Home

ION - CME Digital Drive User`s Manual

1. Signal Name PinNo BitNo _ Digitalln 9 0 Digitalln2 10 Digitalln3 n 2 Digitalln4 12 3 DigitallO5 13 4 DigitallO6 14 5 DigitallO7 15 6 DigitallO8 16 7 The following code sequence illustrates how to read the state of the eight digital inputs open a peripheral handle to the digital input signals PMDPeriphOpenPAR amp hPeriph amp hDevice PMD ADDRESS ION DI 0 PMDDataSize_ 6Bit read the current state of the digital inputs PMDPeriphRead amp hPeriph amp datal6 0 1 4 4 2 Digital Outputs The six digital outputs four are shared with the digital inputs are controlled via the Peripheral Write function The desired output values are contained in the low 8 bits of the 16 bit word parameter and the bit mask is contained in the high 8 bits of the 16 bit word parameter The bit mask sets which bits will be affected by the write The current output state can also be read via the Peripheral Read function and are contained in the lower 8 bits of the returned 16 bit wotd Signal Name Pin No Bit No DigitalOutl 7 0 DigitalOut2 8 l DigitallO5 13 4 DigitallO6 14 5 DigitallO7 15 6 DigitallO8 16 7 The following code sequence illustrates how to set the state of the six digital outputs on the Indexer IO Connector open a peripheral handle to the digital output signals PMDPeriphOpenPAR amp hPeriph amp hDevice PMD ADDRESS ION DO 0 PMDDataSize_ 6Bit read the current sta
2. ION CME o T Serial Port 6 o Rx c o Lr Adapter For RS232 pin 8 must be left floating For RS485 pin 8 must be connected to IO Gound ION CME Digital Drive User s Manual 27 Installation 2 6 Software Installation Each ION CME developer s kit provides several major software packages for motion system development e Pro Motion an interactive Windows based exerciser and software development tool e C Motion a C language library that allows the developer to create motion applications using the C pro gramming language e C Motion Engine Development Tools a set of development resources that allows the developer to create download and monitor programs loaded in the ION CME C Motion Engine Additional information on each of these software packages is provided as follows Locate the Pro Motion CD and install the Pro Motion application on the host computer following the instructions in the Pro Motion Users Guide This software will configure the module and fully exercise the features of the ION CME Digital Drive PDF versions of this manual the Magellan Motion Processor User Guide and the Magellan Motion Processor Programmers Command Reference can be found on the CD included with the ION CME developet s kit Adobe Acrobat Reader is required for viewing these files If the Adobe Acrobat Reader is not installed on your computer you may download it at no cost from http www adobe com 2 7 Communication
3. The ION CME module should be disabled and disconnected from its power source before any attempt is made to fix a hard fault condition ION CME Digital Drive User s Manual 45 P3 Operation The following sequence should be used to recover from the hard fault state 1 Unless the failure is clearly caused by external circumstances the ION CME module should be disconnect ed from the serial network as well as disconnected from all external hardware such as the motor motor encoder power supply etc 2 With all external hardware disconnected restore the module power If the unit is still in the hard fault state as indicated by the red Module Status LED the drive is likely to have sustained an unrecoverable failure and should be considered unusable thereafter A replacement ION CME module should be used in the appli cation 3 If the Module Status LED indicates that a fault is no longer present the cause can be determined by recon necting the communications cable cycling power again and reading the Drive Fault Status from the ION CME module See the Magellan Motion Processor Users Guide for more information on reading the Drive Fault Status 4 Once the nature of the fault is known it must be corrected It is always the responsibility of the user to main tain safe operating conditions of the ION CME module as well as all associated electronics or hardware 5 With the source of the problem corrected the ION CME module can
4. Figure 2 8 Pulse amp direction input connections Index Primary Encoder Quad A B To connect to the ION in this configuration use the following connections Pulse and Direction Controller Connection from Encoder ION Connector Pin ION Pin Pulse amp Direction input Pulse Auxiliary 5 Pulse Pulse Auxiliary 6 Pulse Direction Auxiliary 7 Direction Direction Auxiliary 8 Direction Encoder input optional if controlling step motor Quadrature A Feedback 7 Quad A Quadrature A Feedback 8 Quad A Quadrature B Feedback 9 Quad B Quadrature B Feedback 10 Quad B Index Feedback II Index Index Feedback 12 Index Hall A Feedback 4 Hall A Hall B Feedback 5 Hall B Hall C Feedback 6 Hall C Brushless DC motors only ION CME Digital Drive User s Manual 23 Installation Figure 2 9 Typical I O wiring 24 2 5 7 I O Connector Pin 1 Pin 2 Pin Signal Pin Signal l Shield 8 Limit 4 2 lO Gnd 9 Limit 444A A 3 lO 5V I0 Home 4 A A A AA 4 4 lO Gnd II High Speed Capture dummy 5 lO 5V I2 Axisln i 6 lO Gnd I3 AxisOut Pin14 7 FaultOut I4 Enable This connector is used to wite motion specific I O signals such as overtravel limits home reference and high speed capture input as well as the general purpose AxisIn and AxisOut signals It also has pins for the master Enable input and FaultOut signals
5. Unused Unused Rx Unused Unused j NI AJ aj A wj N ION CME has a standard 8 pin RJ45 connector for Ethernet connection Standard UTP unshielded twisted pair CAT5 Ethernet cabling can be used in most applications For added noise immunity use shielded cable 2 5 10 Serial RS232 485 Connector Serial RS232 RS485 Port 10 100 Ethernet Port An RJ45 type connector provides serial connectivity on the Ethernet Serial ION This serial connector can support both RS232 and RS485 Pinouts for both of these serial protocols are provided in the table below Pin RS232 RS485 l Unused Unused 2 Unused Unused 3 Rx Rx 4 Unused Tx 5 Tx Tx 6 Unused Rx 7 lO Gnd lO Gnd 8 Select Float High Select low ION CME Digital Drive User s Manual Installation For RS232 pin 8 must be left floating For RS485 pin 8 must be connected to IO Gnd For connecting to an RS232 serial port on a host machine an adapter is needed to interface between DB9 and RJ45 connectors PMD P N Adapter 1010 01 Figure 2 11 shows RS232 and RS485 wiring ION CME does not have built in termination for RS485 If a network application requires termination at the ION CME serial connector resistors must be added in the network wiring PMD P N Adapter 1010 01 Standard CAT5 Cable Figure 2 11 RS232 485 wiring Adapter Standard CAT5 Cable o 2 o o o S E Txt FL
6. Y NN M3 x 0 5 threaded through hole 4 places Figure 5 2 ION CME with heat sink attached ION CME Digital Drive User s Manual 67 Options and Accessories Figure 5 3 Attaching the optional DIN rail adapter Figure 5 4 ION mounted on DIN rail 68 5 4 Optional DIN Rail Adapter The optional DIN rail adapter fits on the back of the ION module and allows ION to be mounted to a standard 35mm DIN rail To install the adapter place the tab into the large hole in the enclosure and rotate the adapter clockwise as shown in Figure 5 3 and Figure 5 4 The recommended insertion orientation is indicated When subsequently mounted on a horizontal DIN rail the Communications connector will be up and the adapter release tab down To remove the adapter pry up the two ends while applying rotation force A flat blade screwdriver may be required ION CME Digital Drive User s Manual 6 Electrical Signal Interfacing In This Chapter Motor Feedback Auxiliary Position Input Limit and Home Inputs Position Capture Sources AxisIn and AxisOut Signals Enable and FaultOut Signals General Purpose Digital Inputs and Outputs Analog Inputs vvvvvvvyv 6 1 Motor Feedback The Feedback connector contains the main encoder signals as well as Hall commutation signals These signals are buffered and filtered in the Quadrature Signal Conditioning and Digital Si
7. sesseessesssessecssocssossoossosssosssesssessesssoseo 79 7 ION CME Drive Ratings sesssseseeeeeeneennen een enne 79 7 2 ION CME Controller Performance sseseeeeeeee 80 73 JION CMB Blecirical Ee SERIE RT 81 7 4 ION CME Protection Circuits seen 83 7 5 ION CME Connectors and Pinouts sse 83 7 6 ION CME Mechanical sese 86 7 1 TON CME Environmental esee eene nemen nen 87 7 8 ION CME Safety and Compliance see 87 7 9 ION CME Thermal Operating Curves eee 87 Index vele EPI fU vU Helene s 89 vi ION CME Digital Drive User s Manual List of Figures dh List of Figures Figure 2 1 Connector locator rousie RARE das Soa ooo ba MEER eS 14 Figure 2 2 Typical power Wiring 1 2 cee e seh ht nt 16 Figure 2 3 Typical motor wiring 00 cnet teen tenes 17 Figure 2 4 Recommended feedback wiring 0 cece eect eee nee ee 19 Figure 2 5 Recommended auxiliary encoder wiring 0 ce cette eens 20 Figure 2 6 Single encoder mode connections 0 cee cee eect eee 21 Figure 2 7 Dual encoder mode connections 0 eee eect ee 22 Figure 2 8 Pulse amp direction input connections 23 Figure 2 9 Typical VO Witt sce cp E dead dae tee a GUERRE EAM IRE 24 Figure 2 10 Indexer VO WIE o ev 3 cot oes cheers EUIS EDS DERE NU fete neds 25 Figure 2 11 RS232 485 wirin
8. versions Step motor version Position torque current and voltage Open loop with stall detection current and voltage Digital current loop Filter parameters Configuration Current feedback scaling Scalable PI with integration limit and torque current limit Standard phase A B control or FOC with state vector PWM user selectable 10076 full scale equals 21 2A Current foldback DC brush and brushless DC motor versions Programmable Pt peak limiting Brushless DC commutation modes Sinusoidal and 6 step Hall commutation Mlicrostepping resolution Up to 256 microsteps per step Maximum encoder rate 10 Mcounts per second PWM frequency 20 or 40 kHz user selectable Loop rates Commutation amp current loop Position loop amp trajectory generator 51 2 usec 102 4 usec to 1 67 sec selectable in multiples of 51 2 usec from n 2 to 25 1 ION CME Digital Drive User s Manual ION CME Specifications rN 7 3 ION CMIE Electrical AuxV input voltage 12 56VDC range AuxV maximum current 0 5A IO 5V supply output 5V 2 150 mA total max short circuit protected Differential single ended encoder inputs Signals Voltage range Logic threshold Maximum frequency Main encoder A A B B Index Index Auxiliary encoder A A B B 0 5 VDC RS422 compatible 2 5 MHz Phasing A leads B by 90 20 Index low must align w
9. 12 6 VDC 12 56 VDC transformer isolated power supply Output current per phase Continuous DIN rail mount w heat sink free air 6 ADC 6 Arms 8 5 ADC 5 Arms 7 1 ADC 25 C Continuous coldplate mount Tbp lt 50 C 9 8 ADC 8 Arms 11 3 ADC 5 Arms 7 1 ADC Peak 2 sec 21 2 ADC 15 Arms 21 2 ADC 15 Arms 21 2 ADC Maximum continuous output power Coldplate mount Tbp lt 50 C 450 W 500 W 350 W ION CME Digital Drive User s Manual 79 ha ION CME Specifications 7 2 ION CMIEE Controller Performance Supported motor type DC brush Brushless DC Step motor Communications options Ethernet RS232 485 CANbus Profile modes S curve point to point Trapezoidal point to point Velocity contouring Electronic gearing Position velocity acceleration deceleration jerk parameters Position velocity acceleration deceleration Velocity acceleration deceleration Using auxiliary encoder Position loop filter parameters Scalable PID with Velocity and Acceleration feedforward integration limit offset bias dual biquad filter and settable derivative sampling time Also supports dual encoder feedback Position error tracking Motion error window Tracking window Allows axis to be stopped upon exceeding programmable window Allows flag to be set if axis exceeds a programmable position window Configurable loop modes DC brush and brushless DC motor
10. 3 1 ION CMIE Block Diagram ION CME combines the function of a user code execution platform motion control interfaces to a host computer using an Ethernet or serial interface and connects to all required to drive a DC Brush Brushless DC or step motor Refer to Figure 3 1 ller and amplifier It directly power and feedback signals In addition to the C Motion Engine and the Magellan ION Motion Processor ION CME incorporates several major subsystems including a communications system a high performance MOSFET based conditioning system a trace buffer and a digital and analog I O interface power stage a DC Bus The following sections describe these major sections of the ION CME Digital Drive For a complete description of the Magellan Motion Processor see the Magellan Motion Processor User s Guide and the Magellan Programmers Command Reference DC Bus Monitorin TUS t eue pep eee IPeoation Non Volatile RAM II FI PWM Signals C Motion Engine 256 KB User Code Current feedback Figure 3 1 Space R 36 KB RAM Main Encoder ION CME ION Moti Quad A B Index Magellan l otion Quadrature Signal Auxiliary Quad block diagram Processor Conditioning Encoder A B Serial RS232 Communication Serial RS485 Transceivers Ethernet Hall Sensors Digital Signal sea m itioni igh Spee 4 Bidirectional I Os Digital 1 0 Conditioning Capture 4 Inputs Conditioning 2 Outputs Drive Enable Status LEDs Digital Si
11. AxisOut Gray 14 Enable Tan PMD Part Cable 1005 02 R Pin Signal Color Description ION 500 DC bus stub cable l HV Red Length 2m 2 AuxV White Cable 3C 1 6AWG foil shield Alpha 5363C or equiv 3 PGnd Black Note Drain and PGnd spliced together at Pin 3 PMD Part Cable 1006 02 R Pin Signal Color Description ION 500 Motor stub cable l A U M White Length 2m 2 A V Green Cable 6C 6AWG foil shield Alpha 5366C or equiv 3 B W M Orange 4 B Blue Note Drain and PGnd spliced together at Pin 5 5 PGnd Black ION CME Digital Drive User s Manual 65 amp Options and Accessories PMD Part Number CABLE 1010 01 Pin Signal Color Description Indexer stub cable Case Shield Bare Length Im 2 lO Gnd Black Cable Multiconductor shielded ALPHA 6308 or equivalent 3 lO 5V Red 4 Analogln Black Cable 1010 01 is split into 2 shielded cable sections One section 5 Analogln Red carries twisted pair conductors connected to the analog input 6 IO Gnd White The other section carries conductors connected to the 7 DigitalOutl Blue Red Digital Inputs amp Outputs This ensures that the analog signal 8 DigitalOut2 Orange Red is separate and shielded from the rest of the signals 9 Digitalln Green Black on the Indexer Connector 10 Digitalln2 Orange Black II Digitalln3 Blue Black 12 Digitalln4 Red Black 13 DigitallO5 Black White 14 Digita
12. Digital I O sessseseseseeeeeeenee eene 50 ANS Analog Input enun RR ERR 52 4 6 C Motion Engine Functions essseseeeeeeneeeeeeeeneeneeeee enne 54 4 Communications Functions AA a E EERE E enne 57 48 JON CMERSSSLU aser neret eret ee Etpe PERENNE t PETERE 59 4 9 J Non volatile Memoty 5 3t tenter a hed eae BR 60 4 10 Setting Module Defaults sse eene 61 4 11 ION CME Command Summary sese 62 5 Options and Accessories cc cece cece cece cree cece ntn 63 Sul Stub Cable Set accede een ois aee ORR e een 63 5 2 Development Kit Cable and Plug Specifications sess 64 5 3 Optional Heat Sink 5 az seilicet epe PR e Ox veli m es 67 5 4 Optional DIN Rail Adapter sssssssssseeeeeeeeenee enne 68 6 Electrical Signal Interfacing eeeeeeeeeeeeee enn 69 6 1 Motor Feedback sanciones ee e E PE SOR 69 6 2 Auxiliary Position Input seize nene eee rige ert d ede 71 6 3 Limitand Home Inputs 2 035 nuseostanaispacoceieae p ete ERE eds 72 6 4 Position Capture Sources ee sete tie dei etre eet eni 72 6 5 AxisIn and AxisOut Signals sese 73 ION CME Digital Drive User s Manual v a Table of Contents 6 6 Enable and FaultOut Signals sse 74 6 7 General Purpose Digital Inputs and Outputs ssssssssee 76 6 3 Amalog Inputs sere tr d EE REGI De eite 77 7 TON CME Specifications
13. Indexer Pin Signal Mating connector mfg type Molex MicroFit 3 0 plug Case Shield Mating connector P N 43025 1600 2 IO Gnd Wire range AWG 20 24 3 IO 5V Recommended crimp terminal 43030 0009 4 TUM Alternate wire range AWG 26 30 5 Analogin Alternate crimp terminal 43030 0012 6 lO Gnd 7 DigitalOutl 8 DigitalOut2 9 Digitalln 10 Digitalln2 I Digitalln3 12 Digitalln4 13 DigitallO5 14 DigitallO6 15 DigitallO7 16 DigitallO8 84 ION CME Digital Drive User s Manual ION CME Specifications ba 7 5 3 Communications Connectors Connector Serial RS232 485 Pin RS232 RS485 l Unused Unused Mating Connector Generic RJ45 8 P 8 C 2 Unused Unused 3 Rx Rx 4 Unused Tx 5 Tx Tx 6 Unused Rx 7 IO_Gnd IO_Gnd 8 Select Float High Select low Connector Ethernet Pin Signal l Transmit Mating Connector Generic RJ45 8 P 8 C 2 Transmit 3 Receive 4 Unused 5 Unused 6 Receive 7 Unused 8 Unused ION CME Digital Drive User s Manual 85 ION CME Specifications Figure 7 1 ION CME dimensions 86 7 6 ION CMIE Mechanical Specification Value Dimensions See Figure 7 1 Weight without heat sink 0 6 Ib 0 28 kg with heat sink 1 1 Ib 0 5 kg Enclosure materials Aluminum base and molded plastic cover Mounting options Coldplate panel and DIN rail Recommended mounting screws 6 M3 or M3 5 Protection class IP20 d 7
