phytron MCC-2 User manual

Extreme. Precision. Positioning.
MANUAL 1235-A016 EN
Programmable Stepper Motor Controller for Two Axis
MCC-2

phytron
6/2018 Manual 1235-A016 EN
MCC-2
Programmable Stepper Motor Controller
for Two Axes
TRANSLATION OF THE GERMAN ORIGINAL MANUAL

Manual MCC-2
MA 1235-A016 EN 2
Version Modification
16 Flash memory lifetime
15 MCC-2 in the sheet housing
14 SSI protocol options (p. 41)
Profibus was taken out of MCC-2
13 Profibus
12 Labview
11 Temperature behaviour
10 Design review
2018
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. You find the updated version of this manual on the website of www.phytron.de.
We appreciate suggestions and criticisms for further improvement. Please send your
comments to the following email address: dok[email protected]

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Contents
1The MCC-2 Stepper Motor Controller ....... 4
1.1 Overview............................................. 4
1.2 Structure of the Device........................ 5
1.2.1 Stepper Motor Power Stages ........... 6
1.2.2 Inputs and Outputs........................... 6
1.2.3 Interfaces and Bus Mode.................. 7
1.2.4 REMOTE/LOCAL-Switch R/L ........... 7
1.2.5 Reset Push-Button ........................... 7
1.2.6 Address Switch ................................ 8
1.2.7 Status LED....................................... 8
1.3 Block Diagram..................................... 8
1.4 Extent of Supply.................................. 9
1.5 Accessories: Operator Panel.............. 11
1.6 Directives and Standards ................... 12
1.7 Declaration of Incorporation ............... 13
2To Consider Before Installation ............... 14
2.1 Qualified Personnel............................ 14
2.2 Safety Instructions ............................. 15
2.3 Ambient Conditions............................ 16
3Protective Measure Options .................... 17
4Design Requirements .............................. 19
4.1 Electromagnetic Compatibility (EMC) . 19
4.1.1 Remarks.......................................... 19
4.1.2 EMC Measures ............................... 19
4.2 Cables................................................ 21
5Technical Data ........................................ 22
5.1 Mechanical Data ................................ 22
5.2 Electrical Data.................................... 23
6Installation ............................................... 25
6.1 Mechanical Installation....................... 25
6.2 Electrical Installation .......................... 27
6.3 Connection of the Power Supply ........ 27
6.3.1 X4 Power Supply I/O ....................... 27
6.3.2 X9 Supply Voltage PWR .................. 28
6.4 X7/X8 Motor Connector ......................29
6.4.1 Stepper Motor Connection ...............29
6.4.2 Wiring Schemes for 2-Phase Stepper
Motors.......................................................30
6.4.3 Motor Cable ..................................... 31
6.5 X5 Com Communication Interface ...... 32
6.5.1 Ethernet Interface ............................34
6.5.2 RS 485 Interface..............................35
6.5.3 RS 232 Interface..............................37
6.6 Signal Interface Connection................ 38
6.6.1 X1 AD Converter..............................38
6.6.2 X2 Limit Switch Input .......................39
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(s), I/Os and Limit
Switches ......................................................46
8Programming ...........................................48
8.1 LabVIEW..........................................48
8.2 MiniLog...............................................48
9Heating Curve of MCC-2..........................49
10 Warranty, Trade Marks and Protective
Measures ......................................................51
10.1 Warranty............................................. 51
10.2 Trade Marks ....................................... 51
10.3 ESD Protective Measures................... 51
11 Index........................................................52

Manual MCC-2
MA 1235-A016 EN 4
1 The MCC-2 Stepper Motor Controller
1.1 Overview
MCC-2, 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 with 24 to 48 V
motor voltage.
Fig. 1: Front view
At the front side you'll find connectors for wiring supply voltages, stepper motors, inputs
and outputs.
Machine sequence controls can be programmed on PC by the MiniLog-Comm communi-
cation software. The ready program can be transmitted to the controller via X5
communication interface. The program will be stored and can be locally started by the
REMOTE/LOCAL switch.
MCC-2 and stepper motors need a DC power supply from 24 to 48 VDC.
A separate 24 VDC supply voltage is required for the outputs and limit switches.
The MCC-2 housing contains mounting brackets for different mounting positions. A clip for
rail mounting is mounted on the rear side.

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1.2 Structure of the Device
The figure below shows the layout of the connectors on the MCC-2 front side.
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-2 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-2
MA 1235-A016 EN 6
1.2.1 Stepper Motor Power Stages
A power stage is built-in for each axis. The power stages are used for bipolar control of
two-phase stepper motors with Phytron's welltried technology, the patented
SYNCHROCHOP precision current control.
For smooth stepper motor movement, the power stages solve the motor full step into incre-
ments 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
dynamic motor movements
1.2.2 Inputs and Outputs
MCC-2 can be regarded as independent machine controller because of eight digital inputs,
which are electrically separated from the sequential controller, and eight overload-safe
outputs.
Two signal inputs of each axis can be used for connecting type pnp-NCC (default) or pnp-
NOC limit switches.
A joystick can be connected to the analog input X1.
Additional safety requirement was considered during development, because the MCC-2
was designed for applications in the domain of medical devices:
The motors can be activated by the Enable input – independent of the incoming
control pulse signals (X10).
The encoder inputs for step failure monitoring allow the interpretation of the encoder
signals. Incremental encoder or absolute encoder acc. to SSI-standard can be
connected to the same connector (X6).

