phytron phyMOTION PIDM01.1 User manual

phytron
8/2019 Manual MA 1311-A001 EN
phyMOTIONTM
PID Controller Module
PIDM01.1
Firmware Version:
V1.0.1 (Loader)
V1.0.5 (System)
TRANSLATION OF THE ORIGINAL GERMAN MANUAL

Manual PIDM01
MA 1311-A001 EN 2
2019
All rights with:
Phytron GmbH
Industriestraße 12
82194 Gröbenzell, Deutschland
Tel.: [phone]
Fax: [phone]
Intention of the manual:
In this manual, you will find descriptions and specifications of the phyMOTIONTM module:
Digital Input and Output Module PIDM01.
This manual is a supplementary volume to the operating instructions
phyMOTIONTM Modular Multi-axis Controller for Stepper Motors
In the manual phyMOTIONTM Modular Multi-axis Controller for Stepper Motors
(https://www.phytron.eu) 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: [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.eu/) in
your local agencies.

phytron
3 MA 1311-A001 DE
1 Legal Instructions
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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 PIDM01
MA 1311-A001 EN 4
Observe the following safety instructions!
Qualified personnel
WARNING –Serious injury possible!
Insufficiently trained personnel could cause serious personal injury or serious
damage to the machine and drives!
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.

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5 MA 1311-A001 EN
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.
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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).
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 is
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 PIDM01
MA 1311-A001 EN 6
2 Contents
1Legal Instructions ..................................................................................................3
2Contents..................................................................................................................6
3PIDM01 Module Overview......................................................................................7
4Technical Data........................................................................................................8
4.1 Declaration of Conformity...................................................................................8
4.2 Mechanical Data...............................................................................................10
4.3 Features...........................................................................................................11
4.4 Functional Description......................................................................................13
5Installation............................................................................................................14
5.1 Mechanical Installation of the PIDM01 Module.................................................14
5.2 Electrical Installation.........................................................................................16
5.2.1 Connectors - Overview..............................................................................16
5.2.2 Pin Assignment..........................................................................................17
5.2.3 Input Wiring ...............................................................................................18
5.2.4 Output Wiring.............................................................................................18
5.2.5 Measuring Inputs for Temperature Sensors...............................................19
6PID Control ...........................................................................................................21
6.1 Terms for PID Control.......................................................................................22
6.2 Temperature Control Example..........................................................................23
6.3 phyLOGICTM Commands for Temperature Control ...........................................24
6.4 Description of the Control Algorithm.................................................................25
7Commissioning ....................................................................................................26
7.1 Diagnostics by the LEDs...................................................................................27
7.2 Parameterising of the Modules.........................................................................28
8Service ..................................................................................................................29
9Warranty, Disclaimer and registered trademarks ..............................................30
9.1 Disclaimer ........................................................................................................30
9.2 Warranty...........................................................................................................30
9.3 Registered trademarks .....................................................................................30
10Index......................................................................................................................31

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7 MA 1311-A001 EN
3 PIDM01 Module Overview
PIDM stands for “Proportional Integral-Derivative Controller Module“and is set for the
modular stepper motor control unit phyMOTIONTM. The PIDM01 module is activated by the
main controller module (MCM) and functions as an independent PID controller with PWM
output.
Fig. 1: PIDM01 front view of the panel
Inputs and outputs:
4 analogue measuring inputs for Pt100 sensor or thermocouple type K
4 digital inputs 24 VDC
4 digital outputs 24 VDC, max. 1 A
internal 24 VDC power supply to the inputs and outputs when centrally delivered from
the supply module POWM
external 24 VDC power supply of the inputs and outputs when delivered directly to
the PIDM module. Condition: external power supply = internal power supply + 1 V.

Manual PIDM01
MA 1311-A001 EN 8
4 Technical Data
4.1 Declaration of Conformity

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9 MA 1311-A001 EN

Manual PIDM01
MA 1311-A001 EN 10
4.2 Mechanical Data
Dimension
100 x 100 mm without front panel
Weight
56 g without and 79 g with front panel
Mounting
Plug-in module into the modular stepper motor controller
phyMOTIONTM
Mounting position
vertical

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11 MA 1311-A001 EN
4.3 Features
Features
Main controller
Modular controller phyMOTIONTM
Power supply
- 24 VDC internal via central entry point from the
POWM module
- 24+1 VDC external directly to the PIDM01 module
- 5 VDC internal
Current consumption
(max.)
24 VDC supply:
- internal: 2 A for the complete PIDM01 module if it is
supplied via the central entry point for the POWM
- external: 4 A for the complete PIDM01 module if it is
supplied directly to the PIDM01 module
5 VDC internal:
- 30 mA per temperature module
- 10 mA (24 VDC I/O)
Cable length –digital
inputs
30 m
if longer (100 m max.) use shielded cable and contact shield
close to the controller.
Status LEDs
see chap. 7
Interfaces
4 digital inputs
I1 to I4
Input level: 24 VDC
Switching threshold: about. 2.4 VDC
Electrical isolation via optocoupler
Switching frequency max.: 50 kHz
Protected against over voltage up to 35 VDC
Analogue measuring
inputs
Temperature evaluation
- thermocouple type K (needs sub module: KTS01)
- PT100 sensor (needs sub module: PTS01)

