ST 151
S-DIAS Stepper Motor Output
Stage
Date of creation: 23.10.2017
Version date: 02.12.2019
Article number: 20-014-151-E
Publisher: SIGMATEK GmbH & Co KG
A-5112 Lamprechtshausen
Tel.: +43/6274/4321
Fax : +43/6274/4321-18
Email: office@sigmatek.at
WWW.SIGMATEK-AUTOMATION.COM
Copyright © 2017
SIGMATEK GmbH & Co KG
Translation from German
All rights reserved. No part of this work may be reproduced, edited using an electronic system, duplicated or distributed in any form (print, photocopy, microfilm or in any other process) without the express permission.
We reserve the right to make changes in the content without notice. The SIGMATEK GmbH & Co KG is not responsible for technical or printing errors in the handbook and assumes no responsibility for damages that occur through
use of this handbook.
S-DIAS STEPPER MOTOR OUTPUT STAGE ST 151
02.12.2019 Page 1
S-DIAS Stepper Motor Output Stage ST 151
with 1 stepper motor output stage 50 V/5 A
1 brake chopper
1 incremental encoder input RS485/TTL switchable
2 enable inputs +24 V/3.2 mA/0.5 ms with
STO function
2 latch/digital inputs+24 V/3.7 mA/10 µs
The S-DIAS stepper motor output stage allows the connection of
2-phase stepper motors with a phase current up to 5 A. In the
standard step frequency mode, the operating modes half step,
full step and micro step (up to 64x) is supported.
The integrated brake chopper provides the connection for an
external regen resistor, with which excess energy generated by
the braking process of the motor can be dissipated.
The incremental encoder input, which supports RS422 as well as
TTL encoders, is provided for position feedback.
With both enable inputs, the safety function STO is implemented.
The 2 latch/digital inputs are provided for the reference motion and monitoring the end
positions.
ST 151 S-DIAS STEPPER MOTOR OUTPUT STAGE
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Contents
1 Basic Safety Guidelines ......................................................... 5
1.1 General Information on Safety .................................................... 5
1.2 Further Safety Guidelines ............................................................ 6
1.3 General Requirements ................................................................. 7
2 Safety Conformity ..................................................................11
2.1 Functional Safety Standards ..................................................... 11
2.2 EU Conformity Declaration ........................................................ 11
2.3 Safety-Relevant Parameters ...................................................... 11
3 Technical Data .......................................................................12
3.1 Stepper Motor Output Specifications ....................................... 12
3.2 Brake Chopper Specifications................................................... 13
3.3 Incremental Encoder Input Specifications ............................... 13
3.4 STO Enable Input Specifications .............................................. 14
3.5 Latch/Digital Input Specifications ............................................. 14
3.6 Electrical Requirements ............................................................. 15
3.7 Miscellaneous ............................................................................. 17
3.8 Environmental Conditions ......................................................... 17
4 Mechanical Dimensions ........................................................18
5 Connector Layout ..................................................................19
5.1 Status LEDs ................................................................................. 20
5.2 Applicable Connectors ............................................................... 21
S-DIAS STEPPER MOTOR OUTPUT STAGE ST 151
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5.3 Label Field ................................................................................... 22
6 Wiring ..................................................................................... 23
6.1 Wiring Example ........................................................................... 23
6.2 Note .............................................................................................. 24
7 Description of Functions ...................................................... 25
7.1 Stepper Motor Output Stage Operating Modes ....................... 25
7.1.1 Full Step Mode .................................................................................. 25
7.1.2 Half Step Mode ................................................................................. 25
7.1.3 Micro Step Mode ............................................................................... 26
7.2 Stepper Motor Current Regulator .............................................. 27
7.3 Incremental Encoder .................................................................. 29
7.3.1 Signal Process “Count UP” ................................ ............................... 29
7.3.2 Signal Process “Count DOWN” ......................................................... 29
7.3.3 Signal Process “Reference Pulse (Zero Position)” ............................ 29
7.3.4 Latch Function .................................................................................. 30
8 Additional Safety Information .............................................. 31
8.1 STO ............................................................................................... 33
8.2 Function ....................................................................................... 33
8.3 Function Test .............................................................................. 34
9 Wiring Examples ................................................................... 35
9.1 Performance Level e, Category 4 or SIL 3 – Safety-SPS ........ 35
9.2 Performance Level e, Category 3 or SIL 3 – Safety-SPS ........ 37
9.3 Performance Level e, Category 4 or SIL 3 – Conventional ..... 39
ST 151 S-DIAS STEPPER MOTOR OUTPUT STAGE
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9.4 Performance Level e, Category 2 or SIL 2 – Safety-SPS ........ 41
10 Mounting .................................................................................43
11 Disposal ..................................................................................44
S-DIAS STEPPER MOTOR OUTPUT STAGE ST 151
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1 Basic Safety Guidelines
1.1 General Information on Safety
If the safety guidelines are not followed, dangers to personnel can arise that could lead to
serious injury or in worst cases, death. In less serious cases, systems and equipment can
be damaged.