14. Numerous IO 5V and IO Gnd connections are provided to simplify wiring This connector supports wire gauges from 20 to 30 AWG depending on the crimp terminal used Wiring with 22 AWG shielded cable is recommended Figure 2 9 shows typical I O wiring Limit switch Limit switch Home sensor High speed capture Enable ION CME Digital Drive User s Manual Installation 2 2 5 8 Indexer Connector Pin Signal Pin Signal l Shield 9 Digitalln 2 lO Gnd 10 Digitalln2 3 lO 5v I Digitalln3 4 Analogln 12 Digitalln4 5 Analogin 13 DigitallO5 6 lO Gnd 14 DigitallO6 7 DigitalOutl 15 DigitallO7 8 DigitalOut2 16 DigitallO8 The Indexer connector is used to access general purpose I O signals and a differential input analog signal The analog input wire pair should be run as a twisted pair for noise minimization A general purpose 5V power connection is also provided on the Indexer connector See Figure 2 10 This connector supports wire gauges from 20 to 30 depending on the crimp terminal used Wiring with 22 AWG shielded cable is recommended The shielding on the cable should connect to Pin 1 of the Indexer connector Figure 2 10 Digital I Os EE Indexer I O To From wiring User Application 5V GND ION CME Digital Drive User s Manual 25 Installation 26 2 5 9 Ethernet Connector 10 100 Ethernet Serial RS232 Port RS485 Port Pin Signal
15. and function of these and other PRP actions refer to the PMD Resource Access Protocol Programmers Reference The typical write time to the non volatile RAM is 30 uSec however it may take as long as several 100 mSec If other portions of the user application code or any other PRP connected device depends on these values having been written it is recommended that you ensure that the write operation has been completed by adding code that explicitly checks the value or by waiting a fixed period of time after the NVRAM write operation ION CME Digital Drive User s Manual ION CME Control 4 10 Setting Module Defaults The ION CME utilizes an onboard NVRAM non volatile RAM to hold a number of user settable parameters that are saved while power is off The following table shows these parameters as well as their factory default values Parameter Factory default value Ethernet Communications IP Address 192 168 2 2 Net Mask 255 255 255 0 Gateway 0 0 0 0 PRP Port 40100 Serial Communications Serial settings 57600 no parity 8 data bits stop bit RS485 duplex Full RS485 Address 0 Task Control amp User Application Code Auto start user code No Console output channel None These default values become the active parameter settings after a powerup sequence or after a software commanded ION CME reset To change the default values the PRP action Set sent to the Device resource is
16. and the Magellan Motion Processor Programmers Command Reference fot more information on Operating Modes and on setting up these current foldback parameters 3 3 3 Power Stage Scaling Parameters To correctly control various ION CME features via the Magellan Motion Processor it is helpful to know certain drive specific scale factors The following tables summarize these values ION CME Digital Drive User s Manual 41 P3N Operation 3 3 3 1 ION CME Power Stage Scaling Parameters 42 Parameter Commands Scaling Example Current GetCurrentLoopValue 1 296 mA count GetFOCValue A value of 12 345 from the command GetCurrentLoopValue for the ActualCurrent parameter corresponds to a current of 12 345 counts 1 296 mA count 15 999A Step motor amp Brushless DC Continuous RMS Current Limit DC Brush Continuous DC Current Limit SetCurrentFoldback GetCurrentFoldback 4587 mApws count SetCurrentFoldback GetCurrentFoldback 5619 mApc count To set a continuous current limit of 5 00Agms using the SetCurrentFoldback command a value of 5 000mApms 4587 mApms count 10 900 should be used To set a continuous current limit of 5 00Apc using the SetCurrentFoldback command a value of 5 000mApc 5619 mApc count 8 898 should be used Step motor amp Brushless DC Pt Energy SetCurrentFoldback GetCurrentFoldback 0923 Apms Sec count To set a foldback total energy value of 100 0 Arms Sec
17. current feedback to implement Tt current limiting This feature protects the drive by controlling its ability to operate above continuous current ratings This protection feature is active in all operating modes When the current loop is enabled and the Pt energy limit is exceeded ION CME will automatically fold back the phase currents to a user programmable continuous current limit value Alternatively ION CME can be configured to fault and disable the output stage when the It energy limit is exceeded When the current loop is disabled ION CME is operating in voltage control mode only and the Ik energy limit is exceeded ION CME will always fault and disable the output stage 3 3 2 Overtemperature Protection ION CME uses digital temperature sensors to monitor the operating temperature of the output stage power MOSFETs The motion processor communicates with the sensors over the built in SPI bus If an overtemperature condition is detected ION CME shuts down the output stage indicates the fault with the Module Status LED and optionally activates FaultOut The overtemperature threshold is user settable to any value below the maximum rated operating temperature of the output stage See Section 7 4 ION CME Protection Circuits for the programmable overtemperature range and the Magellan Motion Processor Programmers Command Reference tor more information on setting the temperature threshold Refer to the Magellan Motion Processor Users Guide
18. encoder Quadrature A Feedback 7 Quad A Quadrature A Feedback 8 Quad A Quadrature B Feedback 9 Quad B Quadrature B Feedback 10 Quad B Index Feedback E Index Index Feedback 12 Index From auxiliary encoder Quadrature A Auxiliary 5 Quad A Quadrature A Auxiliary 6 Quad A Quadrature B Auxiliary 7 Quad B Quadrature B Auxiliary 8 Quad B Index 1 0 n High Speed Capture Hall A Feedback 4 Hall A Hall B Feedback 5 Hall B Hall C Feedback 6 Hall C For brushless DC motors an Index signal from the auxiliary encoder is recommended when Hall sensors are not available For all other configurations use of the ION s High Speed Capture signal input is optional Brushless DC motors only ION CME Digital Drive User s Manual Installation 2 2 5 6 3 Pulse amp Direction Input Connections Summary With ION CME it is possible to command the position of the drive using pulse amp direction input signals Refer to Figure 2 8 This mode can be used with all motor types DC Brush Brushless DC and step motor and allows the ION to interface to any general purpose motion controller that outputs pulse amp direction position information Operation of the ION in pulse amp direction input mode is software selectable To enter this mode the encoder source for axis 2 should be set to pulse amp direction and the profile mode should be set to electronic gear See the Magellan Motion Processor User s Guide for more information
19. for the creation of user specific applications running on ION CME or host An open source compiler and motion control C libraries PDF files of all documentation C Motion and VB Motion CD including PDFs of all ION documentation Communications cables with adapters Ethernet and Serial Stub cable set a complete set of cables with matching ION CME connectors on one end and flying leads on the other For more information on these accessory products refer to Chapter 5 Options and Accessories 2 2 1 Developer s Kit Model Numbers Communications Model Number Motor Type Port DK331D0 056 15 Brushless DC Ethernet amp Serial DK311D0 056 15 DC Brush Ethernet amp Serial DK341D0 056 15 Step Motor Ethernet amp Serial 2 3 Required Hardware To install an ION CME Digital Drive the following hardware is required 12 A host controller The recommended PC platform is an Intel or compatible processor Pentium or better one available COM port 200MB of available disk space and a CD ROM drive The supported PC operating systems are Windows XP Vista and Windows 7 An Ethernet port For RS232 or RS485 communications a PCI card PCMCIA card or USB adapter supporting the desired standard connected to the PC Mounting screws to attach the ION module to your cabinet or system Properly sized DC bus power supply Step DC brush or brushless DC motor with encoder as required by the application Cables Either the stub cabl
20. graphical icons representing your ION and axis will be loaded into the Project window If communication is not successful after about 30 seconds a Communications Timeout Error dialog box appears If this happens recheck your connections and retry to establish Ethernet communications See step 1 in Section 2 10 2 Changing the Ethernet Parameters of the ION for details When Ethernet communications are functioning properly the final step is to disable serial communications 2 10 4 Disconnecting Serial Communications To disconnect serial communications 1 Select the serial link version of the ION in the Project window 2 Click the Disconnect toolbar button A dialog box appears asking if you are sure you want to disconnect 3 Click OK You will notice that the serial ION icon and axes graphical icons in the Project box disappear leaving only the Ethernet link icons for the ION and axis Congratulations Ethernet communication is now up and running You are ready to execute all Pro Motion functions via Ethernet Multiple Pro Motion users can connect to the same Ethernet ION There are various situations where this may be useful For example one PC can function as a monitoring station for a particular ION while another PC pro vides commands to that same unit Be aware however that two or more users sending motion commands to the same motion controller can cause unexpected motion and should be avoided When connecti
21. of the Select pin on the fly is not recommended Doing so will change the hardware configuration without changing the active set of communication parameters and will most likely result in loss of communications 2 7 2 Ethernet Communications The ION CME Ethernet port supports standard 10 100 Ethernet connectivity To communicate by Ethernet a setup procedure must be executed which first uses the serial port to communicate with the ION CME and configure the Ethernet port for subsequent communications To accomplish this use the DK provided serial and Ethernet cables and connect the ION CME to your PC as shown in Figure 2 12 If your computer does not have a dedicated serial port use a standard USB to serial converter The Ethernet connection will not be made until serial communications are established See Section 2 10 2 Changing the Ethernet Parameters of the ION for detailed instructions on when to physically make the Ethernet connection When Ethernet is ready to connect use PMD s Cable RJ45 02 R and plug one end of the connector into the ION CME Ethernet port and the other end into a free Ethernet port on your network 2 8 Applying Power Do not apply power to the ION module until the motor and system wiring is complete and the ION module and motor are securely mounted It is best to leave the motor disconnected from its load until after power is applied for the first time and correct operation is verified The customer mu
22. programming these signals 6 6 Enable and FaultOut Signals These dedicated signals are typically used to implement a safety interlock between the ION module and other control portions of the system Enable is an active low input that must be tied or driven low for the ION output stage to be active Similarly FaultOut indicates any serious problem by going high When ION is operating properly FaultOut is low The polarity of these signals is fixed and cannot be changed via software The input buffer for the Enable input is shown in Figure 6 9 This circuit accepts signals in the range of 0 24V and has TTL compatible Schmitt trigger thresholds It has a pull up to 5V to allow direct interfacing to open collector enable sources without the need for an external pull up resistor and a 1 3 kHz R C low pass filter to reject noise 74 ION CME Digital Drive User s Manual Electrical Signal Interfacing b 5V A 4 7K Figure 6 9 Enable input circuit Enable gt gt gt To Magellan Processor SN74HC14PW 5 6n The output driver for FaultOut is shown in Figure 6 10 This circuit can continuously sink over 100 mA and source 4mA from a pull up resistor to 5V The diode in series with the pull up resistor allows loads powered from up to 24VDC to be switched The FET driver is internally protected from shorts up to 30V 5V A y Figure 6 10 1 0K FaultOut circuit DyFaultOut When the ION is powered off FaultOut i
23. using the SetCurrentFoldback command a value of 100 0 Agns Sec 0923 Arms Sec count 1 083 should be used DC Brush Pt Energy SetCurrentFoldback 1385 Apc Sec count GetCurrentFoldback To set a foldback total energy value of 100 0 Apc Sec using the SetCurrentFoldback command a value of 100 0 Apc Sec 1385 A Sec count 722 should be used Brushless DC motors used in Hall based commutation should use the Apc scale factors All other Brushless DC motor modes should use the Apnyg scale factors 3 3 4 Power Stage Defaults and Limits To correctly control various ION CME power stage features via the Magellan Motion Processor it is helpful to know certain drive specific defaults and limits The following tables summarize these values 3 3 4 1 ION CME Power Stage Defaults and Limits Parameter Brushless DC model Default value Limit 8 073AnMs Must be 8 073AgMs Foldback Continuous RMS Current Brushless DC model 443 1 Apms sec Must be lt 443 1 Agns sec Foldback Total Energy DC Brush model Foldback 9 889Apc Must be 9 889Apc Continuous DC Current DC Brush model Foldback 664 7 Apc sec Total Energy Must be lt 664 7 Apc sec Step motor model 5 052An Ms Must be 5 052An Ms Foldback Continuous RMS Current Step motor model 443 1 Apms sec Must be lt 443 1 Agns sec Foldback maximum energy ION CME Digital Drive User s M
24. 000 cycles Show Settings gt gt M ovela soondv M Poris timeaxs oyles 7 Status paling dsable 7 For example for an ION you see the ION name next to an icon of an ION and below that you see two axes icons Highlighting single clicking either the ION icon or the axis icon with the mouse is used to select specific modules or axes and is useful later on in the first time system verification If communications are not correctly established after approximately 10 seconds a dialog box appears indicating that a Communications Timeout Error has occurred If this is the case recheck your connections and repeat from step 1 above If after repeated attempts a connection can still not be established call PMD for assistance If you are using Serial congratulations Communication has been established and you are ready to proceed to the next step described in Section 2 10 5 Initializing Motion Axes ION CME Digital Drive User s Manual 33 Installation 2 10 2 Changing the Ethernet Parameters of the ION If you are using Ethernet communications the next step is to change the Ethernet parameters as follows 1 With serial communications functioning properly click the Device toolbar button The Device window appears 2 Click Network I O The Network I O Defaults dialog box appears 3 Click the Ethernet tab The Ethernet tab appears with data entry fields for the IP Address the Net Mask and the Gatewa
25. 6 9 3 03 a 3 8 2X 15 3 8 4X 9 15 37 5 T 188 22 4 109 2 88 4 30 ION CME Digital Drive User s Manual ION CME Specifications rN 7 7 ION CME Environmental Specification Value Operating ambient temperature 0 60 C Maximum base plate temperature 70 C Storage temperature 20 to 85 C Humidity 0 95 non condensing Altitude Up to 2000 meters without derating Contamination Pollution Degree 2 7 8 ION CME Safety and Compliance Specification Standards CE LVD EN60204 EMC D EN61000 6 1 EN61000 6 3 EN5501 I Electrical safety Designed to UL508c UL840 and EN60204 1 Hazardous materials RoHS compliant Flammability UL 94 V2 or VO Enclosure IP20 7 9 ION CME Thermal Operating Curves 1 2 T T T T Ipc Figure 7 2 ION CME derating curve for DC brush module Continuous current A 0 1 1 1 j 20 30 40 50 60 70 DC brush baseplate temperature 9C ION CME Digital Drive User s Manual 87 ha ION CME Specifications 12 T T T T Sinusoidal loc 10 Hall Commutation loc T Sinusoidal RMS e 8 Figure 7 3 S ION CME 5 derating 2 6 curves for 8 brushless DC module 2 4 o w ar 0 1 1 1 fi 20 30 40 50 60 7O Brushless DC baseplate temperature 9C Note Ipc 1 414 Irms 8 T T T T Microstepping loc Y 4 z 6 2 Microstepping RMS v 5 Figure 7 4 3 ION CME 54 derating S