Manual PIDM01
MA 1311-A001 EN 12
4 digital (PID control)
outputs
O1 to O4
Output level:
24 VDC for internal power supply
with external supply: external supply –1 V
Output current max.: 1 A per output
Total output current:
2 A for internal power supply
4 A for external power supply
Short circuit proof
Thermal overload protection
Switching frequency max.: 1 kHz
24 VDC supply
24 VDC internal and 2 A max. at the central supply via the
delivering modules POWM.
30 VDC external and 4 A max. when delivered directly to the
PIDM module The external power supply must always be
higher than the internal power supply.
Rear bus connection
Proprietary Phytron bus
Communication and Programming
Programming
Via Phytron’s programming environment phyLOGICTM
ToolBox
Communication
Master slave communication from the MCM to the PIDM01

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13 MA 1311-A001 EN
4.4 Functional Description
Inputs and outputs:
analogue measuring inputs for Pt100 sensor or thermocouple type K
digital inputs 24 VDC
digital outputs 24 VDC, max. 1 A
internal 24 VDC supply to the inputs and outputs when centrally delivered from the
supply modules POWM
external 24 VDC supply of the inputs and outputs when delivered directly to the
PIDM01. Condition: external power supply = internal power supply + 1 V.

Manual PIDM01
MA 1311-A001 EN 14
5 Installation
5.1 Mechanical Installation of the PIDM01 Module
Phytron always delivers the phyMOTIONTM completely assembled in order to make sure
you can start with the installation and the wiring right way.
Further Manual
Detailed information on this subject is in a supporting manual:
“phyMOTIONTM Modular Multi-axis Controller for Stepper Motors”
The PIDM01 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 PIDM01 as an expansion module or after repair
or service unpack the module in ESD protected area only.
CAUTION –Possible damage!
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.
Identify the correct slot position for the referring to your order and documentation. The
PIDM01 needs at least a POWM01 module and a MCM01 module on somewhere its left
side.
Before you install or replace modules, make sure that the phyMOTIONTM is unplugged.

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15 MA 1311-A001 EN
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 is
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.
Push the module card carefully into the guide rail until the rear contacts the housing’s
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 PIDM01
MA 1311-A001 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
I/O
2x4
MCDN1,5/8-G1-
3,5P26
FMC1,5/8-ST-3,5
10005881
Power supply
2x2
MCDN1,5/2-G1-
3,5P26
FMC1,5/2-ST-3,5
10007077
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.

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17 MA 1311-A001 EN
5.2.2 Pin Assignment
Here is the pin assignment of the PIDM01:
Fig. 2: Pin assignment
For wiring use the above-defined mating connectors, please.

Manual PIDM01
MA 1311-A001 EN 18
5.2.3 Input Wiring
Switching threshold
2.4 V
Fig. 3: Input wiring
5.2.4 Output Wiring
Fig. 4: Output wiring
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CAUTION –Possible damage!
Damage of the module because of incorrect connection.
- Do not swap the 4-pin connector for the four inputs with the 4-pin
connector for the outputs.

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19 MA 1311-A001 EN
5.2.5 Measuring Inputs for Temperature Sensors
The temperature evaluation module is used for monitoring the stepper motor temperature
or it is used to build up a control loop.
Depending on the selected evaluation module (KTS01 or PTS01), thermal elements type K
or platinum sensors PT100 can be used.
The insulated temperature sensor in Phytron motors is integrated in the motor windings.
The response time is very short, compared to temperature sensors mounted outside the
motor housing. The temperature is measured all the time, even if only one motor phase is
powered at any one time.
Thermocouple type K
With the Type K (NiCr-Ni) in-vacuum and cryo stepper motors, thermal elements in the
temperature range from –270 to +1370 °C, accuracy class 1, are used.
The Type K is a metal thermocouple with nickel-based alloy conductors. Temperature
ranges, accuracy and characteristics of thermal elements for industrial use are defined in
the IEC 584 standard (temperature measuring with thermal elements).
Fig. 5: K element connection
Principle of the stepper motor temperature measurement by element type K:
Fig. 6: Sample form

Manual PIDM01
MA 1311-A001 EN 20
An accurate temperature can only be measured when the temperature at the reference
junction (connector) is exactly known. This is not possible by the connection construction
and und can cause indeterminate deviations of the temperature values.
Software evaluation of the measuring values from -180 °C to +260 °C.
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CAUTION –Possible damage!
Damage of the module by wrong connection or wire break.
- Check the integrity of the element type K and the correct
phyMOTIONTM connection before motor temperature measurement.
An improperly connected or broken wire can result a wrong
temperature evaluation and thus a damage of the motor or other
system components by overheating.
Pt100 Resistor Sensor
Pt100 resistor sensors are used with in-vacuum and cryo stepper motors in the
temperature range –200 to +300 °C.
These precise sensors are used in extreme industrial and laboratory conditions. They
consist of a wound resistance wire that is mounted and unsupported inside a cylindrical
ceramic case.
Fig. 7: Pt100 connection
Principle of the stepper motor temperature measurement by Pt100 resistor sensors:
The PTS generates a constant current between I+ and I-. This current generates a voltage
drop at the Pt100 that is measured at Sens+ and Sens-. The Pt100 sensors are connected
with four leads in order to enable measuring independent of the wire resistance.
Software evaluation of the measuring values from -220 °C to +390 °C.