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1.2.3 Interfaces and Bus Mode
The X5 Com communication interface is available with USB, RS 485(4-wire), RS 232, or
Ethernet layout. The following possibilities are accessible by interface:
•Controller and motor parameter programming
•Controller configuration by software
•Online diagnostics for safe operation and easy maintenance
•Test mode and status information
•Firmware update
•Controller communication via Ethernet
The MCC-2 can be programmed user-friendly by MiniLog-Comm for Windows (see manual
MiniLog-Comm).
1.2.4 REMOTE/LOCAL-Switch R/L
You can select the controller's operating mode with the REMOTE/LOCAL switch:
REMOTE: The controller 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. In the REMOTE mode it is also possible to test single
instructions or to test the motor run using the MiniLog-Comm
communication software.
LOCAL: 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.
1.2.5 Reset Push-Button
The Reset push-button above the REMOTE/LOCAL switch is mounted recessed in order
to inhibit accidential operation.
Reset cancels possibly error messages.
Delay time after end of Reset signal: about 3 sec.

Manual MCC-2
MA 1235-A016 EN 8
1.2.6 Address Switch
The logic device address can be selected by the address switch and set from 0…F.
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
•red •= Error (see status window in the MiniLog-Comm software)
•orange •= Busy (update of the indexer firmware)
1.3 Block Diagram
This block diagram shows a simplified layout. You’ll find details, e. g. pin assignments in
the corresponding chapters.
Fig. 3: Block diagram

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1.4 Extent of Supply
The MCC is available in the following options ( #: Ident number):
•MCC-2 Motion-Controller with mating connector kit
with USB interface for wall mounting (W) #10021228
with USB interface for rail mounting (H) #10021216
with RS 485 interface for wall mounting #10021224
with RS 485 interface for rail mounting #10021215
with RS 232 interface for wall mounting #10021219
with RS 232 interface for rail mounting #10021213
with RS 232 interface for wall mounting with RS 232 adaptor #10008788
with Ethernet connection for wall mounting #10021217
with Ethernet connection for rail mounting #10021212
Included in delivery:
•MCC-2 Manual
•MiniLog Programming Manual
•MiniLog-Comm Manual
•Phytron CD with MiniLog-Comm software
Fig. 4: MCC-2 with USB converter and RS 485 interface

Manual MCC-2
MA 1235-A016 EN 10
Supplementary parts are available:
•Rail mounting kit #02005659
•Mating connector kit (X1 to X4, X6 to X10) #10005871
•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 SPH240-4805 (5 A, 48 V) for wall mounting #10015426
•Power supply unit SPH240-4805 (5 A, 48 V) for rail mounting #10015427
•Power supply unit SPH240-2410 (10 A, 24 V) for wall mounting #10015394
•Power supply unit SPH240-2410 (10 A, 24 V) for rail mounting #10015320

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1.5 Accessories: Operator Panel
A MCC-2 with RS 232 adaptor is used for operator panel connection (e.g. BT 5). The
terminal is connected to the RS 232 connector of the adaptor.
You'll find the description of the operator panel in Phytron's manual 'Operator Panel BT 5'.
Fig. 5: MCC-2 with RS 232 adaptor
Then, enabled functions can be used by the operator personnel without PC: for example:
selection of another program or change of the piece numbers, length.
The operator panel can display textual data or error messages on demand. The function
keys on the operator panel are labeled individually and defined by the controller's
programmer.
More functions can be added in the expert mode like input of drive instructions, setting of
outputs or display of status messages.
Fig. 6: MCC-2 cable BT 5
The MCC-2’s baud rate should be scaled down to 38400 for using the operator
panel.

Manual MCC-2
MA 1235-A016 EN 12
1.6 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-2 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

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1.7 Declaration of Incorporation

Manual MCC-2
MA 1235-A016 EN 14
2 To Consider Before Installation
Read this manual very carefully before installing and operating the MCC-2.
Observe the safety instructions in the following chapter!
2.1 Qualified Personnel
Design, installation and operation of systems using the MCC-2 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!

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2.2 Safety Instructions
i
The MCC-2 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-2 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 screw connectors X7/X8.
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.
DANGER
Danger of electric arching!
Always switch off the supply voltage before connecting or disconnecting any
wires or connectors at the MCC-2.
Do not unplug the connector while powered!

Manual MCC-2
MA 1235-A016 EN 16
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-2 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: 5% ... 85%, no condensation
permissible
Degree of pollution stage 2
Device protection degree of protection acc. to DIN EN 60529:2014-09 IP 20

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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. 7: PELV – Grounding: total
Fig. 8: PELV – Grounding: Power Stage and Motor.
The secondary winding of the transformer (SELV supply) must not be grounded
because the equipment is grounded.
Fig. 9: PELV – Grounding: 0 V and Motor

Manual MCC-2
MA 1235-A016 EN 18
If there is no PE clamp on the motor, the 0 V wire must be grounded to complete the
protective measure PELV (Fig. 10 and Fig.11):
Fig. 10: PELV – Grounding: 0 V and Controller
Fig. 11: 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≤48 VDC.
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).

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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