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.: +49(0)8142/503-0
Fax: +49(0)8142/503-190
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: doku@phytron.de
phytron
3 MA 1235-A016 EN
Contents
1 The 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
2 To Consider Before Installation ............... 14
2.1 Qualified Personnel ............................ 14
2.2 Safety Instructions ............................. 15
2.3 Ambient Conditions ............................ 16
3 Protective Measure Options .................... 17
4 Design Requirements .............................. 19
4.1 Electromagnetic Compatibility (EMC) . 19
4.1.1 Remarks .......................................... 19
4.1.2 EMC Measures ............................... 19
4.2 Cables................................................ 21
5 Technical Data ........................................ 22
5.1 Mechanical Data ................................ 22
5.2 Electrical Data .................................... 23
6 Installation ............................................... 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
7 Putting 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
8 Programming ........................................... 48
8.1 LabVIEW
.......................................... 48
8.2 MiniLog ............................................... 48
9 Heating 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 A
PEAK
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 communication 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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5 MA 1235-A016 EN
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 increments up to 1/256 step.
Run current, stop current and Boost current (acceleration) can be programmed
independently up to 3.5 A
PEAK
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 pnpNOC 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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13 MA 1235-A016 EN
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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17 MA 1235-A016 EN
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 +UB should 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 mm2 with 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
Manual MCC-2
MA 1235-A016 EN 20
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-2 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-2. 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.
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4.2 Cables
maximum cable
length
[m]
minimum cross
section
[mm2]
shielded, grounded
on all sides
Motor cable The length depends on
the cable resistance:
R
cable
< 0.2x
R
phase
Dependent on the
maximum current of
the motor and the
motor cable length is
suitable:
25
0.1 per 1 Ampere
motor current
X
50
0.2 per 1 Ampere
motor current
X
USB 5 __ X
Signal line
(digital)
100 0.14 X
Manual MCC-2
MA 1235-A016 EN 22
5 Technical Data
5.1 Mechanical Data
Device protection IP 20
Dimensions WxHxD 72x127x110 (mm)
Weight with heat sink about 930 g
Mounting The MCC-2 housing is constructed with mounting brackets at
two side panels. We recommend a vertical mounting
(labeling readable) because of a better heat dissipation.
The clip for rail mounting is mounted on the rear side.
Accessories (optional) MCC-2 with additional RS 232 port for connecting a BT 5
operator panel
MCC-2 with attached USB converter
Fig. 12: Dimensions in mm
• Wall mounting: screws type M4 or UNC 6-32.
• Required space at the front side: about 35 mm for connectors and cables
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5.2 Electrical Data
Technical Characteristics
Supply voltage Unregulated filtered DC voltage
Admissible voltage range for
• Controller and motor: 24 to 48 VDC (X9)
• Limit switch and outputs: 24 VDC ( X4)
Reinforced or double insulation between mains and
secondary circuit is required.
Stepper motor Two-phase stepper motors in 4, 6 or 8 lead wiring scheme at
X7/X8
Winding resistance between 0.1 and 10 Ohm
Winding inductance 0.5 to 10 mH per phase
Phase current up to 3.5 A
Peak
Step resolution
1/1, 1/2, 1/4, 1/5, 1/8, 1/10, 1/20 of a full step,
enhanced setting range up to 1/256 step for smoother motor
run
Max. run frequency 40 kHz for full step, 20 kHz for half step
Interfaces RS 485, RS 232, USB or Ethernet (X5)
Connectors 2 Analog inputs (X1)
2 Limit switch inputs (X2)
8 Digital inputs / 8 digital outputs (X3)
1 Encoder per axis (incremental or SSI) (X6)
Fuse 6.3 A fast
Flash memory 10 000 write cycles under normal operating conditions
Ambient temperatures Operation: 5 to 50 °C
Storage: -10 to 60 °C
Transport: -10 to 60 °C
Temperature behaviour Heating curve see chap. 9
Manual MCC-2
MA 1235-A016 EN 24
Technical Characteristics
Error detection The MCC shuts down in case of undervoltage 17 V ±1 V. The
error is set by the status bit and is indicated by the status
LED which can be reset by a hardware or software reset
(power stage reset).
