phytron phyMOTION INAM01.1 Repair manual

phytron
7/2015 Manual MA 1275-A004 EN
phyMOTIONTM
Power Stage Carrier Module INAM01.1 and
1-Axis Module INAM02.1
TRANSLATION OF THE GERMAN ORIGINAL MANUAL

Manual INAM01 / INAM02
MA 1275-A004 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: Carrier Module for APS Power Stage INAM01 and INAM02
(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.

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3 MA 1275-A004 EN
1 Information
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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 INAM01
MA 1275-A004 EN 4
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.
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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).

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5 MA 1275-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 INAM01
MA 1275-A004 EN 6
2 Contents
1Information.................................................................................................................3
2Contents.....................................................................................................................6
3INAM Module Overview.............................................................................................7
4Technical Data...........................................................................................................9
4.1Declaration of Conformity: Modules gen. & External Supply EXT.........................9
4.2 Declaration of Conformity: Modules with Internal Supply INT..............................11
4.3 Mechanical Data...................................................................................................13
4.4 Features...............................................................................................................14
4.5 Functions..............................................................................................................16
5Installation ................................................................................................................17
5.1 Mechanical Installation.........................................................................................17
5.1.1 INAM01 .........................................................................................................17
5.1.2 INAM02 .........................................................................................................18
5.2 Electrical Installation.............................................................................................19
5.2.1 Connectors - Overview..................................................................................19
5.2.2 Pin Assignment .............................................................................................20
5.2.3 Stepper Motor Connection X5.......................................................................21
5.2.4 Limit Switch Connection X2...........................................................................26
5.2.5 Option: Encoder Connection X1....................................................................27
5.2.6 Option: Resolver, LVDT or RVDT Connection X1........................................30
5.2.7 Option: Motor Temperature Sensor Connection X3/X4.................................36
6Commissioning ........................................................................................................39
6.1 Diagnostics by the LEDs......................................................................................40
6.2 Parameterising the Module ..................................................................................41
7Principles of Positioning.........................................................................................42
8Service.......................................................................................................................43
9Warranty, Disclaimer and Registered Trademarks...............................................44
9.1 Disclaimer.............................................................................................................44
9.2 Warranty...............................................................................................................44
9.3 Registered Trademarks........................................................................................44
10Index..........................................................................................................................45

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7 MA 1275-A004 EN
3 INAM Module Overview
INAM stands for internal Amplifier (Power Stage) module. INAM01 is a carrier board for stepper
motor power stages (up to 5 APEAK max.) or the APS01 power stage (as a sub module). INAM02 is
a 1-axis module for the integrated MSX power stage (up to 15 APEAK max.). The INAM02 is only
available in phyMOTIONTM configurations with integrated power supply INT.
Both INAM modules need 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 as well as motor temperature evaluation (PTS01 and KTS01).
Fig. 1: INAM01 / INAM02 View of the front panel

Manual INAM01 / INAM02
MA 1275-A004 EN 8
Ordering code of the 1 axis stepper motor drive module (INAM01):
Ordering code (example): INAM01-ECES01-PTS01:
1 axis stepper motor drive module with integrated encoder
and Pt sensor
Ordering code of the 1 axis stepper motor drive module (INAM02):
Ordering code (example): INAM02-MSX-ECAS01-PTS01:
Module with connected MSX power stage, integrated encoder and Pt sensor

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4 Technical Data
4.1 Declaration of Conformity: Modules gen. & External Supply EXT

Manual INAM01 / INAM02
MA 1275-A004 EN 10

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4.2 Declaration of Conformity: Modules with Internal Supply INT

Manual INAM01 / INAM02
MA 1275-A004 EN 12

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4.3 Mechanical Data
Dimensions 100 x 100 mm (without front panel)
Weight INAM01: 94 g / 71 g (without / with font panel)
INAM02: 75 g / 52 g (without / with font panel)
Mounting Plug-in module into the modular stepper motor controller
phyMOTIONTM
Mounting position Vertical