26. 9 01 4051 2 Motor B Motor A Wire range AWG l6 3 Motor Motor C Motor B Recommended crimp terminal 44476 3112 4 Motor B 5 Case Shield 7 5 2 Signal Connectors Connector Feedback Pin Signal Mating connector mfg type Molex MicroFit 3 0 plug l Shield Mating connector P N 43025 1200 2 lO Gnd Wire range AWG 20 24 3 lO 5v Recommended crimp terminal 43030 0009 4 Hall A Alternate wire range AWG 26 30 5 Hall B Alternate crimp terminal 43030 0012 6 Hall C 7 Quad A 8 Quad A 9 Quad Bt 10 Quad B 6 Index 12 Index ION CME Digital Drive User s Manual 83 ha ION CME Specifications Connector Auxiliary Pin Signal Mating connector mfg type Molex MicroFit 3 0 plug Shield Mating connector P N 43025 0800 2 lO Gnd Wire range AWG 20 24 3 lO 5v Recommended crimp terminal 43030 0009 4 No connect Alternate wire range AWG 26 30 5 Quad A Alternate crimp terminal 43030 0012 6 Quad A 7 Quad Bt 8 Quad B Connector I O Pin Signal Mating connector mfg type Molex MicroFit 3 0 plug Shield Mating connector P N 43025 1400 2 lO Gnd Wire range AWG 20 24 3 lO 5v Recommended crimp terminal 43030 0009 4 lO Gnd Alternate wire range AWG 26 30 5 lO 5v Alternate crimp terminal 43030 0012 6 lO Gnd 7 FaultOut 8 Limit 9 Limit 10 Home E High Speed Capture 12 Axisln 13 AxisOut 14 Enable Connector
27. B icati Contact PMD 3 ION CME Communications Saona 056 15 ION 500 CME B D Digital drive only D Ethernet amp Serial 195 m ION 3000 Heatsink K Developer s kit Motor C CANbus mounting options type N no heatsink DIN rail 1 DC brush H heatsink only 3 brushless DC R DIN rail only 4 step B heatsink amp DIN rail The ION CME family consists of versions to drive three motor types DC brush brushless DC and step with the choice of two communications modes Ethernet or Serial both RS232 and RS485 The units can be provided with or without heat sink and DIN rail mounting options One power level is provided which can drive up to 500W output 2 1 1 ION CME Part Numbers The following table shows the base part number configurations for the ION CME Communications Model Number Motor Type Port DD331D0 056 15 Brushless DC Ethernet amp Serial DD311D0 056 15 DC Brush Ethernet amp Serial DD341D0 056 15 Step Motor Ethernet amp Serial ION CME Digital Drive User s Manual 11 Installation 2 2 ION CME Developer s Kits To facilitate initial system development and integration ION CME is offered in a Developer s Kit version A model number beginning with DK instead of DD specifies the Developer s Kit version The following software and accessory products are included in the ION Developer s Kit Pro Motion CD and User s Guide C Motion Engine Software Developer s Kit including A complete toolset
28. DC bus and the output stage When the AuxV is not connected power for the DC DC converter comes from the main HV input A transformer isolated power supply should be used for powering ION CME The return of this power supply should be grounded The size of the power supply has to meet the load requirement If a regulated power supply is used care should be taken to make sure the power supply can sustain the regenerated power If a diode is used the input capacitor should be able to hold the regenerated power without triggering ION CME into overvoltage protection Figure 2 2 Typical power wiring Pin 3 of the power connector Pwr_Gnd should be connected to earth ground as shown in Figure 2 2 16 ION CME Digital Drive User s Manual Installation 2 2 5 4 Motor Connector P Pin DC Brush Brushless DC Step LW l Motor Motor A U Motor A 2 No connect Motor B V Motor A a 4 gt 3 Motor Motor C W Motor B mh 4 4 4 No connect No connect Motor B 5 Case Shield Case Shield Case Shield Pin 1 This connector is used to connect the ION module to the motor Depending on the type of motor being driven up to five connections are required It should be wired with 16 AWG wire to minimize voltage drops between the ION drive and the motor The use of shielded cable is recommended to minimize noise Figure 2 3 Figure 2 3 Typical motor wiring For best performance the case
29. DeviceSetDefault Get CMotionEngine Console PMDCMEGetConsole TaskState PMDCMEGetTaskState Device Default PMDDeviceGetDefault ResetCause PMDDeviceGetResetCause Version PMDDeviceGetVersion For additional information on how PRP packets are formatted and how they are carried over Ethernet as well as other details of PRP processing refer to the PMD Resource Access Protocol Programmer s Reference ION CME Digital Drive User s Manual 5 Options and Accessories A In This Chaptet Stub Cable Set Development Kit Cable and Plug Specifications Optional Heat Sink Optional DIN Rail Adapter 5 1 Stub Cable Set The following tables summarize the cables and other accessories that come with each ION CME Developer s Kit See the next section for detailed information on each cable type Cable PMD Part Description Cable RS232 03 R 9 pin RS232 Communications Cable Cable 1002 02 R Feedback Stub Cable Cable 1003 02 R Aux Stub Cable Cable 1004 02 R I O Stub Cable Cable 1005 02 R ION 500 DC Bus Stub Cable Cable 1006 02 R ION 500 Motor Stub Cable Cable 1010 01 R Indexer Stub Cable Cable RJ45 02 R Male RJ45 cable wired in a straight through configuration Adapter 1010 01 RJ45 to DB9 Adapter for RS232 ION CME Digital Drive User s Manual 63 5 2 Development Kit Cable and Plug Specifications amp Options and Accessories
30. ION CMIE Digital Drive User s Manual gt PMD Performance Motion Devices Inc 80 Central Street Boxborough MA 01719 Revision 1 1 April 18 2012 NOTICE This document contains proprietary and confidential information of Performance Motion Devices Inc and is pro tected by federal copyright law The contents of this document may not be disclosed to third parties translated copied or duplicated in any form in whole or in part without the express written permission of PMD The information contained in this document is subject to change without notice No part of this document may be reproduced or transmitted in any form by any means electronic or mechanical for any purpose without the express written permission of PMD Copyright 1998 2012 by Performance Motion Devices Inc Magellan ION Magellan ION Pro Motion C Motion and VB Motion are trademarks of Performance Motion Devices Inc ION CME Digital Drive User s Manual Warranty PMD warrants performance of its products to the specifications applicable at the time of sale in accordance with PMD s standard warranty Testing and other quality control techniques are utilized to the extent PMD deems necessary to support this warranty Specific testing of all parameters of each device is not necessarily performed except those mandated by government requirements Performance Motion Devices Inc PMD reserves the right to make changes to its products or to dis
31. MOSFET power stages 40 41 motor case wire 17 motor connector applying power 29 pinouts 17 83 wiring 17 Motor Feedback 69 mounting cooling methods and 13 dimensions diagram 86 DIN rail adapter 68 mechanical specifications 86 optional heat sink 67 recommended surface 13 multi drop networking 40 N networking configurations 28 multi drop 40 termination 28 29 noise minimizing electrical 13 17 25 26 R C lowpass filter 70 ION CME Digital Drive User s Manual 93 PN Index O operating temperature 41 orientation recommended 13 outputs differential encoder 20 digital 77 single ended 20 overcurrent fault 45 overtemperature protection 41 overtravel limits 24 41 overvoltage threshold 43 P packets communications 30 phase current feedback 41 pinouts 14 auxiliary encoder connector 20 84 feedback connector 18 83 I O connector 24 84 Indexer connector 25 84 motor connector 17 83 power connector 16 83 point to point communications 28 ports communication 40 Position Capture Sources 72 position error tracking 80 power applying 29 overvoltage threshold 43 power connector pinouts 16 83 wiring 16 powerup module status LED 30 profile modes 80 Pro Motion application CD 28 protection circuits 83 PWM frequency 40 ripple current 40 switching scheme 40 PWM Power Stage 40 Q quadrature A and B inputs 69 encoders 20 incremental encoders 69 94 ION CME Digital Drive User s Manual Index rN R R C lowpa
32. Manual 4 6 3 Task Control The primary purpose of the C Motion Engine is to execute user application code that has been downloaded to it using the C Motion Engine development system In a production environment this code will typically automatically start upon power up and run continuously while the system is in operation For debugging however there are a number of additional controls At any point in time it is possible to stop or restart execution of the C Motion Engine user application code To access this function the PRP action Command is sent to the CMotionEngine resource Extreme caution should be exercised when stopping or starting user application code running on the C Motion Engine as this may cause unexpected or unsafe motion It is the responsibility of the user to determine whether stopping or restarting of user application code is safe and appropriate Whether or not the user application code automatically executes upon powerup or reset can also be controlled The two options are operation under manual mode in which case the user s code will not begin execution until an explicit start command is given and auto start where the code automatically begins execution from power up or reset The PRP action Set sent to the CMotionEngine resource allows setting of the user code start mode In addition to these functions it is also possible to determine whether the user application code is presently running or not This statu
33. Motion Processor User s Manual for information on these operational modes There is no index pulse input on the auxiliary position input ION CME Digital Drive User s Manual 71 a Electrical Signal Interfacing Figure 6 5 Limit and Home input circuits 72 6 3 Limit and Home Inputs The input buffer for the end of travel limit and home signals is shown in Figure 6 5 This circuit accepts signals in the range of 0 24V and has TTL compatible Schmidt trigger thresholds It has a pull up to 5V to allow direct interfacing to open collector sources without the need for an external pull up resistor and a 1 3 kHz R C low pass filter to reject noise Limit Limit Home gt gt gt To Magellan Processor 6 4 Position Capture Sources The Magellan Motion Processor has the ability to capture the instantaneous position of the main feedback encoder when a trigger is received from a hardware input The ION module supports three trigger sources Encoder Index Home and High Speed Capture input The choice of trigger source is selectable through software The input circuits for Index and Home are described in sections 6 1 1 and 6 3 respectively 6 4 1 High Speed Capture Input This dedicated input is specifically designed for high speed signals See Figure 6 6 It is similar to the Home input with the exception that the R C low pass filter bandwidth has been increased to 1 2 MHz This value is a compromise between noise r
34. PMD Part Cable RS23203 R Pin Signal Pairing Color Description RS232 Comm cable Select None Black Length 2m 2 Tx P2 White Cable 4P 24AWG foil shield Alpha 5474C or equiv 3 Rx PI Red 4 No connect Notes Shield connected to shells at both ends 5 Gnd PI Black Grounded jumper wire included inside DB9M backshell to use for 6 Rx P3 Green Select 7 Rx P3 Black 8 Txt P4 Blue 9 Tx P4 Black PMD Part Cable 1002 02 R Pin Signal Pairing Color Description Feedback stub cable Drain Length 2m 2 IO Gnd PI Black Cable 6P 22AWG foil shield Alpha 2216C or equiv 3 lO 5V PI Red 4 Hall A P5 Brown 5 Hall B P5 Black 6 Hall C P6 Yellow 7 At P2 White 8 A P2 Black 9 B P3 Green 10 B P3 Black E Z P4 Blue 12 Z P4 Black PMD Part Cable 1003 02 R Pin Signal Pairing Color Description Auxiliary stub cable l Drain Length 2m 2 IO Gnd PI Black Cable 3P 22AWG foil shield Alpha 2213C or equiv 3 lO 5V PI Red 4 No connect 5 A P2 White 6 A P2 Black 7 B P3 Green 8 B P3 Black ION CME Digital Drive User s Manual Options and Accessories PMD Part Cable 1004 02 R Pin Signal Color Description I O stub cable Drain Length 2m 2 lO Gnd Black Cable 13C 22AWG foil shield Alpha 1299C 15 or equiv 3 lO 5V Red 4 IO Gnd Blue 5 lO 5v Red Yel 6 IO Gnd Brown 7 FaultOut Pink 8 Limit White 9 Limit Green 10 Home Orange n HSI Yellow 12 Axisln Violet 13
35. User s Manual For additional information or for technical assistance please contact PMD at 978 266 1210 You may also e mail your request to support pmdcorp com Visit our website at http www pmdcorp com PMD Performance Motion Devices 80 Central Street Boxborough MA 01719 ION CME Digital Drive User s Manual 97
36. anual Operation For the ION CME default values and limits for the Foldback Continuous Current Limit and Foldback Energy Limit are designed to be safe for operation in the drive s highest output mounting option namely horizontal to cold plate See Section 2 4 ION CME Hardware Configuration and Mounting for information on ION CME mounting options If the ION CME drive is being operated at a lower voltage it may be possible to specify values for Foldback Continuous Current Limit and Foldback Energy Limit that are higher than the default but lower than or equal to the limit since the continuous output current rating of the ION CME drive is higher for lower input voltages See Section 7 1 ION CME Drive Ratings for drive output specifications For other mounting configurations or for use with motors that have lower current and energy limits it may be useful to set these parameters to values lower than the default values It is the responsibility of the user to set the Foldback Continuous Current and Foldback Energy Limit parameters to values that are safe for the specific ION CME mounting configuration and motor setup being used 3 4 DC Bus 3 4 1 DC Bus Current Monitoring ION CME monitors both the positive and negative DC bus current to detect overcurrent conditions including line to line line to power supply and line to case ground short circuits Both hard short circuits and excessive current conditions ar
37. be reinstalled and reconnected It should now function normally 46 ION CME Digital Drive User s Manual 4 ION CMIE Control A In This Chaptet Communication Protocols ION CME Access Basics Magellan Motion Processor Functions General Purpose Digital I O Analog Input C Motion Engine Functions Communications Functions ION CME Reset Non volatile Memory Setting Module Defaults ION CME Command Summary vvvvvvvvyvv y 4 1 Communication Protocols ION CME Digital Drives can be controlled by an external host controller can be operated internally using application code downloaded into the C Motion Engine or can operate both from external and internal control The ION CME Ethernet and serial ports can be used to send standard commands to IONs attached to the network or can be programmed to implement a custom designed protocol This high level of communication flexibility makes the ION CME an ideal platform for integration into a large variety of control architectures The communication protocol that makes all of this possible is called PRP PMD Resoutce access Protocol This manual will introduce some basic aspects of this protocol but for a complete description of PRP refer to the PMD Resource Access Protocol Programmer Reference 4 1 1 ION CME Control Notes When commanding the ION CME using PMD s standard command language most ION CME users will not concern themselves with the low level details of communication command p
38. compensation step motor stall detection brushless DC motor commutation microstep generation and digital current torque control Network communications options include Ethernet CANbus RS485 and RS232 All members of the ION family have integrated high power drive stages which fully protect from overcurrent under voltage overvoltage overtemperature and short circuit faults In addition to extensive motion I O capability ION also features Auxiliary Encoder inputs and dedicated Enable input and Fault output safety interlocks ION s flexible mount ing configurations include both a vertical and a horizontal option while ION 500 offers an additional DIN rail mount option with optional heat sink In addition to various configurations of motor type and power level the ION family is split into three functional ver sions The standard IONs no additional slash specifier provide network connectivity profile generation and torque control The CME IONs provide the additional capability of an internal C Motion Engine allowing user code to reside inside the ION In addition this version provides an indexer connector for enhanced connectivity The B ION version provides 10V input and torque control of the motor along with pulse amp direction positioning control This manual describes the features and functions of the ION CME Digital Drives For additional information on the standard versions of the ION refer to the ION Digital Driv
