Inovance IS300 Series Servo Drive User Guide: Operation Panel, Position Control, Electronic Gear Ratio, CN1 Terminal Wiring and Fault Troubleshooting

The Inovance IS300 series servo drive is a high-performance vector-controlled servo drive specifically designed for driving permanent magnet synchronous motors (PMSM). It offers closed-loop vector control (VC) with high starting torque (180 percent at 0 Hz), wide speed regulation range (1:1000), and steady-state speed accuracy of plus or minus 0.02 percent. The IS300 supports both speed mode and position mode operation, making it suitable for injection molding machines, CNC machines, automated positioning systems, and general servo applications requiring precise motion control.

1. Operation Panel and Status Indicators

The IS300 servo drive features an integrated LED operation panel that can be either mounted directly on the drive or extended via an 8-core flat cable connected to the RJ45 interface. The panel provides real-time parameter access, monitoring, and control for commissioning and daily operation.

1.1 LED Display and Key Layout

The operation panel includes a 5-digit LED display capable of showing parameter codes, operational status, and alarm codes. The display uses a three-level menu structure for efficient navigation:

• Level I (Function Group): Selects parameter groups such as F0 (basic parameters), F1 (motor parameters), F2 (speed loop), F4 (DI/DO), F5 (relay output), and A3 (servo pump parameters).
• Level II (Function Code): Selects individual parameters within the chosen group.
• Level III (Parameter Value): Displays and allows modification of parameter values.

The panel keys and their functions are:

1.2 Status Indicators

The operation panel includes several LED status indicators that provide immediate visual feedback about the drive and motor state:

In the stopped state, pressing the SHIFT key cycles through parameters such as set frequency, AI1 voltage, AI2 voltage, AI3 voltage, and DC bus voltage. In the running state, it cycles through output frequency, output current, output voltage, motor speed, and AI input voltages.

1.3 Parameter Editing Workflow

Parameters are edited using the three-level menu. For example, to change parameter F0-04 from 0.00 Hz to 15.00 Hz:

1. Press PRG to enter Level I menu. The display shows the function group.
2. Use UP/DOWN to select group F0, then press ENTER.
3. Use UP/DOWN to select function code F0-04, then press ENTER to enter Level III.
4. Use SHIFT to select the digit to modify; use UP/DOWN to change the value to 15.00.
5. Press ENTER to save and return to Level II; press PRG to save and automatically advance to the next parameter.

2. Position Mode Control with External Pulse Input

The IS300 servo drive supports position control mode for precise positioning applications. In position mode, the servo drive receives pulse commands from an external controller (such as a PLC, motion controller, or CNC system) through the CN1 control terminal. Each pulse corresponds to a specific angular displacement of the motor shaft, and the electronic gear ratio scales the pulse count to match the mechanical system requirements.

2.1 Control Circuit Terminal (CN1) Overview

The IS300 control board provides a comprehensive set of terminals via the control circuit connector. Key terminals for position control include:

2.2 Pulse Input Configuration for Position Mode

To configure the IS300 for position control with external pulse input, the following parameter settings are required:

Step 1: Set control mode to non-pump mode (speed/position mode)

Step 2: Set command source

Step 3: Configure DI terminals for position control functions

The pulse input signals are typically connected to the appropriate DI terminals or through the communication interface. For direct pulse input, the drive receives pulse and direction signals that are processed by the internal position loop to control motor movement.

2.3 CN1 Terminal Wiring for Pulse and Direction Signals

For position control applications using external pulse commands, the wiring must ensure clean signal transmission. The general wiring guidelines for the IS300 control terminals are:

Digital Input Wiring (NPN/Sink Type – Most Common):

The IS300 digital inputs support both NPN (sink) and PNP (source) configurations. The default internal 24V power supply can be used, or an external power supply can be connected.

When using an external power supply, remove the shorting jumper between +24V and OP. Connect the external 24V positive to OP, and route the external 0V through the controller contacts to the DI terminals.

