phytron phyMOTION Repair manual

phytron
7/2015 Manual MA 1259-A006 EN
phyMOTIONTM
Modular
Multi-axis Controller for Stepper Motors
with INTernal / EXTernal Power Supply
TRANSLATION OF THE GERMAN ORIGINAL MANUAL

phyMOTIONTM
MA 1259-A006 EN 2
2015
All rights with:
Phytron GmbH
Industriestraße 12
82194 Gröbenzell, Germany
Tel.: [phone]
Fax: [phone]
In this manual phyMOTIONTM Modular Multi-axis Controller for Stepper Motors
(http://www.phytron.eu/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.eu/) in
your local agencies.

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3 MA 1259-A006 EN
1 Legal 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.

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MA 1259-A006 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.

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5 MA 1259-A006 EN
Safety Instructions
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.
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 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.
CAUTION – Possible injury!
The phyMOTIONTM may weigh up to 30 kg, depending on the expansion stage.
Foot injuries can occur from dropping the unit.
- Make sure that the phyMOTIONTM is securely held at all times.
- Wear safety shoes during transport and handling.

phyMOTIONTM
MA 1259-A006 EN 6
2 Available phyMOTIONTM Manuals
The following manuals are available for phyMOTIONTM controller, which are referred to in
this manual by the following remark:
Further manual
Detailed information on this subject is in a supporting manual.
phyMOTIONTM – Multi-axis Controller for Stepper Motors MA 1259-A00x EN
POWM01/POW02/POWM03/POWM04 – Power Supply
Modules MA 1273-A00x EN
MCM01 – CPU and Bus Module MA 1261-A00x EN
MCM02/MCM03 – CPU, Bus Module and Power Supply MA 1294-A00x EN
I1AM01 – 1 Axis Stepper Motor Drive 3.5 A power supply MA 1269-A00x EN
I1AM02 – 1 Axis Stepper Motor Drive 5 A power supply MA 1269-A00x EN
DIOM01 – Digital I/O Module MA 1271-A00x EN
AIOM01/AIM01/AOM01 – Analogue I/O Module MA 1288-A00x EN
INAM01/INAM02 – Power Stage Carrier Module MA 1275-A00x EN
INSM01 – Power Stage Carrier Module with safety shutdown MA 1xxx-A00x EN
EXAM01 – Interface Module for an External Power Stage MA 1277-A00x EN
I4XM01 – Indexer Module MA 1279-A00x EN
phyLOGICTM Command Reference for the phyMOTIONTM
Controller MA 1265-A00x EN
phyLOGICTM ToolBox – Communication Software for the
Stepper Motor Controllers phyMOTIONTM, MCC and OMC/TMC MA 1285-A00x EN
Principles of Positioning for Stepper Motor Controllers MA 1267-A00x EN
ProfiNet/ProfiBus Interfaces MA 1263-A00x EN
phyLOGICTM Control – User Software for the operator
panel/tablet operation of the stepper motor controller
phyMOTIONTM
MA 1299-A00x EN
More manuals are in progress.

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7 MA 1259-A006 EN
3 Contents
1Legal Information ......................................................................................................3
2Available phyMOTIONTM Manuals............................................................................6
3Contents.....................................................................................................................7
4phyMOTIONTM Overview............................................................................................9
4.1 Housing..................................................................................................................9
4.2 Application Scenarios and Embedding in Existing Systems.................................11
4.3 The Basic Functions and Modules at a Glance....................................................14
4.4 Equipment Rules..................................................................................................19
5General Technical Data...........................................................................................22
5.1 Directives and Standards.....................................................................................22
5.2 Declaration of Incorporation: Modules gen. and External Power Supply EXT......23
5.3 Declaration of Incorporation: Modules with Internal Power Supply INT................25
5.4 Transport and Storage Information ......................................................................27
6Project Planning ......................................................................................................28
6.1 Information for a Suitable Installation Location ....................................................28
6.2 Safety Concept.....................................................................................................29
6.2.1 External Power Supply (EXT)........................................................................29
6.2.2 Internal Power Supply (INT)...........................................................................30
6.2.3 phyMOTIONTM with Power Stages up to 70 VDC............................................32
6.2.4 phyMOTIONTM with Power Stages up to 120 VDC..........................................33
6.3 Basic Wiring of the phyMOTIONTM.......................................................................34
6.3.1 with External Supply (EXT)............................................................................34
6.3.2 with Internal Supply (INT) ..............................................................................35
6.3.3 Further Modules.............................................................................................36
6.4 Sizing of the Power Supply for phyMOTIONTM with external Supply (EXT) ........38
6.4.1 For Motor Supply...........................................................................................38
6.4.2 For Input/Output Supply.................................................................................39
6.5 Mains Connection phyMOTIONTM with Internal Supply (INT)...............................40
6.6 EMC Measures ....................................................................................................41
6.7 Shielding..............................................................................................................42
6.8 Grounding for Motor Voltage > 70V (INT) ............................................................43