Manual INAM01 / INAM02
MA 1275-A004 EN 14
4.4 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 with APS
with MSX
24…70 VDC Nominal voltage: 70 VDC
70…120 VDC Nominal voltage: 120 VDC
Phase current with APS
with MSX
0.1 to 5 APEAK, (short-circuit-proof, overload-proof)
0.8 to 15.4 APEAK
Current adjustment with APS
with MSX
10 mA steps
10 / 20 / 30 mA steps (dep. on the MSX type)
Step resolutions with APS
with MSX
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
Full step, half step,1/4, 1/5, 1/10, 1/20
Maximum step frequency with APS
with MSX
500,000 steps/sec.
500,000 steps/sec
Physical resolution with APS Approx. 102,400 positions per revolution (0.00035°
/ step). The optional encoder modules should be
considered for very fine positioning.
with MSX about 4000 (0.09° / step)
Current consumption (max.) with APS
with MSX
3 ADC at 5 APEAK
3 / 6 / 10 ADC at 15 APEAK
(dep. on the MSX type)
Mechanical output power with APS
with MSX
Up to the 250 W range
about 300 / 600 / 1200 W (dep. on the MSX type)
Nominal power of the motor
voltage supply with APS
with MSX
100 W
500 W
Cable length – motor Shielded: 50 m max.

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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
Features
Support of linear and rotary
axes Yes
Hardware error detection with APS
with MSX
Over current, short circuit > 10 A
Over temperature T>85 °C
Over current, short circuit > 8.4 / 16.8 / 25.2 A
(dep. on the MSX type)
Over temperature T>85 °C
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)

Manual INAM01 / INAM02
MA 1275-A004 EN 16
4.5 Functions
INAM01: Integrated APS power stage with encoder and temperature module as
option
INAM02: Connected MSX power stage with encoder and temperature module as
option
•Relative and absolute positioning
•Reference movements/ speed mode
•Step frequency up to 500,000 steps/sec. with APS or MSX
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
INAM02 INT: Verbundene 15,4 APEAK Endstufe MSX
•15.4 APEAK / 70 or 120 VDC stepper motor power stage
•Selectable step resolution up to 1/512 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 resolvers/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.

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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
5.1.1 INAM01
In case you receive an individually packed INAM01 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.
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CAUTION – Possible damage!
The INAM01 module is designed for a maximum supply voltage of 48 VDC. If it is
supplied with >48 VDC the card might be damaged.
- Make sure that a power module (POWM01, POWM02) is supplied on the left
with less than 48 VDC to avoid damage.
Before integrating or switching modules always make sure that the phyMOTION™ is shut down
and the power supplies are disconnected.

Manual INAM01 / INAM02
MA 1275-A004 EN 18
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 INAM01 referring to your order and documentation. The
INAM01 needs at least a preceding power module (POWM01, POWM02), the main controller
module (MCM01) and an additional indexer (EXAM01).
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.
5.1.2 INAM02
The INAM02 module is only installed in phytron’s plant.

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19 MA 1275-A004 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 labeling 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
INAM01:
Motor (X5) 1x4 IC 2,5/4-G-5,08 IC 2,5/4-ST-5,08 10005390
INAM02:
Motor (X5) 1x4 IC 2,5 HC/ 4-G-5,08 FKIC 2,5 HC/4-ST- 5,08 10015856
Limit switches
(X2) 1x10 MCDN1,5/10-G1- 3,5P26 FMC1,5/10-ST-3,5 10013217
Encoder (X1) 1x10 MCDN1,5/10-G1-
3,5P26 FMC1,5/10-ST-3,5 10013217
Temperature
evaluation
(X3/X4)
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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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. Module and encoder can be
damaged.

Manual INAM01 / INAM02
MA 1275-A004 EN 20
5.2.2 Pin Assignment
In the following the pin assignment:
Fig. 2: Pin assignment INAM01 / INAM02
Use the specified mating connectors for wiring.
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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. Module and encoder can be
damaged.