phytron phyMOTION EXAM01.1 User manual

phytron
5/2019 Manual MA 1277-A011 EN
phyMOTIONTM
Interface Module for an External Power Stage
EXAM01.1
TRANSLATION OF THE GERMAN ORIGINAL MANUAL

Manual EXAM01
MA 1277-A011 EN 2
Version
Modification
11
BiSS encoder wiring
2019
All rights with:
Phytron GmbH
Industriestraße 12
82194 Gröbenzell, Germany
Tel.: [phone]
Fax: [phone]
In this manual you will find the descriptions of the features and specifications of the
phyMOTIONTM module: Interface Module for an External Power Stage EXAM01
(http://www.phytron.de/phyMOTION).
This manual is supplementary to the “phyMOTIONTM Modular Multi-axis Controller for
Stepper Motors”manual.
Every possible care has been taken to ensure the accuracy of this technical manual. All
information contained in this manual is correct to the best of our knowledge and belief but
cannot be guaranteed. Furthermore, we reserve the right to make improvements and
enhancements to the manual and / or the devices described herein without prior
notification.
We appreciate suggestions and criticisms for further improvement.
Email address: [email protected]
Questions about the use of the product described in the manual that you cannot find
answered here, please contact your representative of Phytron (http://www.phytron.de/) in
your local agencies.

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1 Information
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This manual:
Read this manual very carefully before mounting, installing and operating the
device and if necessary further manuals related to this product.
- Please pay special attention to instructions that are marked as follows:
DANGER –
Serious injury!
Indicates a high risk of serious injury or
death!
DANGER –
Serious injury from
electric shock!
Indicates a high risk of serious injury or
death from electric shock!
WARNING –
Serious injury
possible!
Indicates a possible risk of serious
injury or death!
WARNING –
Serious injury from
electric shock!
Indicates a possible risk of serious injury
or death from electric shock!
CAUTION –
Possible injury!
Indicates a possible risk of personal
injury.
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CAUTION –
Possible damage!
Indicates a possible risk of damage to
equipment.
CAUTION –
Possible damage
due to ESD!
Refers to a possible risk of equipment
damage from electrostatic discharge.
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“Any heading”
Refers to an important paragraph in the
manual.

Manual EXAM01
MA 1277-A011 EN 4
Observe the following safety instructions!
Qualified personnel
WARNING –Serious injury possible!
Serious personal injury or serious damage to the machine and drives could
be caused by insufficiently trained personnel!
Without proper training and qualifications damage to devices and injury
might result!
- Design, installation and operation of systems may only be
performed by qualified and trained personnel.
- These persons should be able to recognize and handle risks
emerging from electrical, mechanical or electronic system parts.
- The qualified personnel must know the content of this manual and
be able to understand all documents belonging to the product.
Safety instructions are to be provided.
- The trained personnel must know all valid standards, regulations
and rules for the prevention of accidents, which are necessary for
working with the product.
Safety Instructions
Further Manual
This manual is addition to the following main manual:
“phyMOTIONTM Modular Multi-axis Controller for Stepper Motors”
- First, read the main manual and then continue with this manual.
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Intended use:
The phyMOTIONTM is designed for operating in a drive system.
- An installation is allowed only if the requirements of the EC Machinery
and EMC Directives are conformed with.
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Part of a machine:
This product is used as a part of a complete system, therefore risk
evaluations concerning the specific application must be made before using
the product.
- Safety measures have to be taken according to the results and be
verified.
- Personnel safety must be ensured by the concept of this overall system
(e.g. machine concept).

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5 MA 1277-A011 EN
WARNING –Serious injury from electric shock!
If the phyMOTIONTM is not operated with SELV/PELV voltages, the risk of
dangerous voltages may be on the device. Touching these components
carrying high voltages can cause serious injury or death from electric shock:
- Always observe the safety concept SELV / PELV to ensure safe
isolation and separation of low voltage supplies from the mains.
WARNING –Serious injury from electric shock!
During electrical installation cables, connectors, etc. can be live.
- Before starting wiring, make sure that none of the power supplies
are connected to the primary side of the mains supply. Isolate the
power supplies from the mains or remove the appropriate fuses.
- All modules must be inserted and screwed into the phyMOTIONTM
housing before powering up. If necessary, unoccupied module
slots must be covered with the supplied blank front plates.
Never operate the equipment when open.
- Do not plug or unplug the modules while powered.
- Do not plug or unplug the connectors while powered.
- If the equipment was energised, wait 3 minutes after power off to allow
the capacitors to discharge and ensure that there are no residual
charges on cables, connectors and boards.

