phytron phyMOTION INSM01.1 User manual

phytron
5/2019 Manual MA 1307-A004 EN
phyMOTIONTM
Power Stage Carrier Module with Safe Torque Off
INSM01.1
TRANSLATION OF THE GERMAN ORIGINAL MANUAL

Manual INSM01
2 MA 1307-A004 EN
Version
Content
1
new
2
encoder
3
LED disagnostics
4
BiSS encoder wiring
2019
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: Carrier Module with Safe Torque Off INSM01.
This manual is supplementary to the “phyMOTIONTM Modular Multi-axis Controller for Stepper
Motors”manual.
In the manual phyMOTIONTM Modular Multi-axis Controller for Stepper Motors
(http://www.phytron.de/phyMOTION) are the descriptions of the features and specifications for the
phyMOTIONTM stepper motor controller.
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 1307-A004 EN
1 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 INSM01
4 MA 1307-A004 EN
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 in 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 1307-A004 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 insulation
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 INSM01
6 MA 1307-A004 EN
2 Contents
1Information ..............................................................................................................3
2Contents...................................................................................................................6
3INSM (Internal STO Module) –Module Overview ..................................................8
4Technical Data........................................................................................................10
4.1 Declaration of Conformity...................................................................................10
4.2 Mechanical Data.................................................................................................11
4.3 Features.............................................................................................................12
4.4 Functions............................................................................................................14
5The „Safe Torque Off“ (STO) Function .................................................................15
5.1 Safety instructions for the STO Function ............................................................15
5.2 Standards...........................................................................................................17
5.3 Safety-related Parameters..................................................................................17
5.4 Functional principle of the STO Function............................................................18
5.4.1 Technical Details.........................................................................................18
5.4.2 Connection..................................................................................................19
6Installation..............................................................................................................20
6.1 Mechanical Installation.......................................................................................20
6.2 Electrical Installation...........................................................................................22
6.2.1 Connectors - Overview................................................................................22
6.2.2 Pin Assignment............................................................................................23
6.2.3 Stepper Motor Connection X4......................................................................24
6.2.4 Limit Switch Connection X2.........................................................................26
6.2.5 Option: Encoder Connection X1...................................................................27
6.2.6 Option: Resolver, LVDT or RVDT Connection X1........................................31
7Commissioning ......................................................................................................36
7.1 Diagnostics by the LEDs.....................................................................................37
7.2 Parameterising the Module.................................................................................38
8Principles of Positioning .......................................................................................39
9Service ....................................................................................................................40
10Warranty, Disclaimer and Registered Trademarks ..............................................41
10.1 Disclaimer......................................................................................................41
10.2 Warranty........................................................................................................41
10.3 Registered Trademarks.................................................................................41

phytron
7 MA 1307-A004 EN
11Index........................................................................................................................42

Manual INSM01
8 MA 1307-A004 EN
3 INSM (Internal STO Module) –Module Overview
INSM01 is a carrier board for stepper motor power stages up to 5 APEAK with Safe Torque Off
(STO)-Function).
The STO function is suitable for applications that require an immediate interruption of the power
supply to the drive element.
The INSM module needs an Indexer (e.g. I4XM01) in front.
Two limit switches and a third switch, which can be wired as a reference switch evaluation, are
included as standard.
In addition, sub modules can be optionally selected for encoder evaluation (ECAS01, ECES01,
ECMS01, and ECBS01).
Fig. 1: INSM01 View of the front panel

phytron
9 MA 1307-A004 EN
Ordering code of the power INSM01 stage carrier module:
Ordering code (example): INSM01-APS01-ECAS01:
power stage carrier with APS power stage, with integrated SSI
encoder

Manual INSM01
10 MA 1307-A004 EN
4 Technical Data
4.1 Declaration of Conformity

phytron
11 MA 1307-A004 EN
4.2 Mechanical Data
Dimensions
100 x 100 mm (without front panel)
Weight
157 g / 134 g (without / with front panel)
Mounting
Plug-in module into the modular stepper motor controller
phyMOTIONTM
Mounting position
Vertical

Manual INSM01
12 MA 1307-A004 EN
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…70 VDC Nominal voltage: 70 VDC
Phase current
0.1 to 5 APEAK, (short-circuit-proof, overload-proof)
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,
1/32,1/64,1/128,1/256,1/512
Maximum step frequency
500,000 steps/sec.
Physical resolution
Approx. 102,400 positions per revolution
(0.00035° / step).
The optional encoder modules should be considered for very fine
positioning
Current consumption (max.)
3.6 ADC at 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)
1 A (limit switch)
Mechanical output power
up to 70 V / 5 A
Nominal power of the motor
voltage supply
100 W
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.
Diagnostics
Possibility for connection via 2 signal cables with 3.3 V logic
level:
LED1: power stage ready
LED2: error

phytron
13 MA 1307-A004 EN
Support of linear and rotary
axes
Yes
Hardware error detection
Over current, short circuit > 10 A
Over temperature T>85 °C
Interfaces
Analogue outputs
A, B, C, D for a 2 phase stepper motor
Digital inputs
24 VDC (max. 30 VDC) Safe Torque Off input
3 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 and Programming
Programming
Via Phytron‘s programming environment phyLOGICTM ToolBox
Communication
Master-slave communication. The INSM is slave and
communicates with the MCM main controller module.

