phytron MCC-1 User manual

Extreme. Precision. Positioning.
MANUAL 1249-A009 EN
Programmable Stepper Motor Controller for one Axis
MCC-1

phytron
02/2019 Manual MA 1249-A009 EN
MCC-1
Programmable Stepper Motor Controller
for one Axis
TRANSLATION OF THE GERMAN ORIGINAL MANUAL

Manual MCC-1
MA 1249-A009 EN 2
Version
Modification
9
Scope of delivery and power supply unit ID
2019
All rights with:
Phytron GmbH
Industriestraße 12
82194 Gröbenzell, Deutschland
Tel.: [phone]
Fax: [phone]
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.
Please send your comments to the following email address [e-mail]
You’ll find the updated version of this manual on the website of www.phytron.de .

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Contents
1The MCC-1 Stepper Motor Controller .....4
1.1 Overview........................................4
1.2 Front View......................................5
1.2.1 Stepper Motor Power Stage.6
1.2.2 Inputs and Outputs...............6
1.2.3 Interfaces and Bus Mode .....6
1.2.4 REMOTE/LOCAL Switch R/L7
1.2.5 Reset Push-Button ...............7
1.2.6 Address Switch.....................7
1.2.7 Status-LED...........................7
1.3 Block Diagram................................8
1.4 Extend of Supply............................9
1.5 Directives and Standards.............11
1.6 Declaration of Incorporation.........12
2To Consider Before Installation.............13
2.1 Qualified Personnel......................13
2.2 Safety Instructions........................14
2.3 Ambient Conditions......................15
3Protective Measure Options..................16
4Design Requirements............................18
4.1 Electromagnetic Compatibility (EMC)
.............................................18
4.1.1 Remarks.............................18
4.1.2 EMC Measures...................18
4.2 Cables..........................................20
5Technical Data ......................................21
5.1 Mechanical Data ..........................21
5.2 Electrical Data..............................22
6Installation.............................................24
6.1 Mechanical Installation.................24
6.2 Electrical Installation ....................26
6.3 Connection of the Power Supply..26
6.3.1 X4 Power Supply I/O..........26
6.3.2 X9 Supply Voltage PWR.... 27
6.4 X8 Motor Connector.....................28
6.4.1 Stepper Motor Connection. 28
6.4.2 Wiring Schemes for 2-Phase
Stepper Motors.................................. 29
6.4.3 Motor Cable .......................30
6.5 X5 Com Communication Interface31
6.5.1 USB Interface.....................32
6.5.2 Ethernet Interface ..............33
6.5.3 RS 485 Interface................34
6.5.4 RS 232 Interface................36
6.6 Signal Interface Connection.........37
6.6.1 X1 AD Converter................37
6.6.2 X2 Limit Switch Input.......... 38
6.6.3 X3 Digital Inputs/Outputs ... 39
6.6.4 X6 Encoder Connector....... 41
6.6.5 X10 Enable-Connector....... 43
7Putting into Service and Test................45
7.1 Test the Communication between
Controller and PC.................................. 45
7.2 Test Stepper Motor, I/O, Limit Switch
..................................................46
8Programming ........................................48
8.1 LabVIEW....................................48
8.2 MiniLog........................................48
9Heating Curve of the MCC-1................. 49
10Warranty, Trade Marks and ESD Protective
Measures...................................................50
10.1 Warranty......................................50
10.2 Trade Marks................................. 50
10.3 ESD Protective Measures............50
11Index..................................................... 51

Manual MCC-1
MA 1249-A009 EN 4
1 The MCC-1 Stepper Motor Controller
1.1 Overview
MCC-1, the intelligent motion controller, is a user-friendly and compact stepper motor
control unit for two-phase stepper motors up to 3.5 APEAK motor current.
A supply voltage is required from 24 to 48 VDC, for outputs and limit switches 24 VDC.
Fig. 1: MCC-1 Stepper Motor Controller
At the front side you'll find all connectors for wiring and assembling.
The MCC-1 housing contains mounting brackets for different mounting positions on the
side and rear. One option for rail mounting with a removable clip is mounted on the rear
side.
Machine sequence controls can be programmed on PC by the MiniLog-Comm communi-
cation software. The program can be transmitted to the controller via RS- or USB
communication interface. The program will be stored and can be locally started by the
REMOTE/LOCAL switch.