The power stage is deactivated in case of an error.
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6 Installation
6.1 Mechanical Installation
DANGER
Danger of electric shock in case of foreign particles or damage!
Make sure during the installation that not fixed particles, such as pieces of wire
or assembly parts, can fall into the device. Conductive foreign materials in the
product can endanger persons in case of parasitic voltage and destroy the
device by short circuit.
Rail or Wall Mounting
•
The controller should be vertically mounted.
•
Mount the controller to a plane surface with appropriate load capacity.
•
The wall mounting brackets on two sides of the device allow different mounting
positions.
•
The rail mounting clip is fixed with screws on the rear side.
•
The rap holes can also be used for individual mounting solutions on the rear side.
The mounting screws used must intrude not more than 1 mm into the
device's inner parts (housing thickness: 4mm).
•
Minimum free space above and below the controller: 100 mm
Keep the air slots free to allow convective air exchange.
•
Minimum free space to other devices besides the controller: 30 mm
•
Recommended free space before the controller for connectors and cables: about
35 mm.
•
The heated air flow from other devices and components doesn’t result in
excessive heating of the cooling air.
•
The controller has to be mounted and operated at a place free of shocks and
vibrations.
Manual MCC-2
MA 1235-A016 EN 26
Fig. 13: Wall mounting MCC-2, dimensions
Fig. 14: Rail mounting MCC-2, dimensions
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6.2 Electrical Installation
Connectors - Overview
Connector Number
of poles
Phoenix connector
type
Phoenix mating
connectors
Material number
(mating connector)
X1 / X2 2 x 4 MCDN 1,5/4-G1-3,5
P26THR
FMC 1,5/4-ST-3,5 #10005880
X3 / X6 2 x 8 MCDN 1,5/8-G1-3,5
P26THR
FMC 1,5/8-ST-3,5 #10005881
X4 2 MC 1,5/2-G-3,5 THT FMC 1,5/2-ST-3,5 #10007077
X7 / X8 4 IC 2,5/4-G-5,08 IC 2,5/4-ST-5,08 #10005390
X9 2 MSTB 2,5/2-GF-5,08 MSTB 2,5/2-STF-5,08 #02005267
X10 5 MC 1,5/5-G-3,5 FMC 1,5/5-ST-3,5 #10006540
6.3 Connection of the Power Supply
6.3.1 X4 Power Supply I/O
Fig. 15: X4 Connector Supply I/O
DANGER
Danger of electric arcing!
Do not plug or unplug any connector when powered!
The 24 VDC (absolute limit values: 19.2 to 30 VDC) supply voltage I/O is connected to the
X4 connector and supplies outputs and limit switches.
The power requirement depends on the connected outputs and limit switches. 3 A are
allowed.
Manual MCC-2
MA 1235-A016 EN 28
6.3.2 X9 Supply Voltage PWR
The controller and motor supply voltage is connected to the X9 connector.
Permissible supply voltage range:
24 to 48 V
DC
• When the MCC-2 is supplied by means of an unregulated filtered DC voltage
(e.g. transformer), a load capacitor of min. 3,000 μF should be used.
• Protective ground of the supply voltage should be connected to the earthing screw on
the upper or lower side of the device.
• For strain relief the cable should be fixed with one of the cable clamps at the bottom or
the top side of the device.
• Motor voltage is fused with 6.3 A fast.
DANGER
Danger of electric arcing!
Never plug or unplug the screw connectors when powered!
Remark: The maximum motor current is only reached when the supply voltage
exceeds 40 VDC.
The MCC shuts down in case of undervoltage 17 V ± 1 V. The error is set by
the status bit and is indicated by the status LED which can be reset by a
hardware or software reset (power stage reset). The power stage is
deactivated in case of an error.