Manual EXAM01
MA 1277-A011 EN 6
2 Contents
1Information ..............................................................................................................3
2Contents...................................................................................................................6
3EXAM01 Module Overview......................................................................................7
4Technical Data.........................................................................................................9
4.1 Declaration of Conformity....................................................................................9
4.2 Mechanical Data.................................................................................................10
4.3 Features.............................................................................................................11
4.4 Functions............................................................................................................13
5Installation..............................................................................................................14
5.1 Mechanical Installation.......................................................................................14
5.2 Electrical Installation...........................................................................................16
5.2.1 Connectors - Overview................................................................................16
5.2.2 Pin Assignment............................................................................................17
5.2.3 Connection Control signals X5/X6 ...............................................................18
5.2.4 Limit switch connection X2...........................................................................21
5.2.5 Option: Encoder connection X1 ...................................................................22
5.2.6 Option: Resolver, LVDT or RVDT Connection X1.......................................26
5.2.7 Option: Motor Temperature Sensor Connection X3/X4................................31
6Commissioning ......................................................................................................33
6.1 Diagnostics by the LEDs.....................................................................................34
6.2 Parameterising the Module.................................................................................34
7Principles of Positioning .......................................................................................35
8Service ....................................................................................................................36
9Warranty, Disclaimer and Registered Trademarks ..............................................37
9.1 Disclaimer ..........................................................................................................37
9.2 Warranty.............................................................................................................37
9.3 Registered Trademarks......................................................................................37
10Index........................................................................................................................38

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3 EXAM01 Module Overview
EXAM01 stands for external Power Stage module. This module is used as an interface
between indexer and external power stage. The module needs an Indexer (e.g. I4XM01) in
front and sends Control pulses/Direction/Boost and Enable to an external power stage.
Two limit switches and a third switch, which can be wired as limit switch evaluation are
included as standard.
In addition, sub modules can be optionally selected for encoder evaluation (ECAS01,
ECES01, ECMS01, ECBS01) as well as motor temperature evaluation (PTS01 and
KTS01).
Fig. 1:EXAM01 View of the front panel

Manual EXAM01
MA 1277-A011 EN 8
Ordering code of the EXAM01 modules:
Ordering code (example): EXAM01-ECES01-PTS01
Stepper motor power stage module with integrated
encoder and Pt sensor

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4 Technical Data
4.1 Declaration of Conformity

Manual EXAM01
MA 1277-A011 EN 10
4.2 Mechanical Data
Dimensions
100 x 100 mm (without front panel)
Weight
55 g / 75 g (without / with front panel)
Mounting
Plug-in module into the modular stepper motor controller
phyMOTIONTM
Mounting position
Vertical

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4.3 Features
Performance Characteristics
Stepper motor
Suitable for power stages with Control pulses/Direction
input
Superior controller
Modular controller phyMOTIONTM
Supply voltage
I/0 voltage 24 VDC
Current consumption
maximum
250 mA (5 V)
10 mA (24 V)
30 mA (EnDat encoder 5 V)
20 mA + encoder (24 V)
30 mA (temperature module)
1 A (limit switch)
Cable length –digital
inputs / outputs
30 m;
if longer (100 m max.) use shielded cable and contact
shield close to the controller.
Diagnostics
2 Status LEDs on the front panel for monitoring
Support of linear and
rotary axes
yes
Refresh rate
2 ms

Manual EXAM01
MA 1277-A011 EN 12
Interfaces
Digital outputs
Control pulses/Direction/Boost and Enable for an external
power stage
Analogue inputs
Option: Motor temperature evaluation
- K thermal element (needs sub module: KTS01)
- Pt100 sensor (needs sub module: PTS01)
Digital inputs
Limit switches: PNP- NOC/NCC
Option: Encoder evaluation
- with ECAS01 sub module: incremental or SSI
- with ECES01 sub module: EnDat, incremental or SSI
- with ECBS01 sub module: incremental, SSI or BiSS
- with ECMS01 sub module: Resolver, LVDT or RVDT
Communication via
backplane bus
Proprietary phytron bus
Communication and Programming
Programming
Via phytron‘s programming environment phyLOGICTM
ToolBox
Communication
Master-slave communication. The EXAM01 is slave and
communicates with the MCM01 main controller module.

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4.4 Functions
Interface between stepper motor indexer and external power stage
Requires an upstream installed indexer (i.e. I4XM01)
Outputs Control pulses/Direction/Boost and Enable to an external power stage
External stepper motor power stage with ServiceBus can be diagnosed and
parameterised online via the interface on the indexer module (i.e. I4XM01).
3 Limit/reference switches
Evaluation of up to three limit switches/reference switches (PNP- NOC/NCC)
Option: Encoder evaluation
The evaluation of the following encoders depends on the selected sub module:
- with ECAS01 sub module: incremental or SSI
- with ECES01 sub module: EnDat, incremental or SSI
- with ECBS01 sub module: BiSS, incremental or SSI
- with ECMS01 sub module: Resolver, LVDT or RVDT
Option: Motor temperature evaluation
The evaluation of Pt100 temperature sensors (with PTS01 sub module) or K types
(with KTS01 sub module) is possible depending on the selected sub module.