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1.2 Front View
The figure below shows the layout of the connectors on the front side of the control unit.
See table:
Overview of connectors
X5 Com:
There are different connectors dependent
on the built-in PC interface card!
Please mention for all connector figures in this manual:
When the controller is placed in such position that the MCC-1 designation is at the right
upper edge, the upper pin in the drawing also is the upper pin at the device.
Fig. 2: Connector’s layout

Manual MCC-1
MA 1249-A009 EN 6
1.2.1 Stepper Motor Power Stage
The power stage of the MCC-1 controller is used for bipolar control of a stepper motor with
Phytron's welltried technology, the patented SYNCHROCHOP precision current control.
For smooth stepper motor movement, the power stage solves the motor full step into
ministep and increments up to 1/256 step.
Run current, stop current and Boost current (acceleration) can be programmed
independently up to 3.5 APEAK at 48 VDC nominal voltage.
The following errors will switch off the power stage:
Short circuit : between phase and power supply
between both motor phases
within a motor phase
against ground
Overtemperature
Undervoltage: e. g. if the voltage drops due to a weak power supply and
dynamical motor movements
1.2.2 Inputs and Outputs
The MCC-1 controller has eight digital inputs and outputs, electrically insulated and
bidirectional. The user defines by MiniLog software, which pin is connected as input or
output.
Two signal inputs can be used for connecting limit switches type PNP opener.
A joystick can be connected to the analog input.
The motor can be activated by the Enable input –independent of the incoming
control pulse signals.
The encoder inputs for step failure monitoring allow the interpretation of the encoder
signals. Incremental encoder or absolute encoder can be connected to the same X6
connector.
1.2.3 Interfaces and Bus Mode
The X5 Com communication interface is available in USB, Ethernet, RS 485(4-wire) or
RS 232 design. The controller can be connected to a PC or bus system, programmed and
tested by X5 interface.
The MCC-1 can be user-friendly programmed by MiniLog-Comm for Windows (see manual
MiniLog-Comm), included in delivery.

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1.2.4 REMOTE/LOCAL Switch R/L
1.2.5 Reset Push-Button
The Reset push-botton is mounted recessed in order to inhibit accidential operation.
Reset cancels possibly error messages.
Delay time after end of Reset signal: about 3 sec.
1.2.6 Address Switch
The logic device address can be selected by the address switch, which can be set from
0…F. Each address may only be assigned once in a bus system.
This rotary switch is only read after power on or after a reset, i.e. later changes remain
without effect during the regular operation.
1.2.7 Status-LED
The two-color LED shows the status of the device:
Green = ready, no error
Read = Error (see status window in the MiniLog-Comm software)
Orange = Busy (update of the indexer firmware)
You can select the controller's operating mode with the
REMOTE/LOCAL switch:
In REMOTE mode the MCC-1 is connected to the PC via
interface.
In this operating mode, programs edited by the customer, can
be transmitted from PC to controller and back. It is also
possible to test single instructions or to test the motor run using
the MiniLog-Comm communication software.
When switching to LOCAL the stored program will be started.
The program should be stored in the auto start register.
a) The program runs without connection to the PC.
b) Program run with connection to an external computer:
The PC can be called by the sequential program in order to
exchange actual data.
Fig. 3: REMOTE/LOCAL
switch

Manual MCC-1
MA 1249-A009 EN 8
1.3 Block Diagram
This block diagram shows a simplified layout. You’ll find details, e.g. pin assignments in
the corresponding chapters.
Fig. 4: Block diagram

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1.4 Extend of Supply
The MCC is available in the following options ( #: Ident number):
MCC-1 Motion-Controller with mating connector
with USB interface for wall mounting
#10009856
with USB interface for rail mounting
#10007555
with RS 485 interface for wall mounting
#10009857
with RS 485 interface for rail mounting
#10009799
with RS 232 interface for wall mounting
#10009859
with RS 232 interface for rail mounting
#10009858
with USB converter, RS 485 interface for wall mounting
(cable A-A 20 cm included)
#10009861
with USB converter, RS 485 interface for rail mounting
(cable A-A 20 cm included)
#10009860
Included in delivery:
Mating connector
Fig. 5: MCC-1 with USB converter and RS 485 interface