Fig. 16: X9 Connector Supply PWR
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6.4 X7/X8 Motor Connector
6.4.1 Stepper Motor Connection
Suitable stepper motor types for operation with MCC-2:
• Two-phase stepper motors with 4, 6 or 8 lead wiring scheme and up to 3.5 A
Peak
phase
current
• Winding resistance below 10 Ohms
• Winding inductivity of one motor phase 0.5 to 10 mH
• To ensure electromagnetic compatibility (EMC), all parts of the motor housing should
be conductively connected with each other.
The figure below shows the connection of a two-phase stepper motor with 4-lead wiring
scheme and parallel connected windings:
DANGER
Danger of electric arcing!
Do not plug or unplug any connector
when powered!
Fig. 17: Motor connection to X7 or X8 connector
Depending on application and stepper motor design, other wiring modes are possible, e.g.
serial connected windings. See next chap 6.4.2.
WARNING
Power stage damage in case of faulty connection!
• Before running the motor, the motor currents should be set to suitable
values! See chap. 6, Putting into service.
• 5-phase stepper motors must not be operated with MCC-2 controllers.
Connecting 5-phase stepper motors would result in damaging the
power stage
.
i
The supply voltage value affects the setting accuracy of the motor current. In
addition the setting accuracy depends on inductance and resistance of the
motor. The current can be set less exactly, if the current value is smaller than
600 mA.
We recommend to use the linear MCC-2 LIN controller if the accuracy of the
motor current setting must be improved.
Manual MCC-2
MA 1235-A016 EN 30
6.4.2 Wiring Schemes for 2-Phase Stepper Motors
Fig. 18: Wiring schemes for 2-phase stepper motors
WARNING
Motor leads not used should be individually isolated (e.g. 6-lead motors)!
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6.4.3 Motor Cable
Recommendations for Motor Cable Design:
Cable type: 5-pole with shielding mesh
(for stepper motors without earthing screw:
4-pole with shielding mesh )
Lead cross section: 1 mm² recommended, a smaller lead cross section can
be used dependent on the maximum motor current and
the motor cable length.
Acceptable motor cable length: dependent on power stage current setting and motor
winding resistance
Fig. 19: EMC compliant motor cable wiring
DANGER
Danger of electric arcing!
Do not plug in or plug out motor cable leads when motor supply voltage is on!
• The PE lead (green/yellow) of the motor cable should be fixed at the earthing screw
below the MCC-2 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-2. 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.
Manual MCC-2
MA 1235-A016 EN 32
6.5 X5 Com Communication Interface
The X5 Com communication interface is available as USB, RS 232(4-wire), RS 485, or
Ethernet-connection.
Factory setting:
57 600 Baud
8 Data bits
1 Stop bit
No parity
Protocol:: <STX> | Address | Data | Separator | Checksum | <ETX>
Baud rate and Interface parameters can be modified after installation of MiniLog-Comm
in the menu item Options/Interface Parameters.
i
If the MCC-2 is connected via Ethernet, the IP address
• is created by DHCP (dynamic IP configuration) or
• is assigned via Minilog Comm or phyLOGIC® ToolBox (Interface
parameter/Eth-MCM menu).
i
When the MCC-2 is connected to the PC by USB-interface, USB drivers have to
be installed on the PC.
i
An USB converter is needed, if several controller should be connected by USB.
It is mounted either external or at the first MCC-2 with RS 485 interface.
See chapter 6.5.3 RS 485 interface.
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33 MA 1235-A016 EN
USB Interface
MCC-2 and PC can be directly connected by the USB cable type A-B. The USB port of the
PC (type A) is directly connected to the USB port of the controller (type B). The MCC-2
operates in the stand-alone mode.
Fig. 20: X5 Com: USB port type B (DIN
IEC 61076-3-108)
Fig. 21: Wiring scheme PC MCC-2 by
cable A-B
USB-Driver Installation (Windows)
• Insert the Phytron-CD and open the folder USB Driver by the Windows Explorer.