Important Wiring Rules:

• Use shielded cables for all control signals, keeping cable lengths under 20 meters.
• Separate control signal cables from power cables (R, S, T, U, V, W) by at least 30 centimeters.
• When connecting multiple drives in parallel, do not directly parallel the DI terminals without isolation diodes (IF greater than 10 mA, UF less than 1V).
• Ground the shield at one end to prevent ground loops.

3. Electronic Gear Ratio Calculation and Fixed-Length Positioning Example

3.1 Electronic Gear Ratio Formula

The electronic gear ratio is a fundamental parameter in servo positioning systems. It defines the scaling relationship between the command pulse count from the controller and the actual motor rotation. The gear ratio ensures that the mechanical movement matches the controller’s pulse output.

The general formula for electronic gear ratio is:

Or expressed as a ratio:

Where:

• Encoder Resolution: The number of pulses the encoder outputs per motor revolution (e.g., 10000, 2500, or 1000 lines with quadrature encoding).
• Load Movement per Motor Rev: The linear displacement of the mechanical load for each full motor rotation (e.g., 10 mm for a 10 mm pitch ball screw).
• Command Pulse Unit: The desired displacement per command pulse (e.g., 1 pulse = 1 micrometer, or 1 pulse = 0.01 mm).

3.2 Practical Fixed-Length Positioning Example

Consider a linear positioning system with the following specifications:

• Target movement: 100 mm
• Ball screw pitch: 10 mm per revolution (1 rev = 10 mm travel)
• Encoder resolution: 10000 pulses per revolution (using 2500-line encoder with 4x quadrature)
• Desired command resolution: 1 micrometer per pulse (0.001 mm/pulse)

Step 1: Calculate required motor revolutions

Step 2: Calculate encoder pulses for target movement

Step 3: Calculate required command pulses

Step 4: Determine electronic gear ratio

Alternative Example with Different Resolution:

If the desired command resolution is 10 micrometers per pulse (0.01 mm/pulse) for the same 100 mm movement:

On the IS300, the electronic gear ratio parameters are configured through the position control parameter group. The gear ratio determines how many motor encoder pulses correspond to each command pulse from the external controller.

3.3 Parameter Settings for Position Control

After calculating the electronic gear ratio, configure the following IS300 parameters:

4. Fault Codes and Troubleshooting Solutions

The IS300 servo drive provides comprehensive fault detection and protection. When a fault occurs, the drive stops output, the fault relay activates, and the fault code is displayed on the LED panel. The following table lists the most common fault codes and their solutions:

4.1 Overcurrent Faults (Err02, Err03, Err04)

4.2 Overvoltage and Undervoltage Faults (Err05, Err06, Err07, Err09)

4.3 Motor and Drive Protection Faults (Err10, Err11, Err12, Err13, Err14, Err15)

4.4 Encoder and Communication Faults (Err16, Err42, Err43, Err44)

4.5 Additional Important Fault Codes

4.6 Fault Reset Procedures

To reset a fault on the IS300:

1. Panel Reset: Press the STOP/RES key when a fault is displayed. The fault will be cleared if the cause has been resolved.
2. Terminal Reset: Configure a DI terminal as fault reset (function 9) and activate it briefly.
3. Power Cycle: Turn off power, wait for the CHARGE indicator to extinguish, then turn power back on.

For faults like Err08 (buffer resistor fault), the fault is non-resettable and requires service contact. Similarly, encoder-related faults (Err20, Err43) may require re-tuning or hardware replacement.

5. Maintenance and Daily Care

Regular maintenance ensures long-term reliability of the IS300 servo drive:

• Daily: Check for abnormal motor noise or vibration; verify cooling fan operation; check for overheating; keep the drive clean and free of dust, especially metal dust.
• Periodic: Clean air ducts; check and tighten screws; inspect terminals for arc marks; perform insulation testing (disconnect drive first; use 500V megohmmeter).
• Component Replacement: Cooling fans typically last 2-3 years; electrolytic capacitors last 4-5 years under normal conditions. Replace when abnormal noise, vibration, or leakage is detected.

The IS300 is backed by an 18-month warranty from the factory date. For technical support, contact Inovance service at 4000-300124 or 400-777-1260.