bit servo ready now waits also that drive's power stage is ready for active operation. Before this the servo ready flag was set true approximately 50 ms before it should have been set.
Low


1.6.1 download 30.8.2017 10601
  • Fixes
    • Correct readout of certain BiSS C encoders
Low

Beta releases

No beta releases at the moment.


Known bugs & limitations

Bugs that are known in the latest FW revision:

  • Setpoint smoothing does not have effect in velocity or torque modes (only position mode)
  • Install firmware button in Granity does not always have effect with IONICUBE (4 axis). Workaround: insert jumper in position 3 of JP10 and restart 24V power to force devices in firmware upgrade mode. This minor issue affects only first production run IONI drives shipped around April 2015 to June 2015.
  • Overcurrent fault with Fault location 402001 may cause false alarms on some setups. Improvements in future firwmare are planned. If problem occurs, as workaround set Over current toleranceFOC to Maximum.

Credits, copyrights and third party software

Several fantastic pieces of open-source software have helped get IONI firmware to where it is today. For fur list of credits, see Third-party licenses.


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