Manual EXAM01
MA 1277-A011 EN 14
5 Installation
Phytron always delivers the phyMOTION™ completely assembled in order to make sure
you can start with the installation and the wiring right away.
Further manual
Detailed information on this subject is in a supporting manual:
“phyMOTIONTM Modular Multi-axis Controller for Stepper Motors”
5.1 Mechanical Installation
In case you receive an individually packed EXAM01 as an expansion module or after
repair or service unpack the module in ESD protected area only.
CAUTION –Possible damage by ESD!
The modules of the phyMOTIONTM consist of sensitive electronic
components that can be destroyed by electrostatic discharge voltages.
- Always store and transport single modules in ESD protective
packaging.
- Always handle the components in compliance with the ESD
protection measures.
- No liability is accepted for any consequences resulting from
improper handling or non-ESD-friendly packaging.

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Before integrating or switching modules always make sure that the phyMOTION™ is shut
down and the power supplies are disconnected.
WARNING –Serious injury from electric shock!
During electrical installation cables, connectors, etc. can be live.
- Before starting wiring, make sure that none of the power supplies
are connected to the primary side of the mains supply. Isolate the
power supplies from the mains or remove the appropriate fuses.
- All modules must be inserted and screwed into the phyMOTIONTM
housing before powering up. If necessary, unoccupied module
slots must be covered with the supplied blank front plates.
Never operate the equipment when open.
- Do not plug or unplug the modules while powered.
- Do not plug or unplug the connectors while powered.
- If the equipment was energised, wait 3 minutes after power off to
allow the capacitors to discharge and ensure that there are no
residual charges on cables, connectors and boards.
Make sure not to leave free slots in between modules so the module addressing sequence
can work correctly.
Identify the correct slot position for your EXAM01 module referring to your order and
documentation –the EXAM01 needs at least a preceding Indexer module (i.e. I4XM01), a
POWM01 or POWM02 and the MCM01 main controller module.
The EXAM01 module is always built as a sandwich with its subsequent indexer module
(i.e. I4XM01). Cut the red seal tape and the black label tape carefully on the left and right
edge of the module/front panel which you want to remove. Don’t slide the blade between
the front panels by no means.When backfitting by our service the red seal tape is
renewed.
Connect the EXAM01 module to the connector (2x13 pole, ribbon cable) with the
appropriate indexer modules from the rear side.
Push the sandwich module carefully into the guide rail until the rear contacts the housing
frame of the phyMOTIONTM.
In the last few millimetres the module’s plug has to match with the backplane’s socket. You
should be able to push in the module with light pressure. In case you experience problems
move the module’s front plate slightly to the left and to the right while pushing in the
module, so that the plug’s pins can slide into the backplane’s socket.
As soon as the module’s front plate contacts the housing’s frame the module is integrated
properly and can be fixed with two electro-conductive bolts.
Now you can start with the electrical installation.

Manual EXAM01
MA 1277-A011 EN 16
5.2 Electrical Installation
Ensure sufficient bending radius of the cables during installation. Do not lay the cables in
tension or bend them.
We recommend labelling the mating connectors to prevent interchanging the connectors.
If all the connections are made, the last step is to plug in the power supply to the mains.
5.2.1 Connectors - Overview
Connector
Number
of pins
Connector on
the module
(Phoenix)
Mating
connector
Phoenix
Mating
connector
ID number
Encoder X1
1x10
MCDN1,5/10-G1-
3,5P26
FMC1,5/10-ST-
3,5
10013217
Limit switches X2
1x10
MCDN1,5/10-G1-
3,5P26
FMC1,5/10-ST-
3,5
10013217
Temperature
evaluation X3/X4
2x2
MCDN1,5/2-G1-
3,5P26
FMC1,5/2-ST-3,5
10007077
Control signals
X5/X6
2x8
MCDN1,5/8-G1-
3,5P26
FMC1,5/8-ST-3,5
10005881
The mating connector is included in delivery of the module and is usually plugged into the
module at the factory.
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CAUTION –Possible damage!
Damage of the module by wrong connection.
- Do not exchange the 10 pin limit switch connector with the
10 pin connector for the encoder evaluation.

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5.2.2 Pin Assignment
In the following the pin assignment:
Fig. 2:Pin assignment
Use the specified mating connectors for wiring.

Manual EXAM01
MA 1277-A011 EN 18
5.2.3 Connection Control signals X5/X6
This connector is used for the external power stage connection.
Signal level: 5 V
Fig. 3: Digital outputs

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Connection example: EXAM01 with MCD+ power stage
Fig. 4: Signal connection of the MCD+ with EXAM01

Manual EXAM01
MA 1277-A011 EN 20
Optional Accessories:
Adaptor cable for EXAM01 connection with MSD power stage
Fig. 5: Adaptor cable : cable length 0.5 m (ID no. 10015012), 2.0 m (ID no. 10014906)