Select the .exe-program which goes with your system software and start it by double
click. The following window is shown on desktop after a successful installation:
• Connect the MCC-2 directly or via USB converter to the USB port of your PC by
USB cable.
• For checking the correct USB-driver installation, continue as follows:
Start the device manager by clicking StartSettingsSystem control and doubleclick on System. Then select the Device manager tab. The USB components can be
found in Computer Ports and in Universal Serial Bus Controller. Here the new
USB-component is shown: USB Serial Port (Com X)
• You’ll find information about the driver installation for the chip FT232R and more
drivers for Linux and MAC on http://www.ftdichip.com
Manual MCC-2
MA 1235-A016 EN 34
• When the MCC-2 is connected to the PC by USB-interface, USB drivers
have to be installed on the PC.
• Administrator authorizations are required for the driver installation.
• Use a USB cable with a maximum length of 2 m!
• If you want to test several USB devices, which are identical in construction,
you should use the same USB port on the PC. Thus, you avoid to change
the COM port number.
6.5.1 Ethernet Interface
The MCC-2 can be integrated into the firm’s network by the Ethernet adaptor.
The port number of the MCC-2 controller is fixed to 22222 by Phytron.
The Ethernet connection via RJ 45 connector (X5 Com):
Fig. 22: X5: RJ 45 Ethernet connector
phytron
35 MA 1235-A016 EN
6.5.2 RS 485 Interface
When up to 16 MCC-2 are connected together in bus mode (RS 485/4-wire), an individual
address has to be set on the rotary switch ‚Address’ for each MCC-2.
A USB/RS 485 converter has to be used for USB connection to the PC.
Alternatively, a PC with RS 422- or RS 485/4-wire interface can be the master.
Fig. 23: X5 Com: connector, type A (DIN IEC 61076-3-107)
PC with RS 485/4-wire- or RS 422 interface ↔ RS 485 bus
The figure below shows the RS 485 bus connection to MCC-2 by a RS 422 or RS 485/4wire interface on PC.
Fig. 24: Connection PC (RS 422/485 interface) MCC-2 (RS 485 interface)
Remark:
• It is not necessary to use an external bus termination connector for RS 485 bus,
because the bus termination resistors are already built-in the MCC-2.
• In the RS 485 bus mode the PC is the master. Therefore an interface type RS 422
or RS 485/4-wire is necessary.
The complete bus only operates, if all devices are supplied at X9 connector. If
the supply voltage is disconnected on one MCC-2, all following devices on bus
are without communication.
Manual MCC-2
MA 1235-A016 EN 36
PC with USB interface ↔ Converter ↔ RS 485 bus
A USB/RS 485 converter has to be used for USB connection to the PC. An extra converter
or a converter, which is installed on the first MCC-2 must be inserted.
Fig. 25: Bus connection PC MCC-2 with USB-RS 485 converter in RS 485 mode
The figure below shows the connection of the PC to MCC-2 by the Phytron USB-RS 485
converter.
Fig. 26: Controller MCC-2 with Phytron USB-RS 485 converter
phytron
37 MA 1235-A016 EN
6.5.3 RS 232 Interface
The MCC-2 can be used as single device by RS 232 interface.
Fig. 27: 9 pole D-sub male connector acc. to DIN 41652
The following figures point out the cable connections to a PC with RS 232 interface.
Depended on the type this can be a 9 pole or a 25 pole D-sub female connector.
Connecting Cable PC – Controller:
Fig. 28: PC (9 pole female connector) <-> Controller MCC-2
Fig. 29: PC (25 pole female connector) <-> Controller MCC-2
115 200 Baud are allowed as maximum baud rate to receive correct data.
Manual MCC-2
MA 1235-A016 EN 38
6.6 Signal Interface Connection
6.6.1 X1 AD Converter
The X1 analog inputs can be used for voltage measurement, as well as e.g. for a joystick
as AD converter.