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MA 1259-A006 EN 8
7Installation................................................................................................................44
7.1 Mechanical Installation.........................................................................................44
7.2 Housing Types and Dimensions...........................................................................45
7.2.1 Bench ............................................................................................................47
7.2.2 Wall/Rail Mounting for phyMOTIONTM with External Supply EXT..................47
7.2.3 Sub Rack Mounting .......................................................................................47
7.3 Electrical Installation ............................................................................................49
8Commissioning........................................................................................................50
8.1 Condition..............................................................................................................50
8.2 Testing of the Communication MCM Module – PC ..............................................50
9Service and Modular Expansion ............................................................................54
9.1 Service for phyMOTION™ with External Supply EXT..........................................55
9.2 Service for phyMOTION™ with Internal Supply INT ............................................55
9.3 Expansion for phyMOTION™ with External Supply EXT.....................................56
10Warranty, Disclaimer and Registered Trademarks...............................................57
10.1 Disclaimer........................................................................................................57
10.2 Warranty..........................................................................................................57
10.3 Registered Trademarks...................................................................................57
11Index.........................................................................................................................58

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9 MA 1259-A006 EN
4 phyMOTIONTM Overview
4.1 Housing
With our phyMOTION™ you have chosen a high quality stepper motor controller concept
“made in Germany”. Our phyMOTION™ is designed to merge the worlds of PLC and CNC
by combining high-performance components with cost efficient basic functionality –
adjustable to your individual requirements. Contrary to PLC systems our phyMOTION™
opens up the world of co-operative product and module development: as a mid-size family-
owned company your feedback is the basis for our future – whenever off the shelf PLCs
fall short the phyMOTION™ grows with your requirements:
The phyMOTIONTM is a stepper motor controller with modular design and offers the option
for later expansion. It controls, depending on the configuration, multi-axes synchronisation
and interpolation and offers integrated power stages (up to 15 APEAK, 120 VDC)and allows
connection of more powerful external power stages.
Whatever its housing (bench, 19” sub rack, rail), with or without touch panel, motor
temperature evaluation, limit switches, encoders or I/O - the phyMOTIONTM adapts to the
requirements with up to 21 modules per device.
phyLOGICTM programs are edited, transmitted to the controller and stored by the free
development environment phyLOGICTM ToolBox.
Of course, the phyMOTIONTM can be controlled and programmed, if required, via host
interface (ProfiBus, ProfiNet, Ethernet, CAN, RS 485, RS 232, Bluetooth...).
INT:phyMOTIONTM with internal power supply (mains 230 / 115 VAC)
EXT phyMOTIONTM with external power supply (e.g. SPH mains adaptor)
Fig.1 Example 19“ sub rack with module equipment (EXT)
Fig.2 Housing types: sub rack, wall or rail mounting, bench

phyMOTIONTM
MA 1259-A006 EN 10
Fig.3 Example 19“ sub rack with integrated power stages and touch panel (INT)