39. continue any product or service without notice and advises customers to obtain the latest version of relevant information to verify before placing orders that information being relied on is current and complete All products are sold subject to the terms and conditions of sale supplied at the time of order acknowledgement including those pertaining to warranty patent infringement and limitation of liability Safety Notice Certain applications using semiconductor products may involve potential risks of death personal injury or severe property or environmental damage These products are not designed authorized or warranted to be suitable for use in life support devices or systems or other critical applications Inclusion of PMD products in such applications is un derstood to be fully at the customet s risk In order to minimize risks associated with the customer s applications adequate design and operating safeguards must be provided by the customer to minimize inherent procedural hazards Disclaimer PMD assumes no liability for applications assistance or customer product design PMD does not warrant or represent that any license either express or implied is granted under any patent right copyright mask work right or other in tellectual property right of PMD covering or relating to any combination machine ot process in which such products ot services might be or are used PMD s publication of information regarding any third part
40. controller performance specification 80 convection cooling method 13 current foldback See lt current foldback D data traces 44 DC brush motors connection 15 drive ratings 79 phase current feedback 40 power stage configuration 40 DC bus 43 current monitoring 43 overvoltage and undervoltage 43 DC DC converter 16 Defaults amp Limits 42 Developer s Kit 12 diagrams Enable input circuit 75 auxiliary encoder input circuits 71 AxisIn circuit 73 AxisOut circuit 74 connector locator 14 dimensions 86 encoder phasing 70 FaultOut circuit 75 90 ION CME Digital Drive User s Manual Index rN Hall Input circuit 70 High Speed Capture circuit 73 Limit amp Home circuit 72 ION CME mounted on DIN rail 68 ION CME with heat sink attached 67 main encoder input circuits 69 optional DIN rail adapter 68 optional heat sink 67 simplified serial transceiver 40 differential encoder electrical specifications 81 outputs 20 signals 69 digital inputs and outputs 76 dimensions diagram 86 DIN rail adapter 68 grounding and 13 installation 68 removing 68 disabled condition 45 drive ratings 79 Dual Encoder connection summary 22 E electrical specifications 81 Enabled condition 45 encoder auxiliary 71 electrical specifications 81 incremental quadrature 69 main 69 phasing diagram 70 Encoder Connections 20 environmental specifications 87 F FaultOut signal 24 74 faults hard 45 feedback connector 83 pinouts 18 83 wiring 19 forced air cool
41. curves for step 3 motor module 5 20 30 40 50 60 70 Step motor baseplate temperature 9C Note Ioc 1 414 IRMs 88 ION CME Digital Drive User s Manual Index rN Index Symbols Enable and FaultOut Signals 74 Enable input 30 Enable signal 75 Numerics 3 3V supply monitor44 3 phase bridge 40 4 quadrant operation 40 A A and B quadrature inputs 69 auxiliary encoder connector 84 pinouts 20 84 wiring 20 Auxiliary Voltage AuxV input 16 AxisIn and AxisOut signals 24 73 B Block Diagram 39 brushless DC motors connection 15 drive ratings 79 Hall signals 20 22 phase current feedback 40 power stage configuration 40 buffers trace 44 C cable shield See shielded cable circuits auxiliary encoder input 71 AxisIn 73 AxisOut 74 FaultOut 75 Hall input 70 High Speed Capture 73 limit and home input 72 main encoder input 69 protection 83 reset 44 C Motion 28 coldplate cooling method 13 Comm ports 26 Comm Status LED 14 communication ports 40 ION CME Digital Drive User s Manual 89 PN Index RS232 485 version 26 communications point to point 28 ports 26 status LED 30 commutation sinusoidal 70 compliance and safety specifications 87 conditions hard fault 45 operational and fault 45 configurable loop modes 80 connectors auxiliary encoder 20 84 by module type 15 Ethernet 26 feedback 18 83 I O 24 84 locator 14 motor 17 83 power 16 83 RJ45 26 RS232 485 26 serial 26
42. displaying internal variables or for other code development related purposes The default console channel is set to none and should be set to a specific Ethernet TCP port to be used during debug The easiest way to do this is with Pro Motion using the appropriate setup screens Alternatively the PRP action Set with the CMotionEngine resource and Console sub action can be used to set the console channel 4 6 7 Downloading and Verifying User Application Code The C Motion Engine development system is used to create compile and download user application code The development system can download the file image for the current code project being worked on or a specific named file can be downloaded Downloaded files images end with a bin extension Only one code image file may be downloaded into the C Motion Engine at a time Downloading a new image automatically erases the previous code image There are times when it may be useful to read specific characteristics of a code file that has been downloaded into the C Motion Engine For example a host controller in a production environment may want to confirm that the host application code version actually loaded on the C Motion Engine matches the expected production code version To accomplish this the PRP action Get is used specifying a resource ID of CMotionEngine Using this command the file name of the downloaded user application code the checksum of the downloaded file the date amp t
43. e 6 ied ae EER 9 1 1 ION Digital Drive Overview seeseeseeeeerenernnennen nennen ener nnne 9 1 2 Features and Functions eee deine Rd ee e reden 10 2 Installation serere ccc ccc cc cc tcc cee ce cre RII hh n nnn 11 2 1 ION CME Model Numbering sse enne 11 2 2 ION CME Developer s Kits essen 12 2 37 Required Hardware s eese ak Rt ST 12 2 4 ION CME Hardware Configuration and Mounting sse 13 2 5 Connector Pinouts and Wiring sess 14 2 6 Software Installation re Ce RE Eun 28 2 7 Communications Configuration sess 28 2 5 Applying POWER eR Ne OG ERR ei E 29 2 9 Status LEDs ette rrt eite it nd e pie een e E EARN VEENE ERR 30 2 10 First Time System Verification sessssesssseseeeeee eene 31 3 Operation re ar rr E rere xe 39 331 6 TON CME Block Diagram 5 5 ERREUR DERE 39 3 2 Communication Port te e Ete 40 3 3 PWM Power Stage 4e Recette te dette ete kings eti obe cete eee ertet reip 40 3 4 TYG BUS ochenta eH I eee EYE QUE TTE REIR Ee e SERE aee 43 35 7 Trace B ffer e DRE ia ve eT 44 3 6 Operational and Fault Modes sese eene 45 4 ION CME Control 0 ccc ccc ccc ccc ce ce cece hh hh nnn 47 4 1 Communication Protocols eedem ie eerte ere e E 47 4 2 ION CME Access Basics somrer atenerne Ea E enne 48 4 3 Magellan Motion Processor Functions esses 48 4 4 General Purpose
44. e PMD Remote Access Protocol Programmers Reference 4 8 ION CME Reset During power on or if initiated by a software command the ION CME undergoes a reset sequence When this occurs the Magellan Motion Processor and the C Motion Engine modules are reset and some of the ION CME module s output signals ate driven to known states To learn more about a Magellan reset see the Magellan Motion Processor User s Guide The table below indicates the signals of the ION CME that are driven to known states during a reset Signal Name State AxisOut High FaultOut Low inactive DigitalOutl 2 High DigitallO5 8 Set to inputs In addition upon a reset all module default parameters are reloaded See Section 4 10 Setting Module Defaults for more information on default values ION CME Digital Drive User s Manual 59 ION CME Control 4 8 1 Softvvare Commanded ION CME Reset A reset occurs automatically during power up however it is sometimes desirable to reset the ION CME explicitly through a user initiated software command This can be done via the PRP action Reset sent to the Device resource Note that this command can only be performed when the ION CME is not in a hard fault condition An ION CME software reset cannot be performed if the module is in a hard fault state If attempted a return error of PMD ERR MP HardFault will occur and an ION CME reset will not occur To reset the ION CME in this condition you mu
45. e User s Manual For the B versions refer to the ION B Digital Drive User s Manual For more information on the Magellan Motion Processor and its software command set refer to the Magellan Motion Pro cessor Users Guide and the Magellan Motion Processor Programmers Command Reference ION CME Digital Drive User s Manual i Introduction 1 2 Features and Functions At the heart of ION CME are the Magellan Motion Processor and the C Motion Engine CME This member of the ION family provides an extensive list of control functions including Host communications over Ethernet RS232 or RS485 Ability to download and execute user application code in the ION 256 KB of programmable user code space Code execution rate up to 96 MIPS million instructions per second Advanced C Motion Engine development tools Trajectory generation including trapezoidal and S curve point to point profiling velocity contouring and electronic gearing modes Advanced PID position loop with integration limit derivative sample time velocity and acceleration feedforward output bias dual biquad filters and support for dual encoder feedback Indexer connector providing additional digital I O and 16 bit analog input Two encoder input channels capable of up to 10 Mcounts per second Sinusoidal and six step Hall brushless DC commutation modes Microstepping outputs with up to 256 microsteps per step Digital current loop with choice of standard A B or Field Orient
46. e detected ION CME can even detect some ground fault conditions caused by a partial winding short circuit between winding and case within a motor When an overcurrent condition occurs the output stage is shut down and the ION CME module goes into the hard fault state See Section 3 6 1 Hard Fault State for a description of this state 3 4 2 DC Bus Overvoltage and Undervoltage ION CME monitors the main DC bus voltage for overvoltage and undervoltage conditions These thresholds are uset settable within the voltage operating range of the drive When the DC bus voltage drops below the undervoltage threshold ION CME shuts down the output stage indicates the fault with the Module Status LED and optionally activates FaultOut There are two ways for the DC bus to exceed the overvoltage threshold 1 The supplied DC power is too high There is little the ION CME module can do about this ION CME simply turns off the output stage indicates the fault with the Module Status LED and optionally activates FaultOut 2 The motor is decelerating at a rate too high for the DC power supply to absorb the regenerated energy and the DC bus pumps up ION CME will protect itself by turning off the output stage It also indicates the fault with the Module Status LED and optionally activates FaultOut In either case the DC bus voltage must then fall below the threshold before the module exits this fault state and can be re enabled ION CME D
47. e set that comes with ION CME Developer s Kits or custom cables designed for the system Limit switches and other I O as required for the application ION CME Digital Drive User s Manual Installation 2 2 4 ION CME Hardware Configuration and Mounting There are no user settable switches jumpers or potentiometers within the ION CME module All hardware features are configurable from the host computer via the communications port Mount the module firmly in the desired orientation with adequate space to allow it to be effectively cooled ION CME is designed to allow maximum mounting flexibility 2 4 1 ION CME Mounting Options Recommended Recommended Cooling Method Orientation Mounting Surface Mounting Method Coldplate Any Either Horizontal 4 screws Vertical 2 screws Convection Vertical Back small side 2 screws or DIN rail adapter Convection with Vertical Back small side 2 screws or DIN rail adapter Optional Heat Sink Forced Air Any Either 2 or 4 screws or DIN rail adapter Forced Air with Any Back small side Horizontal 4 screws Optional Heat Sink Vertical 2 screws To minimize electrical noise problems the metal base of the ION CME enclosure should be grounded This is usu ally accomplished automatically when the module is mounted to a metal part of a grounded system When mount ed to a DIN rail using the optional DIN rail adapter or when mounted to a non conductive or non grounded surface one
48. eader and an optional return message body The return message body may contain information associated with the requested PRP action or it may contain error information if there was a problem processing the requested action The ION CME supports five resource types The Device resource indicates functionality that is addressed to the entite catd the MotionProcessor resource indicates a Magellan Motion Processor the CMotionEngine resource indicates the C Motion Engine the Memory resource indicates a type of memory and the Peripheral resource indicates a communications connection There are ten different PRP actions including Command which is used to send commands to resources such as the Magellan Motion Processor Send and Receive which are used to communicate using the Ethernet and serial ports and Set and Get which are used to load or read parameters The PMD Resource Access Protocol Programmers Reference describes all of these constructs in more detail In the subsequent sections of this chapter a summary of the PRP actions that are required to access each ION CME function are included with the descriptions of the functions themselves 4 3 Magellan Motion Processor Functions The Magellan Motion Processor block pictured in Figure 4 1 forms the core of ION CME Here is an overview of the functions provided or managed by the Magellan Motion Processor on the ION CME Profile generation Pulse amp direction signal processing Quadratu
49. ed Control FOC for both brushless DC and step motors Single phase current loop for DC brush motors Pulse and direction input High efficiency MOSFET power stages with versions for single phase brush DC motors two phase step motors and three phase brushless DC motors Tt current foldback limiting Selectable 20 kHz and 40 kHz PWM frequencies to support a broad range of motor inductance Overcurrent short circuit overvoltage undervoltage and overtemperature protection Single supply operation An onboard DC DC converter supplies all internal circuitry and also provides 5V for encoders and other external I O Enable input and Fault output safety interlock Differential or single ended encoder input buffers for all encoder channels Signal conditioning buffers and analog filters on all I O signals ION comes packaged in a rugged enclosure with flexible mounting options and reliable signal and power connectors ION is fully RoHS compliant and CE marked 10 ION CME Digital Drive User s Manual 2 Installation In This Chaptet ION CME Model Numbering ION CME Developer s Kits Required Hardware ION CME Hardware Configuration and Mounting Connector Pinouts and Wiring Software Installation Communications Configuration Applying Power Status LEDs First Time System Verification vvvvvvvvvyv 2 1 ION CME Model Numbering DU UU1UO UUU U U Uv U U R LILET AME nm lou 1 Std ION Axes Voltage Current Version 2 ION
50. ejection and trigger latency ION CME Digital Drive User s Manual Electrical Signal Interfacing e Figure 6 6 High Speed Capture High Speed Capture gt To Magellan Processor circuit ni SN74HC14PW 6pF L VV 6 5 Axisln and AxisOut Signals The input buffer for the AxisIn signal is shown in Figure 6 7 This circuit accepts signals in the range of 0 24V and has TTL compatible Schmidt trigger thresholds It has a pull up to 5V to allow direct interfacing to open collector soutces without the need for an external pull up resistor and a 13 kHz R C low pass filter to reject noise 5V A 4 7K Figure 6 7 AxisIn circuit gt gt To Magellan Processor SN74HC14PW The output driver for the AxisOut signal is shown in Figure 6 8 This circuit can continuously sink over 100mA and source 4mA from a pull up resistor to 5V The diode in series with the pull up resistor allows loads powered from up to 24VDC to be switched The FET driver is internally protected from shorts up to 30V ION CME Digital Drive User s Manual 73 a Electrical Signal Interfacing 5V gt 1 0K Figure 6 8 AxisOut circuit AxisOut Axisln and AxisOut are versatile I O signals They are not dedicated to any particular motion control function but can be programmed to implement a wide array of system integration functions See the Magellan Motion Processor User Guide for more information on configuring and
51. er can be found in the Programmer s Command Reference Select Cancel at anytime to close the wizard and disable motor output To continue click Next Cancel 36 ION CME Digital Drive User s Manual Installation Upon a normal completion of the Axis Wizard the axis will be ready to make a controlled move Depending on the signals connected this may also mean that limit switches and other hardware connections are functioning properly The most common reasons for the Axis Wizard to not complete normally are an inability to auto tune the servo motor or problems determining the correct commutation sequence for Brushless DC motors when commutated by the Magellan Motion Processor Should this happen it is possible to perform a manual tuning or commutation setup if desired Refer to the Pro Motion Users Guide for more information or call PMD for technical assistance The Axis Wizard auto tuning routine which is used with servo motors is designed to provide stable but not optimal parameters for motion Pro Motion provides a wealth of functions including a high speed hardware trace oscilloscope that can assist you in determining optimal servo parameters Values provided by the axis wizard dur ing auto tuning may or may not be safe for your system and it is up to the user to determine if and when they should be used 2 10 6 Performing a Simple Trajectory Move The last step in first time system verification is to per