The following symbols identify the individual risks as well as the degree of seriousness;
their respective meanings are briefly explained. You should therefore familiarize yourself
with the safety symbols and their meanings to prevent dangers and risks.
DANGER!
DANGER!
Identifies an immediate danger with high risk, which
can lead to immediate death or serious injury if not
avoided.
Indique un danger direct à haut risque d’un décès
immédiat ou des blessures graves si les consignes de
sécurité ne sont pas respectées.
WARNING
WARNING
Identifies a possible danger with a mid-level risk,
which can lead to death or (serious) injury if not
avoided.
Indique un danger possible d’un risque moyen de
décès ou de (graves) blessures si les consignes de
sécurité ne sont pas respectées.
CAUTION!
CAUTION!
Identifies a low risk danger, which can lead to injury or
property damage if not avoided.
Indique un danger avec un niveau de risque faible des
blessures légères ou des dommages matériels si les
consignes de sécurité ne sont pas respectées.
ST 151 S-DIAS STEPPER MOTOR OUTPUT STAGE
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1.2 Further Safety Guidelines
Warning, dangerous electrical voltage
Avertissement d’une tension électrique dangereuse
Hot surface warning
Avertissement d’une surface chaude
Danger for ESD-sensitive components
Les signes de danger pour les composants sensibles
aux décharges électrostatiques
This symbol identifies important or additional information regarding the operation of the safety modules.
Ce symbole indique des informations importantes ou
supplémentaires concernant le fonctionnement des
modules de sécurité particuliers.
S-DIAS STEPPER MOTOR OUTPUT STAGE ST 151
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1.3 General Requirements
Technical
Documentation
This technical documentation is a component of this product.
• this document must be accessible in the vicinity of the
machine, since it contains important instructions.
• the technical documentation should be included in the
sale, rental or transfer of the product.
Documentation
technique
Cette documentation technique fait partie intégrale du produit.
• Gardez la toujours à portée de main et à la proximité
de la machine, car elle contient des informations importantes.
• Distribuez la documentation technique aux secteurs de
la vente et/ou de la location du produit.
Acceptance of the Safety Guidelines
Before handling the product belonging to this documentation,
the operating instructions and safety guidelines must be read.
SIGMATEK GmbH & Co KG accepts no liability for damages
resulting from non-compliance with the safety guidelines or the
relevant regulations.
Acceptance or the safety guidelines and the explanations in this
document, as well as the Safety System Handbook (see
homepage1) are a basic requirement for proper use. Therefore,
read this operating manual thoroughly and familiarize yourself
with each of them.
More information on standards and regulations etc. can be
found in the system handbook.
1
Using the search function with the keyword “Safety System Handbook”
ST 151 S-DIAS STEPPER MOTOR OUTPUT STAGE
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Prendre connaissance
de consignes de sécurité
Avant toute manipulation on doit impérativement prendre connaissance de consignes de sécurité et du mode d’emploi.