The 5 VDC ±3 % / max. 100 mA voltage is supplied by the MCC-2.
Input voltage: 0 to 5 V
Resolution: 10 Bit
A/D conversion time: about 15 µs
Input resistance: 47 kΩ
The input A/D ENABLE is a digital input (max. 5 V), which can be used e.g. as joystick
Enable. This input is only analyzed by software (see MiniLog-Comm).
Specific information for processing the input signals you’ll find in the programming manual
MiniLog-Comm.
Fig. 30: X1 Pin assignment
CAUTION
Danger of device damage!
Do not exchange X1 and X2!
To improve the accuracy of measurement of the AD converter, use a shielded cable.
We recommend using the shielding as GND analog. With PELV Grounding (except for
SELV supply, see chap. 3) this can be additionally wired to PE. Make sure that no
reverse current couple into the GND Analog shielding. GND Analog should not be
connected to PE, if there is SELV supply.
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39 MA 1235-A016 EN
6.6.2 X2 Limit Switch Input
The controller is designed for connecting two limit switches type PNP NCC or PNP NOC
per axis.
This type has the advantage that cable breaks can be recognized.
Mechanical opening limit switches may be also connected.
The supply voltage for the limit switches and outputs has to be supplied on connector X4.
Fig. 31: X2 Pin assignment
CAUTION
Danger of device damage!
Do not exchange X1 and X2!
6.6.3 X3 Digital Inputs/Outputs
MCC-2 controllers have each eight digital electrically insulated inputs and outputs.
Fig. 32: X3 Pin assignment
CAUTION
Danger of device damage!
Do not exchange X3 and X6!
Manual MCC-2
MA 1235-A016 EN 40
Inputs
The inputs are connected to a common ground connection (GND
I/O
at X2, X4 or
GND at X9).
Input level: 24 VDC
The input circuit protective resistor of
3.3 kΩ corresponds to 7 mA nominal
driver current at 24 VDC.
Signal level Low: < 0.4 VDC
Signal level High: 20 – 30 VDC
Fig. 33: Input circuit diagram
Outputs
The overload-safe outputs are equipped with protective diodes to protect the internal
circuitry. In the case of inductive loads (e.g. relay) each output should be additionally wired
with a protective diode mounted near the load in order to avoid EMC problems.
Max. 1 A current each output
Up to 3 A for all outputs
Fig. 34: Output wiring example
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41 MA 1235-A016 EN
6.6.4 X6 Encoder Connector
• Connection of one encoder per axis.
• Incremental encoder with quadrature signals or absolute encoder acc. to SSI-
standard.
• The following encoders can be evaluated:
SSI protocol resolution n max.
SSI1 n=22
SSI5 n=16
SSI6 n=22
SSI8 n=18
• The incremental encoder supply voltage, 5.3 VDC / max. 200 mA each encoder, is
generated by the controller.
• Use shielded twisted pair wise cables for encoder connection. The transmission mode
includes no protection against faulty transmission values.
Incremental encoder connection Absolute encoder SSI connection
Fig. 35: Encoder connector X6
• When using encoders, the parameters P34 to P39 should be checked and adapted
(MiniLog-Comm communication software ):
P34 incremental encoder / absolute encoder
P35 encoder resolution (SSI)
P36 encoder as counter
P37 not used
P38 preferential encoder direction of rotation
P39 conversion factor (one increment corresponds to ...)
• It is possible to operate one axis with an absolute encoder and the other axis with
an incremental encoder.
Manual MCC-2
MA 1235-A016 EN 42
CAUTION
Danger of device damage!
Do not exchange X3 and X6!
Danger of damage!
Connect the correct encoder type!
Do not parameterize an incremental encoder as SSI.
Fig. 36: Wiring of incremental encoder
Fig. 37: Wiring of SSI absolute encoder
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43 MA 1235-A016 EN
6.6.5 X10 Enable Connector
• The power stage can be deactivated independent of the logic signals (enable
connector X10).