52. ettings for the Ethernet controller of the ION CME Parameter Range Default IP address 0 0 0 0 255 255 255 255 192 168 2 2 Net mask 0 0 0 0 255 255 255 255 255 255 255 0 Gateway 0 0 0 0 255 255 255 255 0 0 0 0 PRP Listen TCP Port 0 65 535 40100 Each physical hardware device on an Ethernet network is assigned one IP address however a given IP address can have multiple ports This is useful because it allows user application code running on the C Motion Engine to open up peripheral connections using port numbers other than the PRP communications port which has a default value of 40100 thereby allowing PRP messages and application specific data in any format to co exist on the same Ethernet IP node To create an Ethernet TCP or Ethernet UDP peripheral conversation the IP Address and port are specified in the PRP message body of an Open command sent to the Device resource To transfer messages via this peripheral connection the PRP actions Send and Receive sent to the Peripheral resource are used After a reset ot at power up the ION CME retrieves default information for the ION CME Stand Alone Ethernet pott To change these default values the PRP Set command is sent to the Device resource For detailed information on PRP action formats and function refer to the PMD Remote Access Protocol Programmers Reference ION CME Digital Drive User s Manual ION CME Control 4 7 2 Serial Communications ION CME pr
53. form a simple move for each axis To perform a simple move 1 In the Project Window select the motion axis that you would like to move by clicking the corresponding icon 2 Click the Axis view button on the far right of the toolbar Alternatively click Axis View on the Axis menu Your screen organization changes to give easy access to windows that are used while exercising the motion axes 3 Click the Trajectory button in the Axis Control window The Trajectory dialog box appears ION CME Digital Drive User s Manual 37 Installation Trajectory ION CME 500 Axis 1 Profile mode ETARE Trajectory parameters Deceleration 0 A counts sec Acceleration 146663 zl counts sec Velocity 1496 3 counts sec Position 1 0 counts C Single move Manual cab ea f Automatic Postion 2 1000 counts Scope syne Dwell 0 4 z seconds 4 In the Profile mode list select Trapezoidal 5 Enter motion profiles for deceleration acceleration velocity and destination position Position 1 that are safe for your system and will demonstrate proper motion 6 Click Go and confirm that the motion occurred in a stable and controlled fashion Congratulations First time system verification for this axis is now complete 38 ION CME Digital Drive User s Manual 3 Operation In This Chapter ION CME Block Diagram Communication Port PWM Power Stage DC Bus Trace Buffer Operational and Fault Modes
54. g oet eee rsen eee es eget mee e pce een RA 27 Figure 2 12 Serial port connection ooir ose EE ccc hh 28 Figure 3 1 ION CME block diagram 0 ce nett nent nen nes 39 Figure 3 2 Simplified serial transceiver diagram 0 0 c cece eese 40 Figure 4 1 ION CME block diagram 1 0 ec ee I 49 Figure 4 2 Analog inputs simplified diagrams 0 0 ccc eee eee 53 Figure 4 3 C Motion Engine architecture 2 eese 54 Figure 321 ION CME heat sink sspe bsnbperwubbTGIUMQ P ee eee ede Deena es na 67 Figure 5 2 ION CME with heat sink attached 2 0 0 0 cece cece esee 67 Figure 5 3 Attaching the optional DIN rail adapter 0 0 ee cee eens 68 Figure 5 4 ION mounted on DIN rail nenun anere 68 Figure 6 1 Main encoder input circuits 0 0 6 eee cee cnt e ent t nen nes 69 Figure 6 2 Encoder phasing diagram 2 cece ce ett e 70 Figure 6 3 Hall inp t Circuits a zo see tans Sena OL YS ON SERA Se A neas 70 Figure 6 4 Auxiliary encoder input circuits 2 0 0 eee ene nt eens 71 Figure 6 5 Limit and Home input circuits 5 72 Figure 6 6 High Speed Capture circuit 6 usanu uneer rarene 73 Figure 6 7 AXISIIOHCUIU truco but SA he DEI VOS D ER Bes et hea oW ree 73 Figure 6 8 AxisOut circuit ssion RR EUR dade sis UEM IR eG EN Pee 74 Figure 6 9 Bnableanp t circuit esere oses hax pee as Moa oy ee leche eee Dad Pag e Oey Foes 75 Figure 6 10 FaultOut circuit osis epei meninei eL o ene e cnet ene nees 75 Figu
55. g of 4 MOSFETs e Brushless DC motors are driven with a 3 phase bridge consisting of 6 MOSFETs e Step motors are driven with two H Bridges one for each phase for a total of 8 MOSFETs The use of 3 phase and H Bridge topologies provides full 4 quadrant operation from a single non isolated DC supply ION CME Digital Drive User s Manual Operation 73 ION CME uses an advanced PWM switching scheme that minimizes the ripple current on the motor windings while maximizing the current loop performance The PWM frequency is selectable between 20 kHz and 40 kHz to cover a broad range of motor inductance The fundamental frequency of the ripple current is at twice the PWM frequency and well out of the audible range in all cases Two channels of phase current feedback are used for brushless DC and step motor current loops In the brushless DC version the third phase is simply calculated as the negated sum of the other two phase currents For DC brush motors only one phase current feedback is used By monitoring the DC bus voltage the DC bus current and the output phase currents the ION CME Digital Drive s output stage is fully protected from overcurrent overvoltage and undervoltage faults and line to line line to power supply and line to earth case ground short circuits The Magellan Motion Processor also implements Vt current foldback and automatic holding current reduction for step motors 3 3 1 t Current Foldback Protection ION CME uses the
56. g of the user s application code is to use the capability of the PRP system to connect directly to the user application code on the C Motion Engine Messages sent and received by the C Motion Engine from a host controller are stored in a special buffer and can be easily read or written to by the user application code In addition PMD s Pro Motion application supports a simple way of entering sending and or receiving such messages This makes it easy to manually enter commands from Pro Motion and exercise the user application code which is programmed to parse these messages To utilize this approach a PRP Send or Receive action is sent to the CMotionEngine resource To receive these messages within the C Motion Engine a special user packet peripheral is opened For more information see the PMD Resource Access Protocol Programmers Reference In addition to these communications commands when sent to the CMotionEngine resource the PRP action NOP performs a basic connection check The message body is empty A return without a PRP error code indicates that the C Motion Engine is accessible and processing commands 4 6 5 Connecting To the C Mlotion Engine Code During Development To develop code that is downloaded to the C Motion Engine a communications link is required between the C Motion Engine and the PC based C Motion Engine Development Environment This link contains the information required for code downloads as well as other informa
57. gnal Conditioning blocks respectively ION supports incremental quadrature encoders with count rates up to 10 Mcounts per second and for the ION 3000 module Pulse amp Direction input on the auxiliary position input at up to 10 Mpulses per second 6 1 1 Main Encoder Inputs The differential input circuitry for the main encoder A B and Index signals is shown in Figure 6 1 This circuit accepts both differential and single ended signals in the range of 0 5V For single ended operation the unused input should be left floating A B Index Figure 6 1 A B Index Main encoder DS26LV32AT input circuits ION CME Digital Drive User s Manual 69 a Electrical Signal Interfacing For full functionality ION requires a three channel with Index incremental encoder for the main feedback The required index alignment is shown in Figure 6 2 ION qualifies the Index with the page 70A and B quadrature inputs and recognizes an Index event when all signals A B and Index are low Figure 6 2 44 90 i l Encoder l l phasing Quad B l diagram I I Correct Index phasing and polarity is required for the ION to operate properly The A amp B channels can be swapped and the quadrature signals inverted as required at the differential inputs to achieve the above phasing alignment Oo While the motion processor has the ability to invert the polarity of the A B and Index signals with a software j command this co
58. gnal i 10V to 10V k g g AxisIn 16 bit A D Converter itioni Input Conditioning AxisOut FaultOut ION CME Digital Drive User s Manual 39 P3 Operation Figure 3 2 Simplified serial transceiver diagram 40 3 2 Communication Port 3 2 1 Ethernet The ION CME features a standard 10 100Mbps Ethernet interface An RJ45 connector with link lights is provided for the connection 3 2 2 RS232 485 The ION CME supports both the RS232 and RS485 protocols A simplified transceiver circuit diagram is shown in Figure 3 2 Pin 8 on the RJ45 connector is used to select between RS232 and RS485 operation For RS232 pin 8 can be tied high to 3 3V or simply left floating For RS485 operation pin 8 must be tied to IO Gnd RJ45 Connector gt gt SRL_RS485_SELECT Cte vcc ct GND Z BYT1OUT Y AyT2OUT RIOUT ION CME supports point to point and multi drop networking in RS485 and point to point only in RS232 The Select line pin 8 is read only once when the ION CME comes out of powerup reset The communications cable must be connected before power is supplied to the ION CME module 3 3 PWM Power Stage The ION CME module contains a high efficiency MOSFET power stage with PWM control and phase current feedback A slightly different configuration is used for each motor type e DC brush motors are driven with an H Bridge consistin
59. icates successful packets by blinking green and invalid packets or commands returning an error status by blinking red A serious fault in the communications port is indicated with solid red If the LED is solid red check the cabling and then try cycling power and reconfiguring the communications configuration Note that this LED will not blink until communications occur Therefore the LED may not blink until further steps in the setup procedure occut 30 ION CME Digital Drive User s Manual Installation 2 2 10 First Time System Verification The first time system verification procedure summarized below has two overall goals The first is to connect the ION with the PC so that they are communicating properly and the second is to initialize the axis and bring it under stable control capable of making trajectory moves While there are many additional capabilities that Pro Motion and ION can provide these steps will create a foundation for further successful exploration and development Here is a summary of the steps used during first time system verification Each of these steps is described below in a separate manual section 1 Initiate Pro Motion and establish communication between the PC and the ION For Serial communica tions this is as simple as connecting the ION and running Pro Motion For Ethernet communications this involves a few additional steps as detailed below 2 Run Pro Motion s Axis wizard for each axis of your system to ini
60. ication code and that is executed by the C Motion Engine on the ION CME Figure 4 3 provides an overview of the architecture of the C Motion Engine To communication bus C Motion Engine communications processor 8 KB data j i RAM space clock 8 KB code lt lt _ _ stack space C Motion Code Execution Unit 256 KB user Task control ibis defaults prog space The following table provides an operational overview of the memory segments provided by the C Motion Engine Segment Specification User program space stored in flash 256 KB User data RAM space 8 KB User code stack space 8 KB ION CME Digital Drive User s Manual ION CME Control 4 6 2 Powerup amp Operation Upon reset or power up the C Motion Engine initializes itself and checks to see whether execution of user application code if downloaded should automatically begin If the factory default settings have not been changed the C Motion Engine will hold in a wait state and code execution will not occur While there are numerous safety checks and features built into the C Motion Engine system application code developed for the C Motion Engine is C based and thus there are limits to code size RAM usage and stack usage that should be observed during run time operation of downloaded C Motion code The table in the previous section provides these numerical limits For user dow
61. igital Drive User s Manual 43 P3N Operation 44 3 4 3 IO 5V Monitor ION CME features a separate 5V supply for powering external encoders Hall sensors and other I O devices This supply is monitored to detect overloading or out of tolerance operation and if either condition occurs ION CME goes into the hard fault state See Section 3 6 1 Hard Fault State for a description of this state 3 4 4 Motion Processor 3 3V Supply Monitor and Reset Circuit The 3 3V supply for the motion processor automatically forces the processor into the reset state if the supply voltage falls out of regulation 3 4 5 DC Bus Scaling Parameters To correctly control ION CME DC Bus features via the Magellan Motion Processor it is helpful to know the DC Bus scale factor The following table summarizes this value 3 4 5 1 ION CMIE DC Bus Scaling Parameters Parameter Commands Scaling Example Bus Voltage GetBusVoltage 1 361 mV count A value of 12 345 from the command SetBusVoltageLimits GetBusVoltage corresponds to a GetBusVoltageLimits voltage of 12 345 counts 1 361 mV counts 16 801V 3 4 6 Undervoltage and Overvoltage Limits 3 4 6 1 ION CME DC Bus Defaults and Limits Parameter Default value Limit Undervoltage Limit 9 935V Must be gt 9 935V and lt 56 00V Overvoltage Limit 60 02V Must be 60 02V and 20 00V 3 5 Trace Buffer Trace capture is a powerful feature of the Magellan Motion Processor that allows various pa
62. ils Stage FaultOut Module Status LED Enabled Enable low Normal operation On Low inactive Green solid in programmed operating mode Disabled Enable high Off Programmable Green blinking slow Overvoltage DC bus voltage exceeded Off Programmable Red blinking fast programmable threshold Undervoltage DC bus voltage below programmable threshold lt Current Foldback Output stage disabled by Pt Off Programmable Red blinking slow foldback protection Overtemperature Power stage temperature exceeded programmable threshold Hard Electrical Output Fault Details Stage FaultOut Module Status LED Overcurrent Short circuit or overload Off High active Red solid Ground Fault Excessive current to ground IO 5V Fault Overloaded out of tolerance Internal Logic Fault Internal hardware failure 3 6 1 Hard Fault State All hard electrical faults put the ION CMB into the hard fault state In this state communications and CME user code execution are allowed along with a few Magellan commands but otherwise the unit is dormant The table below summatizes what operations are allowed when the ION CME is in hard fault state Operation Status ION CME reset command Not allowed Magellan GetVersion command Allowed Magellan GetDriveFault command Allowed All other Magellan commands Not allowed All other PRP commands Allowed CME user code execution Unaffected except restrictions on Magellan commands as noted above
63. ime of file creation and the version number of the C Motion Engine itself loaded by PMD during production can be retrieved For complete information on the format and function of these and other PRP actions refer to the PMD Remote Access Protocol Programmers Reference 4 7 Communications Functions The ION CME provides two different network connection types Ethernet and Serial Access to these communication resources is provided via a peripheral connection A peripheral is a resource and is utilized by various PRP actions to send and receive messages to network connections Basic access to either the Ethernet or Serial port is accomplished by opening a peripheral with the detailed connection parameters that will be used during communications associated with that peripheral connection and then sending and receiving messages via that peripheral resource address For example to create an Ethernet TCP peripheral connection the IP Address and port number is provided If the connection is successfully established that peripheral is used as the reference for any future communications through that connection In the subsequent sections the operational characteristics of the Serial and Ethernet network ports will be detailed ION CME Digital Drive User s Manual 57 58 ION CME Control 4 7 1 Ethernet Communications The ION CMEs support two different Ethernet protocols TCP Transmission Control Protocol and UDP User Datagram Protoc