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11 MA 1259-A006 EN
4.2 Application Scenarios and Embedding in Existing Systems
There can be many different ways to operate and integrate the phyMOTIONTM into your
system architecture:
Via PC:
As stand-alone unit:
As distributed or intelligent I/O (PLC):

phyMOTIONTM
MA 1259-A006 EN 12
In a network:
Embedded in a customer’s system:
In combination with higher-powered amplifiers:
Fig.4 phyMOTIONTM for power stages > 5 A/70 V as in this case, for example, with
phytron‘s MCD+or a phytron’s SLS sub rack with 8 ZMX+or
4 MSX power stages

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13 MA 1259-A006 EN
Power adaptor and power stages are integrated: INT
Fig.5 phyMOTIONTM with power adaptor, touch panel and MSX power stages

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MA 1259-A006 EN 14
4.3 The Basic Functions and Modules at a Glance
The modules of the phyMOTIONTM can be split up into the following functions:
Main functions
There is a power supply in the module (power supply unit).
Modules with a CPU contain intelligent processors to execute all of the
sequential programs and enable the phyMOTIONTM to drive in stand-
alone mode.
The INDEXER represents the functionality to generate signals from the
commands of a programming language, which the power stage amplifies.
Normally, the signals are control/direction pulses or SIN/COS inputs.
The POWER STAGE represents a stepper motor amplifier. Incoming
control/direction pulses or SIN/COS signals are amplified and output to
the motor.
Auxiliary functions
Encoder evaluation
Motor temperature evaluation
Digital inputs and/or outputs
Analogue inputs and/or outputs
Power distribution
Host interface

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15 MA 1259-A006 EN
With the following modules the phyMOTIONTM is tailored to your requirements:
Type Description Current
consumption
[mA]
Weight [g]
(without/with
front panel)
Power supply
from the
mains
(230 VAC /
115 VAC)
NETM01 230 VAC / 115 VAC
supply, motor voltage
and 24 V I/O or
encoder supply are
internally generated
–
Supply
with external
supply
voltage
POWM01: Mains supply and
configuration 68 / 90
POWM02: Intermediate supply 53 / 86
with internal
supply
voltage
POWM03: Mains supply and
configuration
POWM04: Intermediate supply
CPU and
Host
interface
MCM01: Intelligent CPU with
selectable host
interface
180
70 (RS
interface)
120 (ProfiNet)
61 / 82
MCM02: Intelligent CPU with
selectable host
interface with
external power
supply
180
70 (RS
interface)
120 (ProfiNet)
65 / 85
MCM03: Intelligent CPU with
selectable host
interface with internal
power supply
180
70 (RS
interface)
120 (ProfiNet)
65 / 85

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MA 1259-A006 EN 16
Type Description Current
consumption
[mA]
Weight [g]
(without/with
front panel)
Axes I1AM01: Indexer with
integrated 3.5 A
power stage;
encoder and
temperature
evaluation optional
170 (5 V)
30 (EnDat
encoder 5 V)
10 (24 V)
20 + encoder
(24 V)
30 (temp-
module)
axis load (24-48
V)
102 / 116
I1AM02: Indexer with
integrated 5 A power
stage;
encoder and
temperature
evaluation optional
170 (5 V)
30 (EnDat
encoder 5 V)
10 (24 V)
20 + encoder
(24 V)
30 (temp-
module)
Axis load
(24-70V)
90 / 112
I4XM01: High end stepper
motor indexer for 1 to
4 axes
52 / 73
INAM01: Carrier module for
APS power stage;
encoder and
temperature
evaluation optional
80 (power
stage)
30 (EnDat
encoder 5 V)
20 + encoder
(24 V)
30 (temp-
module)
axis load (24-48
V)
71 / 93