• Two opto-decoupled Enable inputs are used to activate the motor supply.
Both Enable inputs must be wired for activation!
• The Monitor Enable output is used to check the Enable inputs A and B, i.e. when both
inputs are wired, the Monitor Enable output is set to ‚high’.
The function Enable doesn´t fulfill
‘Protection against unexpected start‘
according to EN 945-1 for application
in the extended safety sections.
Fig. 38: X10 Connector Enable
• The Enable inputs A and B can be permanently activated by bypassing the inputs with
the+24 V
DC
output. This will work only, if +24 VDC is supplied to the connector X4.
Fig. 39: Activation of A and B Enable inputs
A deactivation of the Enable signals during increasing stop and run current
values can cause an error and the axes will be stopped by an emergency stop. If
the Enable functionality should be checked e. g. after power-on, we recommend
either to reduce the current parameters or to detect the extern deactivation in the
Minilog program by commands and to reset the axes (see manual MiniLog).
Minilog command for reading the system status:
ST, Bit 5 is set (32
Dec
) = input Enable is OK
See also MiniLog for MCC programming manual.
Manual MCC-2
MA 1235-A016 EN 44
Fig. 40: Enable connector wiring
phytron
45 MA 1235-A016 EN
7 Putting into Service and Test
7.1 Test the Communication between Controller and PC
1. Connect the serial interface of the PC to the controller (X5), see Chap. 1.2.
2. Connect the supply voltage PWR to the controller (X9). The LED should light green.
3. Set the Remote/Local switch to REMOTE.
4. Switch on the PC.
5. Install MiniLog-Comm program package delivered with the controller.
6. Select the required settings in MiniLog-Comm, menu item Options/Interface
parameters, and save them: Active COM, transmission protocol and baud rate.
The baud rate in the controller can be changed by clicking on
Advanced >>
and can be
saved by
Set!
.
Baud rates MCC-2
can be selected in menu item Options/Interface
parameters or by programming instruction
9 600 38 400
14 400 57 600
19 200 115 200
28 800
Factory settings
Baud rate programming instruction:
ICpSnnn
IC Code: programming a baud rate
p Port number 1 or 2
S Write (Schreiben)
nnn Enter baud rate
Data format for transmission:
No Parity
1 Stop bit
8 Bit ASCII Code
57 600 Baud
All instruction strings must have the following format: STX Data ETX
Control characters: see ASCII table
The programming instructions are listed in the MiniLog programming manual.
Manual MCC-2
MA 1235-A016 EN 46
7.2 Test Stepper Motor(s), I/Os and Limit Switches
If not done before, now inputs, outputs, limit switches and stepper motor(s) should be
wired. Supply voltages should be wired after that!
Do not connect or disconnect screw terminals
as long as the matching supply voltage is on!
1. Switch on the PWR supply voltage. The LED will light green.
2. Switch on the supply voltage for I/O.
3. Start MiniLog-Comm.
4. Select menu item File/New/Parameter for motor current setting.
Run current, stop current and boost current1 can be set in the range 0.1 bis 2.5 A
r.m.s.
independent from each another. Stage 1 = 0.1 A
r.m.s.
to stage 25 = 2.5 A
r.m.s.
In menu item Transmission/Send/Parameter the parameter list is saved in the MCC-2.
On delivery the following settings are valid:
Run current: 0.6 A, stop current: 0.2 A, boost current: deactivated
Set motor currents corresponding to the motor winding parameters!
See chap. 6.4
5. In the menu item Parameter the step resolution can also be set between full step and
1/256 step. It is better to choose a high step resolution in most application situations,
because the motor will run more smoothly.
6. After the motor currents have been set to suitable values you can test the motor’s run
by selecting the menu items Transmission/Direct Mode or Transmission /Operation.
7. Menu item Transmission/Direct Mode
Many customers are already familiar with MINILOG program instructions. They can
enter all types of MINILOG instructions into a dialog box. The instruction is executed at
once.