64. ing method 13 frequency PWM 40 ripple current 40 G ground fault 43 45 ION CME Digital Drive User s Manual 91 PN Index H Hall signals 20 22 70 hard electrical faults 45 hard fault state 45 H Bridge 40 heat sink mounting optional 67 High Speed Capture 24 72 Home inputs 72 I I O connector pinouts 24 84 wiring 24 Tt current foldback 41 energy limit 41 incremental quadrature encoders 69 index alignment 69 event 69 phasing 70 inputs Enable 30 A and B quadrature 69 auxiliary encoder 71 digital 76 Hall 70 High Speed Capture 24 73 limit and home 72 main encoder 69 quadrature 69 installation applying power 29 communications configuration 28 configuration and mounting 13 connector pinouts 14 DIN rail adapter 68 hardware requirements 12 model numbers 11 software 28 status LEDs 30 wiring 14 Internal Logic Fault 45 IO 5V 24 auxiliary encoder connector 20 fault 45 feedback connector 18 Indexer connector 25 I O connector 24 monitor 44 92 ION CME Digital Drive User s Manual Index rN power connector 16 L LEDs communications Comm status 14 hard electrical faults 45 Module Status 30 operational and fault modes 45 limit input 72 loop rates 80 M main encoder input circuits 69 main encoder signals 69 mechanical specifications 86 microstepping drive connection 15 model numbers 11 modes configurable loop 80 fault 45 operational 45 Module Status LED 30 monitor 3 3V supply 44 IO 5V 44
65. ith the A low and B low states and be low for less than 540 total Digital inputs Signals Hall A Hall B Hall C Home Limit Voltage range Logic threshold Limit AxisIn High speed Capture Enable 0 24VDC TTL compatible Digital outputs Signal Voltage range Output current AxisOut FaultOut 0 24VDC 4 mA source 100mA sink short circuit protected to 30V General purpose digital Available Inputs 4 inputs Signals Digitalln 4 Digital Input Type Single Ended with internal 4 7Kohms pull up to 5V Low Pass Filter Frequency 6 KHz Logic type TTL Input voltage range 0 24VDC Overvoltage Protection lt 30V General purpose digital Available Outputs 2 outputs Signals DigitalOutl 2 Digital Output Type Open collector with internal k pull up to 5V Maximum Sink Current 100mA Overvoltage Protection lt 30V ION CME Digital Drive User s Manual 81 ha ION CME Specifications General purpose bidirectional digital Input output Available I Os Signals Digital Input Type Digital Output Type Low Pass Filter Frequency Maximum Sink Current Overvoltage Protection 4 DigitallO5 8 Single Ended TTL with internal 4 7Kohms pull up to 5V Open collector with internal 4 7k pull up to 5V 6 KHz 100mA lt 30V Analog input characteristics RS232 485 communications Available Input Signals Input Signal Voltage Range Resolution Maximum Recommended Input Sig nal Fre
66. llO6 Red White 15 DigitallO7 Green White l6 DigitallO8 Blue White PMD Part Cable RJ45 02 R Pin Signal Color Description Male RJ45 to male RJ45 cable wired in Ethernet Tx a straight through configuration 2 Ethernet Tx 3 Ethernet Rx Length 2m 4 No Connect 5 No Connect Cable 4P 24AWG UTP Cat 5E 6 Ethernet Rx 7 No Connect 8 No Connect PMD Part Adapter 1010 01 RJ45 Pin DB9 Pin Color Description ION DB to RJ45 serial adapter to enable RS232 l No Connect communication Adapter used for connecting to RJ45 style 2 No Connect serial interface connector on applicable ION model 3 3 Black 4 No Connect 5 2 Green 6 No Connect 7 5 Brown 8 No Connect ION CME Digital Drive User s Manual Options and Accessories 5 3 Optional Heat Sink The optional heat sink can be used to increase the continuous output current and power in applications where the ION module is not cold plate mounted or is operating in high ambient environments It is especially effective when forced ait cooling is available See Section 7 9 ION CME Thermal Operating Curves for the ION specifications with and without the heat sink attached To enhance thermal conductivity the heat sink has a thermal pad permanently attached to its mounting surface The heat sink attaches to the ION enclosure base using the four mounting holes and four M3x10 cross head screws sup plied See Figure 5 1and Figure 5 2 Figure 5 1 ION CME heat sink
67. mmand cannot be used to alter the index alignment because the inversion takes effect after index qualification 6 1 2 Hall Inputs The input buffer for the Hall A B and C signals is shown in Figure 6 3 This circuit accepts signals in the range of 0 24V and has TTL compatible Schmidt trigger thresholds It has a pull up to 5V to allow direct interfacing to open collector sources without the need for an external pull up resistor and an R C low pass filter to reject noise Figure 6 3 Hall input circuits HallA HallB HallC gt gt gt To Magellan Processor 70 ION CME Digital Drive User s Manual Electrical Signal Interfacing The Hall signals are only used with brushless DC motors They are used to directly commutate the motor in 6 step commutation mode or to provide an absolute phase reference for sinusoidal commutation 6 2 Auxiliary Position Input The differential input circuitry for the auxiliary position input signals is shown in ligure 6 4 This circuit accepts both differential and single ended signals in the range of 0 5V For single ended operation the unused input should be left floating Figure 6 4 Auxiliary encoder input A B circuits A B DS26LV32AT Auxiliary encoder input is optional and can be used for general purpose position feedback as the master in electronic gearing applications or as part of a dual loop filter compensation scheme See the Magellan
68. ng your ION for use on an Ethernet network be sure that the IP address provided for the ION does not conflict with the addresses of other users on the network See Section 2 10 2 Changing the Ethernet Parameters of the ION for a description of changing the IP address ION CME Digital Drive User s Manual 35 Installation 2 10 5 Initializing Motion Axes The next step to verify the correct operation of the system is to initialize the axis thereby verifying correct encoder feedback connections if an encoder is used and other motion functions All of this can be conveniently accomplished using Pro Motion s Axis Wizard function This versatile and easy to use tool initializes all supported motor types including step DC Brush and Brushless DC To operate the axis wizard 1 Click to select the 1 axis icon in the Project window to the left of the screen 2 With this icon highlighted click the Axis Wizard toolbar button The Axis Wizard initialization window appears 3 Click Next and follow the Axis Wizard instructions for each page of the axis initialization process A typical Axis Wizard sequence takes 3 5 minutes If you have specific questions about the Axis Wizard refer to Pro Motion Users Guide for detailed information on the Axis Wizard Axis 1 Wizard Welcome to the Axis Wizard This wizard will guide you through the motor connections and parameters for an axis amp description of each processor paramet
69. nloaded code that does not correctly observe these limits or for files that have become corrupted there are a number of fault conditions that can occur while the C Motion Engine is executing downloaded user application code These very serious run time faults include instruction errors indicating that an unknown instruction was encountered during execution of the user s code and address faults indicating that either a program space or RAM space access limit was violated If either of these conditions occurs the C Motion Engine will immediately halt user code execution and reset the ION CME This C Motion Engine initiated reset is identical to the reset that occurs after sending a PRP Reset action except that the cause of the reset is recorded as C Motion Engine user code Fault rather than commanded reset See Section 2 8 Applying Power for more information on the Reset command and on retrieving the reset cause Whether or not user application code is running after reset or power up the C Motion Engine begins processing PRP actions sent to it These commands ate typically sent from a host controller The supported commands include functions such as checking the downloaded user application code version stored in the C Motion Engine and sending and receiving messages to the user code loaded onto the C Motion Engine For additional guidelines on managing run time usage of the C Motion Engine see the C Motion Engine Development Tools
70. of the free mounting holes can be used to attach a grounding wire Note that to make proper elec trical contact to the ION s mounting holes it may be necessary to scrape off the ION s powder coating in this area It is the responsibility of the user to ensure proper electrical conduction to the metal base of the ION CME enclosure Refer to Section 7 6 ION CME Mechanical for information on mounting dimensions and mounting hole sizes for the ION CME Refer to Figure 2 1 for cable connection locations ION CME Digital Drive User s Manual 13 Installation 2 5 Connector Pinouts and Wiring 2 5 1 ION CME Connector Locator Indexer 3 Feedback Auxiliary Power Module Status LED Figure 2 1 Connector locator Comm 10 10 Ethernet Comm Serial RS232 RJ45 Comm Status LED Connector 14 ION CME Digital Drive User s Manual Installation 2 2 5 2 Motor Module Type Quick Reference The following table summarizes the recommended connections for the various motor types and the corresponding ION CME modules Module Type Connector Required Signals Optional Signals All Power HV Pwr_Gnd AuxV DC brush Motor Motor Motor Case Shield Feedback Main encoder Quad A Quad A Quad IO 5V B Quad B Index Index IO Gnd Shield Brushless DC Motor Motor A Motor B Motor C Case Shield Feedback Main encoder Quad A Quad A Quad Commutation Hall A Hall B B Quad B Inde
71. ol TCP is typically used for primary Ethernet communications to the ION CME while UDP is typically used for non critical applications such as data logging or for the Pro Motion console window See Section 4 6 6 Debug Console Window for more information on the C Motion Engine console window When used to receive PRP messages the physical node on the Ethernet network controller is assigned a 32 bit IP Internet Protocol address along with a 32 bit net mask and a 32 bit gateway value The Netmask is used to indicate which IP addresses are local and the gateway value is used to route non local addresses To correctly receive communications from the host controller a 16 bit identifier known as a port must also be specified Note that when used as the connection between the host controller and the ION CME TCP rather than UDP communications are used To determine what the unused IP addresses are for your Ethernet network and what values for net mask and gateway to use contact your network administrator The PRP messaging system utilizes a default TCP port address of 40100 so this address should not be used for user created application communications By convention the 32 bit values for IP Address Net mask and Gateway are shown in Dotted Quad Notation In this notation each of the four numbers are separated by dots and denote a decimal value for each byte of the four byte word The table below shows the range and default s
72. on Command is used The Magellan command packet is loaded into the PRP message body and the return PRP message body contains the return packet provided by the Magellan A return without error indicates that the command was processed successfully If an error occutred while the Magellan was processing the command the message body is loaded with the specific error that occurred For more information see the PMD Resource Access Protocol Programmers Reference In addition to accessing the on ION CME Magellan it is also possible to access Magellan Motion Processors that are connected via the ION CME S attached Ethernet networks An additional PRP action Open sent to either the Device or the Peripheral resource is used to establish a connection to such a motion processor See the PMD Resource Access Protocol Programmers Reference for more information on connecting to motion processors on attached networks 4 3 1 1 Magellan Reset Although a reset occurs automatically during power up it is sometimes desirable to reset the Magellan Motion Processor explicitly through a user initiated action The PRP action Reset when sent to the MotionProcessor resource causes a reset of the Magellan Motion Processor This reset affects the Magellan Motion Processor and a number of Magellan controlled signals Note however that this type of reset is different than a full ION CME reset initiated via the PRP action Reset described in Section 2 8 Applying P
73. ovides asynchronous serial communications in either RS232 or RS485 mode Access to the serial port controller is managed using peripheral connections In RS485 mode the serial port may be operated in either half duplex or full duplex mode Pin 8 of the Serial Connector selects whether RS232 or RS485 communications mode is used If left open the default condition the ION CME operates the serial port in RS232 mode If closed tied to ground the serial port is operated in RS485 mode Note that a change in the status of this pin takes effect only after a power on or a reset of the ION CME The serial port can be operated at various communication settings as shown in the following table Parameter Range Serial Baud rate 1 200 to 460 800 57 600 Parity none even odd none Data bits 5 6 7 8 8 stop bits 1 2 l To create a serial port peripheral connection the above parameters are specified in the PRP action Open with the resource set to Device Messages to and from the Serial port are transmitted via the Send and Receive actions sent to the Peripheral resource Whenever a new serial port peripheral is opened its previous function is canceled By default Serial is the console port After a reset or at power up the ION CME retrieves default information for the serial port To change these default values the PRP action Set is sent with a resource of Device For detailed information on PRP action formats and function refer to th
74. ower After a Magellan reset occurs some of the ION CMES output signals will be driven to known states These are summarized in the following table Signal Name State AxisOut l FaultOut 0 4 4 General Purpose Digital I O In addition to special purpose digital signals such as AxisIn AxisOut Home and QuadA which are input to or output from the ION CME and which are directly processed by the Magellan Motion Processor the ION CME also supports several general purpose input and output signals through its Indexer connector There are two outputs four inputs four bi directional I Os and one 16 bit 10V analog input These signals provide a convenient way of accessing additional application specific general purpose digital I O The I Os are accessed via the CME peripheral functions Open Peripheral Parallel Peripheral Read and Peripheral Write The general purpose digital inputs are TTL compatible with a typical input range of 0 5 5V The inputs are overvoltage protected to 30V The general purpose digital outputs are 5V TTL compatible with an output sink current of 00mA There is an internal pull up to 5V on Digital Outputs amp 2 The bidirectional I O lines have an internal pull up to 5V 50 ION CME Digital Drive User s Manual ION CME Control 4 4 1 Digital Inputs The eight digital inputs are read via the Peripheral Read function and are contained in the lower 8 bits of the returned 16 bit word
75. quency Throughput Integral Non Linearity Error Typical Integral Non Linearity Error Maxi mum Overvoltage Protection Common Mode Range Typical Differential Impedance Common Mode Rejection Ratio Min imum Baud Rates Isolation Termination Analogin Analogln 10 to 10V 16 Bits 2 KHz 40 kSPS LSB 3 LSB 35 to 40V 10 to 25V 108 Kohms 80 dB 1200 2400 9600 19 2k 57 6k 115k 230k 460k Default baud rate is 57 6k 460k support for RS485 only None None Ethernet communications Compatibility IOOBASE TX IOBASE T 82 ION CME Digital Drive User s Manual ION CME Specifications ba 7 4 ION CMIE Protection Circuits Overtemperature User programmable between 0 70 C Overvoltage User programmable between 20 60V Undervoltage User programmable between 10 56V Overcurrent Fixed at lt 200 of drive peak rating Short circuit protection Line to line line to power supply and line to case ground 7 5 ION CMIE Connectors and Pinouts 7 5 1 High Power Connectors Connector Power Pin Signal Mating connector mfg type Molex MiniFit Jr plug l HV Mating connector P N 39 01 4031 2 AuxV Wire range AWG l6 3 Pwr_Gnd Recommended crimp terminal 44476 3112 Connector Motor Pin Signal Mating connector mfg type Molex MiniFit Jr plug Motor Motor A Motor A l Mating connector P N 3
