phytron phyMOTION I1AM01.2 User manual

phytron
10/2015 Manual MA 1269-A007 EN
phyMOTIONTM
1 Axis Stepper Motor Drive
I1AM01.2 / I1AM0a.2
Firmware Version:
V
1.1.2 (Loader)
V
1.1.2 (Loader)
V
1.1.6 (System)
V
1.1.6 (System)
TRANSLATION OF THE GERMAN ORIGINAL MANUAL

Manual I1AM01 / I1AM0a
MA 1269-A007 EN 2
©2015
All rights with:
Phytron GmbH
Industriestraße 12
82194 Gröbenzell, Deutschland
Tel.: [phone]
Fax: [phone]
In this manual you will find the descriptions of the features and specifications of the
phyMOTIONTM module: 1 Axis Stepper Motor Drive I1AM01/I1AM0a
(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: [e-mail]
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.

phytron
3 MA 1269-A007 EN
1 Legal Information
i
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.
i
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.
i
”Any heading“ Refers to an important paragraph in the
manual.

Manual I1AM01 / I1AM0a
MA 1269-A007 EN 4
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.
i
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.
i
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).

phytron
5 MA 1269-A007 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 I1AM01 / I1AM0a
MA 1269-A007 EN 6
2 Contents
1Legal Information ...................................................................................................... 3
2Contents..................................................................................................................... 6
3I1AM01/I1AM0a Module Overview............................................................................ 7
4Technical Data ........................................................................................................... 9
4.1 Declaration of Conformity...................................................................................... 9
4.2 Mechanical Data................................................................................................... 11
4.3 Features ............................................................................................................... 12
4.4 Functions.............................................................................................................. 14
5Installation ................................................................................................................ 15
5.1 Mechanical Installation ......................................................................................... 15
5.2 Electrical Installation............................................................................................. 17
5.2.1 Connectors - Overview.................................................................................. 17
5.2.2 Pin Assignment ............................................................................................. 18
5.2.3 Stepper Motor Connection ............................................................................ 19
5.2.4 Limit Switch Connection ................................................................................ 21
5.2.5 Option: Encoder Connection ......................................................................... 22
5.2.6 Option: Resolver, LVDT or RVDT Connection ............................................. 25
5.2.7 Option: Motor Temperature Sensor Connection ........................................... 29
6Commissioning ........................................................................................................ 31
6.1 Diagnostics by the LEDs ......................................................................................32
6.2 Parameterising the Modules................................................................................. 33
7Principles of Positioning .........................................................................................34
8Service....................................................................................................................... 35
9Warranty, Disclaimer and Registered Trademarks ............................................... 36
9.1 Disclaimer............................................................................................................. 36
9.2 Warranty............................................................................................................... 36
9.3 Registered Trademarks........................................................................................ 36
10 Index .......................................................................................................................... 37

phytron
7 MA 1269-A007 EN
3 I1AM01/I1AM0a Module Overview
I1AM01/I1AM0a stands for “1 Axis Indexer with Integrated Power Stage (amplifier)”. This
module is a full stepper motor drive up to 3.5 APEAK max. It can be connected directly next
to a MCM (main controller module). The module includes a mid-performance indexer and
a mid-performance 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) as well as motor temperature evaluation (PTS01 and KTS01).
Fig. 1: I1AM01/I1AM0a View of the front panel

Manual I1AM01 / I1AM0a
MA 1269-A007 EN 8
Ordering code of the 1 axis stepper motor drive module (I1AM01/I1AM0a):
Ordering code (example): I1AM01-ECES01-PTS01:
1 axis stepper motor drive module with integrated encoder
and PT sensor

phytron
9 MA 1269-A007 EN
4 Technical Data
4.1 Declaration of Conformity

Manual I1AM01 / I1AM0a
MA 1269-A007 EN 10

phytron
11 MA 1269-A007 EN
4.2 Mechanical Data
Dimensions 100 x 100 mm (without front panel)
Weight 109 g / 124 g (without / with font panel)
Mounting Plug-in module into the modular stepper motor controller
phyMOTIONTM
Mounting position Vertical

Manual I1AM01 / I1AM0a
MA 1269-A007 EN 12
4.3 Features
Performance Characteristics
Stepper motor Suitable for bipolar control of 2 phase stepper motors with
4, (6) or 8 lead wiring
Superior controller Modular phyMOTIONTM controller
Supply voltage 24…48 VDC
Nominal voltage: 48 VDC
5 VDC internal
Phase current 0.1 to 3.5 APEAK
Current adjustment 10 mA steps
Step resolutions Full step, half step, 1/2.5, 1/4, 1/5, 1/8, 1/10, 1/16, 1/20,
1/32, 1/64, 1/128, 1/256 micro step
Maximum step frequency 40,000 steps/sec.
Physical resolution Approx. 51,200 positions per revolution (0.007° / step).
The optional encoder modules should be considered for
very fine positioning.
Current consumption
(max.)
2.6 ADC at 3.5 APEAK
250 mA (5 VDC internal)
10 mA (24 VDC I/O)
30 mA (EnDat Encoder 5 VDC internal)
20 mA + Encoder (24 VDC I/O)
30 mA (temperature module)
Mechanical output power Up to the 250 W range
Nominal power of the
motor voltage supply
200 W (full load)
Cable length – motor Shielded: 50 m max.
Cable length – digital
inputs
30 m; if longer (100 m max.) use shielded cable and
contact shield close to the controller.