Example: Enter X+200
The motor axis 1 drives 200 steps in direction +.
1
Run current is the motor’s rated current for normal operation without acceleration or
deceleration phases.
Stop current is a reduced current for motor standstill (about 50% of the run current).
Boost current is the motor current for acceleration and deceleration. During these
phases the motor needs more energy as during constant speed.
The boost current should be set to 120 to 130% of the run current. On delivery, boost is
deactivated, that means the motor will always run with the selected run current.
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47 MA 1235-A016 EN
The corresponding instruction for the other motor would be: Y+200.
8. An icon in the menu bar Transmission/Operation opens the following dialog box which
enables you to drive the motor per mouse click.
1.
9. Click on simply one of the buttons
Axis1– (X–)
to
Axis2+ (Y+)
. Direction + means
clockwise, seen onto the motor axis from outside.
2. If the motor should move in the wrong direction, exchange the connecting leads of
one motor phase, e.g. A and B.
10. You can enter drive instructions for both axes into the window "Drive relative ... “
The symbol + or – before the entered number of steps defines the direction.
When you click on the button
Start
the instruction will be executed. Now the button
has the marking
! STOP !
in order to cancel the movement if required.
11. You can change the drive frequencies of both motors with two slider controls at the
bottom of the window ‘Frequency’.
12. You can initialize each axis with click on one of the buttons
Axis1 M0P–
or
Axis2 M0P+
. The initializing can be cancelled by
! STOP !
.
13. Another MiniLog-Comm window allows to test inputs and outputs.
Manual MCC-2
MA 1235-A016 EN 48
8 Programming
8.1 LabVIEW
LabVIEW is a graphical programming environment with symbols.
Graphic icons (in the programming language G), which are representing a particular
function, are linked. These programs are called virtual instruments (VIs).
Phytron has created special VIs for MCC-controllers. The user therefore needs LabVIEW
qualification. Basic programming knowledge like data types, loops etc. are required.
The MCC-VIs are developed for LabVIEW 8.0 and higher.
A detailed description can be found in the LabVIEW-VIs MCC manual.
8.2 MiniLog
The "Phytron Programming Language" MiniLog is welltried for editing sequential programs
for machine controllers.
Complete sequential programs can be realized with MiniLog: drive instructions, initializing
axes, sub programs, jump instructions, reading and setting registers and many other
special instructions (see MiniLog programming manual).
MCC-2 controller can store MiniLog programs up to 128 kB program memory.
For editing and managing MiniLog programs, the MiniLog-Comm communication software
for PC is delivered together with the controller. Actual MiniLog-Comm program versions
can be downloaded from the Phytron homepage: http://www.phytron.de/
In the MiniLog-Comm menu item File/New you can enter and edit parameters, sequential
programs and registers.
Please refer to the MiniLog programming manual for all programming instructions.
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49 MA 1235-A016 EN
9 Heating Curve of MCC-2
i
The adjusting housing temperature depends on the motor type, the motor cable
length, phase current, supply voltage, arrangement of the housing and the
tolerance of the components.
In practice it can differ from the diagrams below.
The housing temperature should not exceed 75 °C (measured on the right side of the
housing and MCC-2 vertically arranged). In order to prevent destruction of the hardware,
the internal emergency cutout shuts down actively at higher temperature.
On the basis of the heating curve (fig. 41) the τϑ thermal time constant can be computed
(point of intersection between 0.63∆ϑ and the heating curve).
The expected housing temperature at different ambient conditions can be estimated by τϑ
time constant, start tangent and the combination of heating- and cooling curve.