Manual INSM01
14 MA 1307-A004 EN
4.4 Functions
INSM01: Integrated APS power stage with encoder as option
Relative and absolute positioning
Reference movements/ speed mode
Step frequency: up to 500,000 steps/sec.
INSM01: Integrated 5 APEAK power stage APS01
Integrated 5 APEAK / 24 to 70 VDC stepper motor power stage
Selectable step resolution up to 1/512 micro step
Online power stage parameterisation and diagnostics
STO input
Safe switching off into the torqueless state
3 Limit/reference switches
Evaluation of up to three limit/reference switches (PNP NCC/NOC)
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

phytron
15 MA 1307-A004 EN
5 The „Safe Torque Off“ (STO) Function
This chapter describes the safety function "Safe Torque Off (STO)" integrated in the INSM01
module.
The STO function is a functional safety device, i.e. it protects people from mechanical damage
when properly designed, installed and operated. This function does not disconnect the system from
the power supply.
The STO function brings the motor into the torqueless state as defined by the IEC61800-5-2
standard: "Power that can cause rotation (or movement in the case of a linear motor) is not
transmitted to the motor. The (safety-relevant) power drive system does not supply the motor with
energy that can generate torque (or force in the case of a linear motor)".
The STO function is therefore suitable for applications that require an immediate interruption of the
power supply to the drive element leading to an uncontrolled stop due to no-load (which is
activated by an STO request).
Additional protective measures must be applied if the application requires a different hold.
5.1 Safety instructions for the STO Function
WARNING –Serious injury and property damage possible!
-The use of the STO function alone does not guarantee safety. Planning
security systems requires expertise and special skills.
-Only qualified specialists may install and adjust the STO function.
-A comprehensive risk assessment is necessary to ensure that the system
put into operation is safe.
-Safety devices must be correctly integrated into the entire system, which
must be designed in accordance with all relevant standards in the
industrial sector.
WARNING –Serious injury and property damage possible!
-The information in this manual helps you to use the STO function. This
information is in accordance with generally accepted practice and the
provisions at the time of the constitution.
-It is the task of the technical planner of the end product / system to ensure
that the end system is safe and complies with the applicable regulations.
WARNING –Serious injury and property damage possible!
The STO function does not prevent unintentional starting.
-To meet these requirements, additional external components are required
in accordance with the relevant standards and application requirements.

Manual INSM01
16 MA 1307-A004 EN
WARNING –Serious injury and property damage possible!
-If the STO safety function is active, the motor cannot generate torque. This
can cause gravity-loaded axes to sink. If the motor moves when STO is
activated, it will coast uncontrolled.
-Secure gravity loaded axes with brakes or other suitable measures.
-Make sure that the motor coasting does not cause any hazards.
WARNING –Serious injury by electric shock possible!
-If the safety function STO is active, only the rotary field generation at the
motor is interrupted. High, dangerous voltages may still be present at the
motor.
-Make sure that live parts cannot be touched.
-If the supply voltage must be switched off, observe the requirements for
an emergency stop in accordance with DIN EN 60204-1.

phytron
17 MA 1307-A004 EN
5.2 Standards
The STO function is designed to be used in accordance with the following standards:
IEC 61508, parts 1-7
Functional safety of safety-related
electrical/electronic/programmable electronic systems
EN 61800-5-2
Adjustable speed electric power drive systems - Part 5-2: Safety
requirements - Functional safety
EN 62061
Safety of machinery - Functional safety of safety-related electrical,
electronic and programmable electronic control systems
ISO 13849-1
Safety of machinery - Safety-related parts of control systems -
Part 1: General principles for design
EN 954-1
Safety of machinery - Safety-related parts of control systems
IEC 60204-1
Safety of machinery - Electrical equipment of machines -
Part 1: General requirements
5.3 Safety-related Parameters
Safety function according to EN 61800-5-2
Safe Torque Off (STO)
Performance Level (PL) according to EN ISO
13849-1
Category 3, PLe
Safety Integrity Level (SIL) according to EN
61508
SIL 3
MTTFd
STO/1902 years
PFH
6 x 10–8
SFF
98 %

Manual INSM01
18 MA 1307-A004 EN
5.4 Functional principle of the STO Function
In the INSM01 module, the STO function is created by disconnecting the supply of the 24 VDC STO
input. This deactivates the motor:
Fig. 2: Functional principle
The STO input is a digital input designed for a nominal input voltage of 24 VDC, positive logic.
5.4.1 Technical Details
Max. voltage
30 VDC
Typical input current at 24 VDC
60 mA
Logic threshold
in accordance with IEC 61131-2
„1“: >18 V
„0“: <2.4 V
Switch-off time
max. 5.5 ms
The shutdown time of the STO function is the time span from the time the function is requested
until the time the system is in the safe state. For the INSM01 module the switch-off time is
max. 5.5 ms.

phytron
19 MA 1307-A004 EN
5.4.2 Connection
Fig. 3: Pin assignment STO input 2-pole Phoenix MCDN1,5/2-G1-3,5P26
WARNING –Serious injury and property damage possible!
-The STO inputs must always be controlled via a safety relay.

Manual INSM01
20 MA 1307-A004 EN
6 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”
6.1 Mechanical Installation
The INSM01 is delivered as a single module card if sent after service or repair or when an
expansion card was ordered.
In case you receive an individually packed INSM01 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.
i
CAUTION –Possible damage!
The INSM01 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.
Before integrating or switching modules always make sure that the phyMOTION™ is shut down
and the power supplies are disconnected.