76. r axis SetPosition Axisl 12345 load a destination position for axis SetVelocity Axis 223344 load a velocity for axis SetAcceleration Axis 1000 load an acceleration for axis SetDeceleration Axis 2000 load a deceleration for axis SetUpdateMask Axis Profile II specify that an update of profile parameters only Il is to occur Update Axis Double buffered registers are copied into the active registers thereby initiating the move Magellan instructions are encoded in packets which are sent to and from the Magellan Motion Processor The Magellan processes these packets performs requested functions and returns requested data Within the ION CME the Magellan connects to the ION CME s communications bus which allows the Magellan to be controlled via the C Motion Engine or via an external host controller connected to the ION CME by Ethernet or serial port Two manuals describe how the Magellan Motion Processor operates and how it is programmed the Magellan Motion Processor Users Guide and the Magellan Motion Processor Programmers Command Reference These documents also describe VB Motion and C Motion which are the software libraries that are used to send commands to the Magellan chip and exercise its many functions ION CME Digital Drive User s Manual 49 ION CME Control 4 3 1 Accessing the Magellan Motion Processor To send and receive command packets to the Magellan Motion Processor the PRP acti
77. rameters and registers to be continuously captured and stored to an internal memory buffer The captured data may later be downloaded by the host using software commands Data traces are useful for optimizing DC brush and brushless DC performance verifying trajectory behavior capturing sensor data or to assist with any type of monitoring where a precise time based record of the system s behavior is required The ION CME module features 1 5 kB RAM for trace This will hold up to 384 trace samples Refer to the Magellan Motion Processor User Guide and the Magellan Motion Processor Programmers Command Reference for complete information on trace configuration and operation ION CME Digital Drive User s Manual Operation E 3 6 Operational and Fault Modes The ION CME is commanded by the host controller to perform various motion control functions During the course of these operations it is possible for the ION CME to enter various fault states based on operational conditions within the power stage the motor the electrical bus or based on the state of the Enable input signal Hard electrical faults are serious module or system malfunctions that must be rectified before proceeding The following tables summarize the operational and fault modes of the ION CME Digital Drive More information about these modes can be found in the Magellan Motion Processor Users Guide Output Condition Deta
78. re 6 11 Digital inputs circuite cues coc steele Re MO yt EOS GR ROG AZ ATH S 76 Figure 6 12 Digital outputs circuit 1 cee eee e nee e n nes 77 Figure 6 13 Digital O circuit ncn enews Soke hel Pena eats ow detbae leet vend 77 Figure 6 14 Analog inputs simplified diagram 0 2 0 0 cece cee eee 78 Figure 7 1 ION CME dimensions 0 cece eee cence ne nee a m 86 Figure 7 2 ION CME derating curve for DC brush module 0 cece eee eee 87 Figure 7 3 ION CME derating curves for brushless DC module 000 0 e eee eee 88 Figure 7 4 ION CME derating curves for step motor module 00 eee eee eee 88 ION CME Digital Drive User s Manual vii PN List of Figures This page intentionally left blank viii ION CME Digital Drive User s Manual 1 Introduction In This Chapter ION Digital Drive Overview Features and Functions 1 1 ION Digital Drive Overview The ION Digital Drives are a family of single axis motion controllers with integrated power electronics and network commu nications Various models are available to drive DC brush brushless DC and step motors In addition two overall power levels are available The ION 500 providing up to 500 watts of power output and the ION 3000 providing up to 3 000 watts of pow er output ION digital drives are based on PMD s Magellan Motion Processor technology and perform profile generation encoder position feedback position servo
79. re encoder processing and index capture DC brush and brushless DC servo loop closure Breakpoint processing AxisIn and AxisOut signal processing Trace Motion error detection tracking windows and at settled indicator Limit switches 48 ION CME Digital Drive User s Manual ION CME Control DC Bus Monitorin dnd ume EU Isolation Non Volatile RAM II FI PWM Signals C Motion Engine 256 KB User Code Current feedback IDEA Main Encoder Figure 4 1 Magellan ION Motion Quadrature Signal Quad A B Index ION CME block NUN Auxiliary Quad l Processor Conditioning Encoder A B diagram Serial RS232 C T A ommunication Serial RS485 Transceivers Ethernet Hall Sensors Digital Signal pus omie egies fis ifioni igh Spee 4 Bidirectional I Os Digital 1 0 Conditioning Capture 4 Inputs Conditioning 2 Outputs Drive Enable Status LEDs Digital Signal i 10V to 10V r g g Axisin 16 bit A D Converter itioni Input Conditioning AxisOut FaultOut The Magellan Motion Processor interfaces with motion hardware components such as feedback encoders signal generation hardware and others through various signal conditioning circuitry The Magellan instruction set is very flexible and powerful The following example which would be used to set up and execute a simple trapezoidal profile illustrates just a small part of the overall command set SetProfileMode Axis trapezoidal II set profile mode to trapezoidal fo
80. rotocols because they will use the library of C lan guage routines provided by PMD This library of C language functions insulates the user from protocol and platform details by providing virtualized C language interfaces to all supported commands So for example code that is written to control a Magellan located ona setial connected ION CME will work just as well when used with an Ethernet connected ION CME or microprocessor connected Magellan IC on a user designed motion control card ION CME Digital Drive User s Manual 47 ION CME Control 4 2 ION CMIE Access Basics Access to the ION CME from the Ethernet or serial port is provided by a protocol called the PMD Resource access Protocol PRP This easy to use yet powerful system utilizes actions resources and addresses to access the ION CMES functions Various ION CME functions are organized into resources and resources process actions sent to them Actions can send information request information or command specific events to occur Addresses allow access to a specific resource on the unit or connected to it via the Ethernet or serial connections A basic communication to the ION CME consists of a 16 bit PRP header and an optional message body The message body contains data associated with the specified PRP action but some actions do not require a message body After a PRP communication is sent to the ION CME a return communication is sent by the ION CME which consists of a PRP h
81. s Configuration Depending on the communications port you plan to use with your ION there may be some configuration steps required to communicate correctly between the host computer and the ION module 2 7 1 Serial Communications To communicate by RS232 connect ION CME to the PC using the straight through serial cable provided with the Developer s Kit For more information refer to Figure 2 12 If the PC does not have a serial port use a USB to serial converter and note the COM port number that the converter installed as using the Device Manager in Windows Select this COM port in Pro Motion s Connect dialog The following RS232 485 values are pre programmed into non volatile memory at the factory You can change the operational values using Pro Motion after communications at this default rate has been established Note that the new parameters will take effect at the next ION powerup RS232 485 default values 57 6 kbaud no parity 1 stop bit and multi drop networking mode disabled Figure 2 12 Serial port connection DB9 to RJ45 Adapter Host Computer ae ION CME Serial Port 1 T Serial Port 28 ION CME Digital Drive User s Manual Installation First time communication with an ION cannot be accomplished using RS485 half duplex To configure an ION for RS485 half duplex multi drop use either RS232 or RS485 point to point Changing the state
82. s effectively high impedance and unable to sink current This state should 1 be interpreted as Fault by the receiving circuit ION CME Digital Drive User s Manual 75 a Electrical Signal Interfacing 6 7 General Purpose Digital Inputs and Outputs There are four bidirectional general purpose I Os GPIO four Inputs and two Outputs available to the ION CME user Use of these General Purpose Signals is optional The signals provide a TTL interface to the application environment of the ION CME Digital Inputs are of single ended type with an internal pull up resistor of 4 7 Kohms to 5V Refer to Figure 6 11 They feature a low pass RC filter with a corner frequency of 6 KHz and a Schmitt trigger for noise protection Digital Outputs are open collector with an internal 1 Kohm pull up resistor to 5V The maximum allowed sink current is 100mA Refer to Figure 6 12 Digital I Os have a single ended type input with an internal pull up resistor of 4 7 Kohms to 5V Output is open collector with a 4 7 Kohm to 5V Maximum sink current in output mode is 10 mA Refer to Figure 6 13 5V MM 47K Figure 6 11 Digital inputs circuit Digitaln1 4 X gt To ION CME Internal Bus 2 7n 76 ION CME Digital Drive User s Manual Electrical Signal Interfacing e 5V A 1 0K x Figure 6 12 Digital outputs circuit DigitalOut1 2 5V A 4 7K Figure 6 13 To ION CME Internal Bus lt l
83. s information may be useful during code debugging or to help diagnose problems This capability is accessed via a Get action sent to the CMotionEngine resource ION CME Digital Drive User s Manual 55 ION CME Control For a detailed description of the supported ION CME commands see the PMD Remote Access Protocol Programmer s Reference 4 6 4 Sending Messages To From User Application Code A common function of user application code running on the C Motion Engine is to parse command messages sent to it by a host controller For example a user might write code for the C Motion Engine that responds to an Extend Robot Arm command sent by the host controller and then send a series of commands to the Magellan Motion Processor to execute this motion sequence At the end of the motion sequence the user application code might send an Arm Extended message confirming the movement sequence has completed One method of achieving this is to use the ION CMES peripheral mechanism to open and operate a low level communications link via the Ethernet or serial link This method has the advantage of giving relatively direct control over the communication traffic The disadvantage is that the user has to implement specific send and receive communications in the host controller and the C Motion Engine needs to have similar code implemented that can process these messages Another method that may be more convenient particularly during early debuggin
84. servo filter operation See the Magellan Motion Processor User s Guide for more information on these control modes Figure 2 6 and the table that follows it summarize the connections for a single encoder 20 ION CME Digital Drive User s Manual Installation Quad A B Single Encoder Figure 2 6 Single encoder mode connections Main Encoder Mode Connection from Encoder ION Connector Pin ION Pin Quadrature A Feedback 7 Quad A Quadrature A Feedback 8 Quad A Quadrature B Feedback 9 Quad B Quadrature B Feedback 10 Quad B Index Feedback N Index Index Feedback 12 Index Hall A Feedback 4 Hall A Hall B Feedback 5 Hall B Hall C Feedback 6 Hall C Brushless DC motors only ION CME Digital Drive User s Manual 21 Installation Figure 2 7 Dual encoder mode connections 22 2 5 6 2 Dual Encoder Connections Summary In a two encoder connection one encoder measures the load position and is the primary encoder The second auxiliary encoder is located on the motor shaft measures the motor position and is used for stabilization Figure 2 7 and the table that follows show how to connect two encoders to the ION Feedback Auxiliary Auxiliary Encoder Primary Encoder Quad A B Quad A B Dual Encoder Mode Connection from Encoder ION Connector Pin ION Pin From primary
85. ss filter bandwidth Enable and FaultOut signals 74 Hall inputs 70 high speed capture input 72 limit and home inputs 72 reset condition 44 RJ45 connector 26 RS232 485 connector communication ports 26 electrical specifications 81 wiring 27 S safety and compliance specifications 87 safety interlocks 74 servo motors 40 shielded cable 15 auxiliary encoder connector 20 feedback connector 18 I O connector 24 Indexer connector 25 motor connector 17 signal connectors 83 Single Encoder connection summary 20 single ended auxiliary encoder signals 71 encoder inputs 69 sinusoidal commutation 70 software installation 28 specifications controller performance 80 drive ratings 79 electrical 81 environmental 87 mechanical 86 safety and compliance 87 status LEDs 30 step motors automatic holding current reduction 41 drive ratings 79 phase current feedback 41 power stage configuration 40 stub cable 63 T temperature sensors 41 Thermal Operating Curves 87 Trace Buffer 44 ION CME Digital Drive User s Manual 95 PN Index trace capture 44 trigger latency 72 trigger sources 72 U undervoltage condition and threshold 43 W wiring applying power 29 auxiliary encoder connector 20 feedback connector 18 I O connector 24 Indexer I O 25 motor connector 17 power connector 16 recommended auxiliary encoder 20 recommended feedback 19 RS232 485 wiring 27 typical I O 24 typical motor 17 typical power 16 96 ION CME Digital Drive
86. st not attempt to service or rewire an ION drive without first shutting down the drive and disconnecting it from its power source Failure to follow this warn ing may result in fire bodily harm or damage to the product Upon first time power up ION is in a reset condition In this condition no motor output will be applied and the motor will remain stationary If the motor does move or jump remove power from the module and re check the wiring If anomalous behavior is still observed call PMD for application assistance Complete PMD contact information is listed on the final page of this manual ION CME Digital Drive User s Manual 29 Installation 2 9 Status LEDs ION has two bi color LEDs to indicate the basic operational status of the module and the communications link The location of these LEDs is shown in Figure 2 1 2 9 1 Module Status LED Upon powerup or reset the module Status LED should either be solid green or blinking green depending on the state of the Enable input If enabled the LED will be solid green b The Enable input is active low A Status LED of any other color indicates a fault or unusual condition that must be rectified before going further See Section 2 10 2 Changing the Ethernet Parameters of the ION for complete information on ION Operational and Fault modes and the resulting color and blink rate of the Status LED 2 9 2 Communications Status LED The Comm Status LED ind
87. st power cycle the ION unit 4 9 Non volatile Memory The ION CME module has a general purpose 4 094 byte memory that retains its contents after a module power down ot teset This memory is useful for storing parameters that are set only occasionally and stay with the module such as machine calibration information NVRAM addresses are specified from 0 to 4 093 When writing to this memory a typical write takes 130 Secs however under certain circumstances it can take much longer up to several 100 mSec Read speed takes just a few nanoseconds Byte size memory operations are not supported by the non volatile memory The smallest memory unit that can be accessed is 16 bits The non volatile memory can be rewritten a limited number of times The worst case write limit cycle is 100 000 times for a given memory address but in typical operation the limit is much higher As a general guideline to avoid erase write cycle limit problems the non volatile RAM should not be used for general purpose scratch RAM and should only be used to store permanent or semi permanent parameters To read or write to the NVRAM a resource address must first be obtained by sending the Open action to the Memory resource This resource address is used for all further access to the NVRAM To write data to the NVRAM the action Write is sent to the Memory resource To read the contents of the NVRAM the action Read is used For complete information on the format
88. t Pro Motion File View Actions Help CONNECT 5 7 OPEN SAVE SAVE AS a S266 eel aE Interface Select Interface Type C None Demo C pa C S C COM C CAN hend 192 168 2 2 Sere If communication is correctly established a set of object graphics loads into the Project window to the left as shown in the following figure ION CME Digital Drive User s Manual Installation 2 Project Pro Motion Fle View Actions Help eu ERU OFEN SAVE SAVERS PROJECT CEVICL ANS SIRIUS SCOPI CHO MONTOR CONSOLE E FESET STOP DEV xS TUNNG CUSIOM S ve 3 E 6 Be e Ez ES tke Ss 9 RBs Poet EET am i Eos B S PRP Interface TCP IP 192 168 2 2 eae i Ef row cwe 500 cmm G Axis 2 Aux Enceder en PRP Serial Interface COM2 S7600 n Postion 4 4 Feedback ION CME S00 Brushless DC 3 phase Ge Axis 1 Pro Hotion functions amp Axis 2 Aux Enceder Operating Tec Umit Brockport Avis 0 Event Units Made rng Switches Eee pen aus Manager i mn gt J Koma Scope EN For a list of connands press Tat press Tat gt taxis 1 A amp X1 MaticnProcessor Time V AX1 Commanded Position gt axis 1 JZ amp X1 Commended Velocty JV AX1 Commanded Acceleration gt axis 1 gt ecunts 2 counts eec courts sec 5000 X 10 000 15000 20000 25000 30 000 35000 40 000 45