Measuring conditions or operation:
• Device vertical arranged (LED on the top)
• 48 VDC supply voltage
• Motor type: ZSS42.200.2.5
• Temperatures are normalized, i.e. relatively without bench mark
Normalized housing temperature, maximum current, 100% duty cycle
Fig. 41: Heating curve for one/two axes operation and maximum current
Manual MCC-2
MA 1235-A016 EN 50
Normalized housing temperature, half current, 100% duty cycle
Fig. 42: Heating curve for one/two axes operation and half current
Normalized housing temperature, half current, 60% duty cycle
Fig. 43: Heating curve for one/two axes operation and 60 % duty cycle
phytron
51 MA 1235-A016 EN
10 Warranty, Trade Marks and Protective Measures
In this chapter warranty, trade marks and ESD protective measures are described.
10.1 Warranty
The MCC controllers are subject to legal warranty. Phytron will repair or exchange devices
which show a failure due to defects in material or caused by the production process. This
warranty does not include damages which are caused by the customer, as there are, for
example, not intended use, unauthorized modifications, wrong treatment or wrong wiring.
10.2 Trade Marks
In this manual several trade marks are used which are no longer explicitly marked as trade
marks within the text. The lack of this signs may not be used to draw the conclusion that
these products are free of rights of third parties.
• MiniLog-Comm is a trade mark of the Phytron GmbH.
• Microsoft is a registered trade mark and WINDOWS is a trade mark of the Microsoft
Corporation in the USA and other countries.
10.3 ESD Protective Measures
All the products which we deliver have been carefully checked and submitted to a longterm
test. To avoid the failure of components sensitive to electrostatic discharge (ESD), we
apply a great number of protective measures during manufacturing, from the component
input check until the delivery of the finished products.
Warning:
Manipulation of ESD sensitive devices must be effected by respecting special protective
measures (EN 61340–5). Only return the modules or boards in adapted packaging.
Phytron's warranty is cancelled in case of damages arising from improper
manipulation or transportation of ESD modules and components.
Manual MCC-2
MA 1235-A016 EN 52
11 Index
A
AD converter 38
Address switch 8
B
Baud rate 32
Boost current 46
C
Cable clamp 20, 28, 31
Connectors 23
D
Dimensions 22
E
Earthing screw 28, 31
EMC 20, 29
EMC compliance 31
Enable connector 44
Encoder 41, 42
ESD protective measures 51
Ethernet 7, 32
F
Firmware 8
Fuse 23
H
Handling 15
Heating curve 49
I
Input level 40
Inputs 39
Installation 14
Interface 23
IP address 32
L
LabVIEW 48
LED 8, 45
Limit switch 6, 27, 39, 46
LOCAL 7
Low voltage error 6
M
MiniLog 48
MiniLog-Comm 4, 8, 41, 46
Motor cable 31
Mounting clip 22
Mounting place 25
O
Operating mode 7
Operator panel 11
Outputs 39, 40
Overtemperature 6
P
PE 20, 28, 31
PELV 17
Phase current 23, 29
Power stage 6
Power supply 27
Programming 48
Protection against unexpected start 43
Protective diode 40
Protective measure 17
Putting into service 45
R
Rail mounting 25
Rap holes 25
REMOTE 7
Reset push button 7
RJ 45 34
RS 232 7, 32, 37
RS 422 35
RS 485 7, 32, 35
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53 MA 1235-A016 EN
Run current 46
Run frequency 23
S
Screws 25
Shielding mesh 20, 31
Step resolution 23
Stepper motor 23, 29
Stop current 46
Supply voltage 23
SYNCHROCHOP 6
T
Technical Data 23
Temperature 23
Touch voltage 18
Trade marks 51
U
Undervoltage 24
USB 7, 32, 33
USB-driver 32
V
Virtual instrument 48
W
Wall mounting 25
Warranty 51
Weight 22
Winding inductivity 29
Wiring schemes 30
Phytron GmbH
Industriestraße 12 – 82194 Gröbenzell
T+49-8142-503-0 F +49-8142-503-190
www.phytron.de
Phytron, Inc.
600 Blair Park Road, Suite 220
Williston, VT 05495, USA
T +1-802 872-1600 F +1-802 872-0311
www.phytron.com
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