Manual MCC-1
MA 1249-A009 EN 10
Supplementary parts are available:
Rail mounting kit #10007882
Mating connector kit (X1 to X4, X6, X8 to X10) #10007554
Cable (connection A-A) 20 cm #10006857
Cable (connection A-A) 100 cm #10006880
USB cable (connection A-B) 200 cm #10006881
USB-485 converter stick #10012292
Power supply unit SPH 240-4805 (5 A, 48 V) for wall mounting #10015426
Power supply unit SPH 240-4805 (5 A, 48 V) for rail mounting #10015427
Power supply unit SPH 240-2410 (10 A, 24 V) for wall mounting #10015394
Power supply unit SPH 240-2410 (10 A, 24 V) for rail mounting #10015320

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1.5 Directives and Standards
CE Mark
With the declaration of conformity and the CE Mark on the
product the manufacturer certifies that the product complies
with the requirements of the relevant EC directives. The unit,
described here, can be used anywhere in the world.
EC Machine Directive
The drive system, described here, isn´t a machine in the sense
of the EC machine directive (2006/42/EC), but a component of
a machine for installation. They have no functional moving
parts. But they can be part of a machine or equipment. The
conformity of the complete system in accordance with the
machine guideline is to be certified by the manufacturer with
the CE marking.
EC EMC Directive
The EC Directives on electromagnetic compatibility
(2014/30/EU) applies to products, which can cause
electromagnetic interference or whose operation can be
impaired by such interference.
The controller’s compliance with the EMC Directive cannot be
assessed until it has been installed into a machine or
installation. The instructions provided in “Installation” must be
complied with to guarantee that the MCC-1 is EMC compliant
when fitted in the machine or installation and before use of the
device is permitted.
Standards for safe
operation
EN 60204-1: 2007-6: Electrical equipment of machines,
degree of pollution 2 must be observed
EN 60529: 2014-09: IP Degree of protection
Standards for
observing the EMC
limit values
EN 61000-3-2: EMC
EN 61000-6-1, 3, 4: Emission standard
EN 61000-6-2:2005: EMC Immunity for industrial environments
Standards for
measuring methods of
observing EMC limit
values
EN 55011 class B: Noise field and voltage measuring
EN 61000-4-2...6,11: Emission standard test

Manual MCC-1
MA 1249-A009 EN 12
1.6 Declaration of Incorporation

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2 To Consider Before Installation
Read this manual very carefully before installing and operating the MCC-1.
Observe the safety instructions in the following chapter!
2.1 Qualified Personnel
Design, installation and operation of systems using the MCC-1 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
planned.
The trained personnel must know all valid standards, regulations and rules for the
accident prevention, which are necessary for working with the product.
WARNING
Without proper training and qualifications damages to devices and injury might
result!

Manual MCC-1
MA 1249-A009 EN 14
2.2 Safety Instructions
i
The MCC-1 is designed for operating as a wall or rail mounting device.
An installation is only allowed, if the requirement of the EC Machine Directive and
EMC are conformed with. See chap. 1.6.
i
This product is used as a part of a complete system, therefore risk evaluations
must be made before the use of the product regarding the concrete application.
According to the results safety measures have to be taken and verified.
Personnel safety must be ensured by the concept of this complete system (e.g.
machine concept).
WARNING
Injury or damage by overvoltage!
The MCC-1 must only be operated in accordance with the protective measures in
chap. 3.
CAUTION
Risk of damage by false motor current setting!
In case of motor voltages > 24 V:
The controller must only be operated if the unit and the motor housing both are
connected to protective ground.
CAUTION
Risk of damage by not fixed cables!
Motor cables and motor supply cables should be fixed to the device by the cable
clamps at the front side.
DANGER
Danger of electric shock!
Be careful handling the X8 screw connectors.
As long as the power stage is connected to supply voltage, a hazardous voltage
level is present at these components, even if the motor is not wired. Up to 3
minutes after turning off the supply voltage, dangerous voltages may still exist at
the connectors.
The instrument setting (e. g. motor current) must only be done while separated
from the power supply with a special instrument.