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17 MA 1259-A006 EN
Type Description Current
consumption
[mA]
Weight [g]
(without/with
front panel)
INAM02: 1-Axis module for
MSX power stage
with internal supply
voltage;
encoder and
temperature
evaluation optional
10 A (MSX
power stage)
30 (EnDat
encoder 5 V)
20 + encoder
(24 V)
30 (temp-
module)
axis load
(up to 120 V)
71 / 93
PEM01: Grounding module
for motors with motor
voltage >70 V
EXAM01: Interface between
indexer and an
external power stage;
encoder and
temperature
evaluation optional
30 (EnDat
encoder 5 V)
20 + encoder
(24 V)
30 (temp-
module)
axis load (24-48
V)
51 / 67
Expansions DIOM01: Digital input and
output module 75 (5 V) load + 5 (24 V) 56 / 79
AIOM01: Analogue input and
output module 75 (5 V) 5 (24 V) 66 / 87
AIM01: Analogue input
module 75 (5 V) 5 (24 V) 66 / 87
AOM01: Analogue output
module 75 (5 V) 5 (24 V) 66 / 87

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MA 1259-A006 EN 18
Type Description Current
consumption
[mA]
Weight [g]
(without/with
front panel)
TPM01: Android-based
integrated touch
panel;
mountable on
connection side or
plain side
TPE External touch panel
Control by Android-
based tablets via
Bluetooth interface

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19 MA 1259-A006 EN
4.4 Equipment Rules
The following equipment rules are useful for the configuration of your phyMOTIONTM:
Our personnel will be pleased to advise you on your desired configuration:
phone: [phone]
POWM01 / POWM02 / POWM03 / POWM04 supply modules
Every configuration starts
for external supply voltage (EXT):
– with a touch panel (optional)
– with the POWM01 power input and configuration module followed by the CPU
module MCM01, which holds the selectable host interface sub module or
– with the MCM02 module, the combined supply, configuration module and CPU
module
for internal supply voltage (INT):
– with a touch panel (optional)
– with the POWM03 power input and configuration module followed by the CPU
module MCM01, which holds the selectable host interface sub module or
– with the MCM03 module, the combined supply, configuration module and CPU
module
Each power input module:
•is designed to supply up to 10 more modules with an internal logic voltage (5 V)
•can draw 20 A maximum at 24-70 V from the external power supply to the axis
modules, which is the limitation on the number of cards per power input module.
•can draw a total of 5 A from the 24 V I/O supply for outputs (analogue or digital) or to
power limit switches.
If more current is needed an additional POWM02/POWM04 module should be considered.
An intermediate power input module can also be used to divide the backplane into different
motor voltage sections. That way several different motor voltages can be used within one
unit.
Indexer modules
The indexing functionality can be found integrated with the power stage functionality within
one module or can be combined by including sub modules. Power stages that use external
indexer functionality have to be placed directly after the indexing module.

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MA 1259-A006 EN 20
Stepper motor modules
Several stepper motor modules already contain some power stage functionality; others
need additional power stage modules. In both cases encoder and temperature evaluation
are additional modular options (for INAM01, INAM02, I1AM01, I1AM02...).
In case the internal power stage supply of 5 A (per power stage) at 70 V is not sufficient,
external power stages can be addressed with control/direction signals via the EXAM01
module.
Mains power module NETM01 for internal supply voltage (INT)
The NETM01 power module is always placed at the right end of the connection side.
If the motor voltage >70 VDC, it applies: the grounding module PEM01, which is placed
right next to the last INAM02 module, is used for grounding of up to six motors.
Backplane, expandability
Expandability options (for additional power input modules) have to be specified during the
ordering process. The backplane separation is permanent and has to be considered when
your phyMOTION™ is configured.
For the internal supply voltage is applied (INT): The first INAM02 module terminates the
backplane, all phyMOTIONTM modules, which are not controlled by the corresponding 4-
axis indexer must be placed left to the indexer module.
Empty slots
The slots must be filled from left to right without gaps in between. Empty slots at the
housing's end must be covered with blanking plates.
Sub modularity
The following modules can be expanded with sub modules: MCM01, MCM02, MCM03,
INAM01, INAM02, EXAM01, I1AM01, I1AM02, INSM01...
Android-based touch panel
The touch panel can be installed as the first or last module, or outside of the housing as an
external touch panel.
The touch panel can be integrated either on the connection side or on the plain side or
outside of the housing configuration as an external touch panel
Alternative configurations
By integrating independent backplanes, several autonomous main units with their own
host interface each can be built into one housing. This way several phyMOTION™
controllers can be combined using a minimum of space.