phytron
13 MA 1269-A007 EN
Diagnostics 2 Status LEDs on the front panel
Features
Support of linear and
redary axes
Yes
Hardware error detection Over current, short circuit
Refresh rate 2 ms
Interfaces
Analogue outputs A, B, C, D for a 2 phase stepper motor
Analogue inputs Option: Motor temperature evaluation
- K thermal element (needs sub module: KTS01)
- PT100 sensor (needs sub module: PTS01)
Digital inputs 3 Limit switches: PNP- NOC/NCC
Option: Encoder evaluation
- SSI/Quadrature (needs sub module: ECAS01)
- EnDat (needs sub module: ECES01)
- Resolver or LVDT/RVDT (needs ECMS01)
Communication via
backplane bus
Proprietary phytron bus
Communication and programming
Programming Via phytron‘s programming environment phyLOGICTM
ToolBox
Communication Master-slave communication. The I1AM01/I1AM0a is slave
and communicates with the MCM main controller module.

Manual I1AM01 / I1AM0a
MA 1269-A007 EN 14
4.4 Functions
Integrated stepper motor indexer for standard functions
•Relative and absolute positioning
•Reference movements/ speed mode
•Step frequency up to 40,000 steps/sec.
Integrated 3.5 APEAK power stage
•Integrated 3.5 APEAK / 24 to 48 VDC stepper motor power stage
•Selectable step resolution up to 1/256 micro step
•Online power stage parameterisation and diagnostics
3 Limit/reference switches
•Evaluation of up to three limit/reference switches (PNP NCC/NOC)
Option: Encoder evaluation
•The evaluation of a SSI / quadrature encoder (with ECAS01 sub module) or
EnDat (with ECES01 sub module) or resolver/LVDT/RVDT (with ECMS01 sub
module) is possible depending on the selected sub module.
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.

phytron
15 MA 1269-A007 EN
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 I1AM01 as an expansion module or after repair
or service unpack the module in ESD predected 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 predective
packaging.
- Always handle the components in compliance with the ESD
predection measures.
- No liability is accepted for any consequences resulting from improper
handling or non-ESD-friendly packaging.
i
CAUTION – Possible damage!
The I1AM01/I1AM0a module is designed for a maximum supply voltage of
70 VDC. If it is supplied with >70 VDC the card might be damaged.
- Make sure that a power module (POWM01, POWM02) is supplied on
the left with less than 70 VDC to avoid damage.

Manual I1AM01 / I1AM0a
MA 1269-A007 EN 16
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 I1AM01/I1AM0a referring to your order and
documentation. The I1AM01/I1AM0a needs at least a preceding power module (POWM01,
POWM02) and the main controller module (MCM01/MCM02).
Push the 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.

phytron
17 MA 1269-A007 EN
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
Motor 1x4 IC 2,5/4-G-5,08 IC 2,5/4-ST-5,08 10005390
Limit
switches
1x10 MCDN1,5/10-G1-
3,5P26
FMC1,5/10-ST-3,5 10013217
Encoder 1x10 MCDN1,5/10-G1-
3,5P26
FMC1,5/10-ST-3,5 10013217
Temperature
evaluation
2x2 MCDN1,5/2-G1-
3,5P26
FMC1,5/2-ST-3,5 10007077
The mating connector is included in delivery of the module and is usually plugged into the
module at the factory.
i
CAUTION – Possible damage!
Damage of the module by wrong connection.
- Do not exchange the 10-pin connector for limit switches with the
10-pin connector for the encoder evaluation.

Manual I1AM01 / I1AM0a
MA 1269-A007 EN 18
5.2.2 Pin Assignment
In the following the pin assignment:
Fig. 2: Pin assignment
Use the specified mating connectors for wiring.
i
CAUTION – Possible damage!
Damage of the module by wrong connection.
- Do not exchange the 10-pin connector for limit switches with the
10-pin connector for the encoder evaluation.

phytron
19 MA 1269-A007 EN
5.2.3 Stepper Motor Connection
In the next chapter the connection of a 2 phase stepper motor with 4, (6), or 8 lead wiring
is described.
Stepper motors with 0.1 to 3.5 APEAK can be controlled at maximum 48 VDC by the
I1AM01/I1AM0a.
Wiring schemes
Fig. 3: Connection diagrams for 4,(6) and 8 lead stepper motors

Manual I1AM01 / I1AM0a
MA 1269-A007 EN 20
Stepper motors with 8 leads can be connected with the windings wired in parallel (1) or
series (2).
For 6 lead stepper motors, wiring scheme (3) with series windings is recommended.
If wiring scheme (3) cannot be used because of the motor construction, the motor may be
operated with only two of the four windings energized according to wiring scheme (4).
i
CAUTION – Possible damage!
Destruction of the power stage by connecting a 5 phase stepper motor.
- Do not connect any 5 phase stepper motors to avoid damage.
Motor time constant τ:
R
L
=
τ
applies to the electrical motor time constant τ.
The total inductance Ltotal is equal to the winding inductance in a parallel circuit,
because of interlinked inductances.
Ltotal=4 x L applies to a series circuit.
The result is an equal motor time constant τ for a serial and a parallel circuit:
Circuit series parallel
Resistance Rtotal 2 x R
2
R
Inductance Ltotal 4 x L L
Motor time constant τ
R
Lx2
Rx2
Lx4
series ==τ R
Lx2
R/2
L
=τparallel =