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DANGER
Danger of electric arching!
Always switch off the supply voltage before connecting or disconnecting any
wires or connectors at the MCC-1.
Do not unplug the connector while powered!
i
Please consider when connecting the X10 Enable connector:
Both Enable inputs must be wired for activation!
DANGER
Danger of touch voltage!
To avoid dangerous touch voltages, all voltages should be safely separated from
the mains. The maximum voltage limits are the specified values of the
corresponding chapters.
WARNING
Danger of injury if touching the surface!
The surface of the MCC-1 reaches temperatures more than 75 °C during
operation.
The controller has to be deactvated at temperatures more than 75 °C.
2.3 Ambient Conditions
Installation
wall or rail mounting
Permissible ambient
temperature
operation: 5 to 50 °C
storage: –10 to +60 °C
transport: –10 to +60 °C
Permissible heat sink
temperature
max. 75 °C
heating curve see chap. 9
Relative humidity
ambient conditions: class 3K3 acc. to
EN 60721-3-3:1995-09: 5% ... 85%, no condensation
permissible
Degree of pollution
stage 2
Device protection
degree of protection acc. to DIN 60529:2014-09: IP 20

Manual MCC-1
MA 1249-A009 EN 16
3 Protective Measure Options
The control unit must be operated by the protective measure PELV acc. to VDE 0100.
Board and motor housing have to be grounded and/or connected to 0 V.
Various options are possible to achieve the protective measure PELV:
Fig. 6: PELV –Grounding: total
Fig. 7: PELV –Grounding: Power Stage and Motor.
The secondary winding of the transformer (SELV supply) must not be grounded
because the equipment is grounded.
Fig. 8: PELV –Grounding: 0 V and Motor

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If there is no PE clamp on the motor, the 0 V wire must be grounded to complete the
protective measure PELV (Fig. 9 and Fig.10):
Fig. 9: PELV –Grounding: 0 V and Controller
Fig. 10: PELV –Grounding: 0 V
Protective measure PELV for application of the +UBshould not exceed 70 VDC
or 50 VAC at dry environment (environmental conditions 3 acc. to IEC 61201).
It is essential for MCC: +UB48VDC.
The supply transformer must be constructed with reinforced or double
insulation between supply and secondary winding (acc. to EN 61558).
Only use motors which are checked acc. to EN 60034-1 (500 VAC/1 minute).

Manual MCC-1
MA 1249-A009 EN 18
4 Design Requirements
4.1 Electromagnetic Compatibility (EMC)
4.1.1 Remarks
WARNING
Risk of injury by interference of signals and devices!
Perturbed signals can cause equipment to react unexpectedly.
• Connect the controller to the EMC requirements.
• In electrically noisy environments ensure the correct execution of the EMC
measures. Disregarding these precautions can cause death, serious injuries
or material damages.
4.1.2 EMC Measures
EMC Measures
Effect
Device
Mounting
Use cable clamps for shielding, connect
metallic parts at a large area.
Good conductivity due
to planar contacts.
Connect the housing via cable diameter
more than 2 mm2with potential equalisation.
Reduction of mutual
interference.
Fit switching devices such as contactors,
relays or solenoids with interference or
spark suppressors (e. g. diodes, varistors,
RC elements).
Cabling
Keep cables as short as possible.
No “safety loops“.
Avoidance of capacitive
and inductive
interference
Connect the shielding of all shielded cables
to the housing by the cable clamps to a
large area.
Reduction of EMC
emissions.
Lay the cables spatially separated from
each other (distance at least 20 cm):
signal and power cables
power and master cables
line filter input and output cable
Avoidance of mutual
interference

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Ground a large surface area of the
shieldings of digital signal cables.
Stray interference on
control cables,
reduction of emissions.
Power Supply
Protective circuit to mitigate over voltage or
lightning strikes.
Protection of damage
by over voltage.
Preset for EMC: Motor cable
The motor cable is a source of interference and must be carefully laid.
Use the cables recommended by Phytron. They are tested for EMC safety and are
suitable for movement.
The motor and the encoder cable of the driving system must be connected to a large
surface area of the output of the control cabinet and the motor with a low resistance.
The PE lead (green/yellow) of the motor cable should be fixed at the earthing screw
below the MCC-1 motor connector.
The PE lead at the motor side of the cable should be fixed at the motor's earthing
screw.
For EMC compliant wiring it is important to conductively connect the motor cable
shielding mesh with the controller housing. Use the cable clamps at the bottom and
the top side of the MCC-1. Remove the external cable sheath in that range of the
cable where you fix it with one of the cable clamps.
The cables connecting motor and controller should not be interrupted (e.g. by
connectors).
At the motor side the cable's shielding mesh should be connected to the motor
housing at a large area. We recommend to use special EMC type conduit fittings.
In case of motors without adapted conduit fittings the cable shielding must be
connected as near to the motor as possible and has to be applied to PE.
Potential equalization cables
Connect the shielding on all sides for protection from interference.
The difference of potential can cause incorrect currents on the shielding and must be
avoided by potential equalization cables.