89. t O gt Digitallos 8 Digital I O SN74ACT14 circuit From ION CME Internal Bus X 6 8 Analog Inputs The High Resolution Analog Input has a voltage range of 10V The ION CME teceives both single ended and differential analog inputs as shown in the following table and Figure 6 14 When used in single ended configuration Analogln should be connected to Ground of the transmitter When used in differential configuration Analogln and Analogln are connected to the differential output of the transmitter In addition it is recommended to connect the ground of the transmitter to IO GND of the ION CME Refer to the Figure 6 14 77 ION CME Digital Drive User s Manual Electrical Signal Interfacing Figure 6 14 Analog inputs simplified diagram 78 Differential Analog Input Shield Analogln Differential Driver ION CME AnalogIn SingleEnded Analog Input Shield VOut 2 HMM m Analogln IO Gnd ION CME Digital Drive User s Manual 7 ION CMIE Specifications In This Chapter ION CME Drive Ratings ION CME Controller Performance ION CME Electrical ION CME Protection Circuits ION CME Connectors and Pinouts ION CME Mechanical ION CME Environmental ION CME Safety and Compliance ION CME Thermal Operating Curves vvvvvvvyvyyv 7 1 ION CMIE Drive Ratings Motor Model Specification DC Brush Brushless DC Step Nominal supply voltage 48VDC 48VDC 48VDC Supply voltage range 12 56VDC
90. tal6 0 1 The analog input has a voltage range of 10V The ION CME receives both single ended and differential analog inputs as shown in the following table and Figure 4 2 When used in single ended configuration Analogln should be connected to Ground of the transmitter When used in differential configuration Analogln and Analogln are connected to the differential output of the transmitter In addition it is recommended to connect the ground of the transmitter to IO Gnd of the ION CME Please refer to the diagrams in Figure 4 2 Analog Input Characteristics Value Range Input Signal Voltage Range 10V to 10V Resolution 16 Bits Maximum Recommended Input Signal Frequency 2 KHz Throughput 40 Kilo samples per second Integral Non Linearity Error Typical 1 LSB Integral Non Linearity Error Maximum 3 LSB Overvoltage Protection 35V to 40V Common Mode Range 10V to 25V Typical Differential Impedance 108 Kohms Common Mode Rejection Ratio Minimum 80 dB 52 ION CME Digital Drive User s Manual ION CME Control Differential Analog Input Shield Analogln Differential Driver ION CME AnalogIn SingleEnded Analog Input Shield VOut 2 HD LL v Analogln IO Gnd Figure 4 2 Analog inputs simplified diagrams ION CME Digital Drive User s Manual 53 ION CME Control Figure 4 3 C Motion Engine architecture 54 4 6 C Motion Engine Functions The C Mo
91. tallation 2 Differential Encoder Figure 2 4 Recommended feedback wiring Single ended Encoder amp Halls The shield drain wire should be connected at the ION module connector end only ION CME Digital Drive User s Manual 19 Installation 2 5 6 Auxiliary Connector Pin 1 Pin 2 444A SAP Pin 8 Pin Signal Shield lO Gnd lO 5V No connect 2 3 4 5 Quad A or Pulse 6 7 8 Quad A or Pulse Quad B or Directiont Quad B or Direction ION provides a second quadrature encoder port for use as a master in master slave and electronic gearing applications or a pulse and direction input for use in electronic gear applications As on the main encoder port ION supports both single ended and differential signal input This connector supports wire gauges from 20 to 30 AWG depending on the crimp terminal used Wiring with 22 AWG twisted pair shielded cable is recommended Figure 2 5 Figure 2 5 a Differential Recommended Aix auxiliary Encoder encoder wiring The shield drain wire should be connected at the ION module connector end only 2 5 6 1 Single Encoder Connections Summary ION can be connected to feedback encoders in both a single and a dual encoder configuration Dual encoder input may be useful for general purpose auxiliary encoder position feedback master slave electronic gear operation or dual loop
92. te of the digital outputs optional PMDPeriphRead amp hPeriph amp datal6 0 1 set Digital Output to low and bits Digital Input Output 5 to high a value of Ox1110 will set bits 0 and 3 DO and DIOS to 0 and respectively datal6 Ox 110 PMDPeriphWrite amp hPeriph amp datal6 0 1 ION CME Digital Drive User s Manual 51 ION CME Control 4 4 2 1 Bi directional Signal Considerations The four bi directional digital signals are accessed via separate peripheral addresses One for reading the digital inputs and one for reading and writing the digital outputs The digital outputs are open collector logic When an output pin is set to 1 high the output transistor is off and the pin can be used as an input When an output pin is set to 0 low the output transistor is on which pulls the signal to ground and the pin cannot be used as an input 4 5 Analog Input The analog input is a 16 bit 10V analog input The input value is read via the Peripheral Read function The range of the returned value is 0 65 535 where 0 10V and 65 535 4 10V To read the state of the analog input the following code sequence can be used open a peripheral handle to the analog input signal PMDPeriphOpenPAR amp hPeriph amp hDevice PMD ADDRESS ION AI 0 PMDDataSize_ l6Bit read the current state of the analog input the range of the returned value is 0 65535 O 10V 65535 10V PMDPeriphRead amp hPeriph amp da
93. tialize parameters such as encoder direction and safe servo parameters if you are using a servo motor 3 Execute a simple trajectory profile on each axis demonstrating that it is operating correctly and under stable control During this first time system setup you may find it useful to refer to other PMD manuals including the Pro Mo ion Users Guide for complete information on the Pro Motion application You may also want to refer to the Magellan Motion Processor Users Guide to familiarize yourself with operation of the Magellan Motion Processor which lies at the heart of all ION Digital Drives 2 10 1 Establishing Communications To establish communications 1 Make sure the ION is powered and connected to the PC 2 OntheStart menu click the Pro Motion application When Pro Motion is launched you will be prompted with an Interface selection window A typical screen view when first launching Pro Motion appears below 3 Click the Connect icon on the toolbar Alternatively on the File menu select Connect 4 Click Serial then click OK The Serial Port dialog box displays the active default communication values 5 Click OK without changing any of these settings The purpose of the Interface dialog box is to indicate to Pro Motion how your ION CME is connected to the PC o It provides various selectable communication options such as serial and Ethernet j ION CME Digital Drive User s Manual 31 Installation Projec
94. tion Engine on the ION CME allows C Motion code to be downloaded and executed on the ION CME The C Motion Engine is a powerful and flexible engine that can be used to e Operate ION CMEs in a standalone mode e Offload time critical code from the host to the ION CME Create a complete machine controller that communicates via Ethernet or serial to a cell controller or other high level controller Extend the functionality of the Magellan Motion Processor with higher level functions such as contouring macros ot other complex behaviors Lower system cost by combining a supervisor function with a dedicated motion controller function in a single module format 4 6 1 C Motion Engine Hardware Configuration The C Motion Engine is a self contained module that provides non volatile RAM space to store downloaded user application code RAM space for scratch data variable storage and connections to the communication bus allowing the C Motion Engine to send and receive messages through the network ports communicate with the Magellan Motion Processor and access other ION CME resources such as the general purpose I O Creating compiling downloading and verifying a specific user C Motion application on an ION CME is accomplished with the C Motion Engine development system described in C Motion Engine Development Tools The outcome of such a development sequence is a downloadable code image run on the C Motion Engine that contains the user appl
95. tion utilized during application debugging While Ethernet or serial can both be used as the communications link typically this link is chosen to be Ethernet because it is significantly faster than the other two If the production machine network is also Ethernet then only one network need be used for both code development and operation of the machine It is also possible to use separate communication channels so that one type of link is used for code development and download and another for the application communications This has the advantage that application and code development traffic are not intermingled For example in a production machine control application that involves a PC and two ION CMEs communicating via serial Ethernet can be used as the development link while the application software contained in the C Motion code will send and receive messages using the serial port Selecting which ION CME channel will be used for download is specified via the C Motion development system For more information see the C Motion Engine Development Tools Manual 56 ION CME Digital Drive User s Manual ION CME Control 4 6 6 Debug Console Window During development the user can use procedure calls similar to printf from the downloaded application on the C Motion Engine to send messages to the PC Development Environment for display in a special console window These console messages may be useful for checking code progress
96. used To read back the current default parameters stored in the module the action Get is used For detailed information on the format of these PRP messages consult the PMD Resource Access Protocol Programmer s Reference ION CME Digital Drive User s Manual 61 ION CME Control 4 11 ION CME Command Summary 62 The following table summarizes all PRP commands provided by the ION CME Action Resource ub action Procedure NOP Device PMDDeviceNoOperation MotionProcessor PMDNoOperation Reset Device Reset PMDDeviceReset MotionProcessor Reset PMDReset Command CMotionEngine Flash PMDDeviceStoreUserCode Task PMDCMETaskStart PMDCMETaskStop MotionProcessor Various Open Device Memory32 PMDMemoryOpen32 CMotionEngine PMDPeriphOpenCME COM PMDPeriphOpenCOM TCP PMDPeriphOpenTCP UDP PMDPeriphOpenUDP Parallel PMDPeriphOpenPAR Peripheral Device PMDRPDeviceOpen MotionProcessor PMDMPDeviceOpen MultiDrop PMDPeriphOpenMultiDrop Close Peripheral PMDPeriphClose Device PMDDeviceClose MotionProcessor PMDDeviceClose Memory PMDMemoryClose Send CMotionEngine PMDPeriphSend Peripheral PMDPeriphSend Receive CMotionEngine PMDPeriphReceive Peripheral PMDPeriphReceive Write Memory Dword PMDMemoryWrite Word PMDMemoryWrite Peripheral Byte PMDPeriphWrite Word PMDPeriphWrite Read Memory Dword PMDMemoryRead Word PMDMemoryRead Peripheral Byte PMDPeriphRead Word PMDPeriphRead Set CMotionEngine Console PMDCMESetConsole Device Default PMD
97. wire should run within the cable shield If the motor does not come with a case J wire or other dedicated case connection a lug under a motor mounting screw can be used j The shield drain wire should be connected at the ION module connector end only j ION CME Digital Drive User s Manual 17 Installation 2 5 5 Feedback Connector Pint Pin2 Pin DC Brush Brushless DC Step Shield Shield Shield 2 lO Gnd lO Gnd lO Gnd 3 lO 5v lO 5v lO 5V 4 Not used Hall A Not used 5 Not used Hall B Not used 6 Not used Hall C Not used Pin 12 7 Quad A Quad A Quad A 8 Quad A Quad A Quad A 9 Quad B Quad B Quad B 10 Quad B Quad B Quad B II Index Index Index 12 Index Index Index This connector is used to wire the signals from the main feedback encoder to the ION module For brushless DC motors it also connects the Hall Effect signals typically used to commutate the motor The Halls are not used with DC brush or step motors ION directly supports quadrature encoders with either single ended or differential outputs IO 5V and IO Gnd are provided to power the encoder and Hall Effect transducers This connector supports wire gauges from 20 to 30 AWG depending on the crimp terminal used Wiring with 22 AWG shielded cable is recommended For differential encoders twisted pair cable should be used Figure 2 4 shows recommended feedback wiring 18 ION CME Digital Drive User s Manual Ins
98. x Index IO Gnd Hall C IO 5V Shield Microstepping Motor Motor A Motor A Motor B Motor B Case Shield Feedback Main encoder Quad A Quad A Quad B Quad B Index Index IO Gnd IO 5V Shield All Auxiliary Auxiliary encoder Quad A Quad A Quad B Quad B IO Gnd IO 5V Shield Pulse Pulse Direction Direction All o Enable IO Gnd Limit Limit Home High Speed Capture AxisIn AxisOut FaultOut lO 5V Shield Serial Comm RS232 Tx Rx IO Gnd Select RS485 Select Tx Tx Rx Rx IO Gnd Ethernet Comm Select Tx Tx Rx Rx All Indexer Shield IO Gnd IO 5V Analogin Analogin DigitalOutl DigitalOut2 Digitalln Digitalln2 Digitalln3 Digitalln4 DigitallO5 DigitallO6 DigitallO7 DigitallO8 ION CME Digital Drive User s Manual 15 Installation 2 5 3 Power Connector Pin Signal l HV 2 AuxV 3 Pwr_Gnd This connector supplies the main DC power to the ION CME module ION CMEs should be wired with 16 AWG wite ION CME has a built in DC DC converter that derives all required internal voltages from the main DC bus A separate logic supply is not required This DC DC converter also provides IO 5V for powering encoders limit switches and other system I O Pin 1 As an additional safety feature ION CME provides a separate Auxiliary Voltage AuxV input that can be used to power just this DC DC converter without powering the main
99. y This is shown below with default values visible Network I O Defaults Ethernet Serial IP address 182 168 2 2 Net mask 255 255 255 Q0 Gateway 0 0 0 0 x J sees 4 Enter the IP Address in the corresponding data field as well as the net mask and gateway if this is required for your netwotk For a typical installation you will not change the Net mask and Gateway default values but you must specify a valid unique IP Address for the ION CME to be located on your Ethernet network If you are not sure what IP addresses are free and available for your Ethernet network contact your system administrator 5 Click OK to store as the power on default 6 Click the Reset toolbar button After the ION is reset it uses the default parameters that you specified 7 Connect the Ethernet cable See Section 2 7 Communications Configuration for details The ION CME is now ready for Ethernet communications 34 ION CME Digital Drive User s Manual Installation 2 2 10 3 Establishing Ethernet Communications The ION s IP Address has now been set but Pro Motion does not know what IP address it should use for Ethernet communications to the ION To establish Ethernet communications 1 Click the Connect toolbar button 2 Select Ethernet and then click OK 3 Enter the same IP Address as was specified for Ethernet ION 4 When complete click OK If Ethernet communication is successful an additional set of
100. y s products or services does not constitute PMD s approval warranty or endorsement thereof ION CME Digital Drive User s Manual A Related Documents Magellan Motion Processor User s Guide Complete description of the Magellan Motion Processor features and functions with detailed theory of its operation Magellan Motion Processor Programmer s Command Reference Desctiptions of all Magellan Motion Processor commands with coding syntax and examples listed alphabetically for quick reference Pro Motion User s Guide User s guide to Pro Motion the easy to use motion system development tool and performance optimizer Pro Motion is a sophisticated easy to use program which allows all motion parameters to be set and or viewed and allows all features to be exercised C Motion Engine Development Tools Manual Describes the C Motion Engine Development Tools that allow user application code to be created and compiled on a host PC then downloaded executed and monitored on a CME device C Motion Engine module PMD Resource Access Protocol Programmer s Reference Describes the PMD Resource access Protocol PRP used for communication between the host and a PRP device the software interfaces and binary protocols the procedures and data types used for programs software libraries and C Motion library code iv ION CME Digital Drive User s Manual Table of Contents D Table of Contents I Introduction 9 2 sess einen eE ae EE 6 EE a

ION - CME Digital Drive User`s Manual

Contents

Download Pdf Manuals

Related Search

Related Contents