SIGMATEK GmbH & Co KG n'assume aucune responsabilité
pour les dommages causés par le non-respect des consignes
de sécurité ou du mode d’emploi respectif.
La connaissance de consignes de sécurité et le contenu de
cette documentation ainsi que le mode d’emploi du système de
sécurité constitue une condition préalable à l'utilisation prévue.
Lisez ce mode d’emploi et assurez-vous de le comprendre
jusqu’aux détails.
Pour plus d'informations sur les normes et les lignes directrices,
etc., reportez-vous au mode d’emploi.
Qualified Personnel
Installation, assembly, programming and initial start-up, operation, maintenance and decommissioning of control and automation technology products in general, as well as safety-related
products especially, can only be performed by qualified personnel.
Qualified personnel in this context are people, who have completed training or have trained under supervision of qualified
personnel and have been authorized to operate and maintain
safety-related equipment, systems and facilities in compliance
with the strict guidelines and standards of safety technology.
Personnel qualifié
Installation, montage, programmation, mise en service, l'exploitation, l'entretien et mise hors service de produits de commande
et d'automatisation en général, et de produits liés à la sécurité,
en particulier, ne peut être effectuée que par le personnel qualifié.
On entend sous terme personnel qualifié les personnes ayant
acquis une formation professionnelle dispensé par un spécial-
iste sur l’utilisation et surveillance des composants et des sys-
tèmes de sécurité, ceci conformément aux lignes directrices et
les normes en vigueur.
S-DIAS STEPPER MOTOR OUTPUT STAGE ST 151
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Designated Use
The Safety modules are designed for use in safety-oriented
applications and meet the required conditions for safety operation in compliance with Performance level e (PL e), in accordance with EN ISO 13849-1/-2 and SIL3 or SIL CL 3 in accordance with EN 62061.
For your own safety and the safety of others, use safety modules for their designated purpose. Correct EMC installation as
well as proper transport and storage are also included in designated use.
Non-designated use consists of
• Any change made to the safety modules of any kind.
• The use of damaged safety modules.
• The use of the safety module outside of the instruc-
tions described in this handbook.
• The use of the safety module outside of the technical
data described in this handbook.
Utilisation prévue
Les modules de sécurité sont conçus pour une utilisation dans
les applications sollicitant un niveau de sécurité et répondent à
toutes les conditions nécessaires pour un fonctionnement sûr
conformément au niveau de performance e (PL e) selon la
norme EN ISO 13849-1/-2 et SIL3 ou SIL CL 3 de la norme EN
62061.
Utilisez le module de sécurité conformément à son mode
d’emploi pour votre propre sécurité et celle d'autres personnes.
L'utilisation conforme comprend également une installation
conforme CEM ainsi que le transport et le stockage conforme.
L'utilisation abusive comprend entre autres:
• Les modifications quelconques apportées aux modules
de sécurité.
• Utilisation de modules de sécurité endommagés.
• Utilisation de modules de sécurité en dehors du cadre
décrit dans ce mode d’emploi.
• Utilisation de modules de sécurité en dehors des
spécifications décrites dans ce mode d’emploi.
ST 151 S-DIAS STEPPER MOTOR OUTPUT STAGE
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Operator Due Diligence
The operator must ensure that
• the Safety modules are to be used for their designated
purpose only.
• the Safety modules are to be operated in error-free,
fully functional condition only.
• only sufficiently qualified and authorized personnel my
operated the Safety modules.
• the documentation is complete and in readable condi-
tion and available at the site of operation.
Obligation de diligence
L’utilisateur doit s'assurer que
• les modules de sécurité ne sont utilisés que selon les
spécifications.
• uniquement les modules de sécurité en parfait état de
fonctionnement peuvent être utilisés.
• seulement le personnel qualifié et autorisé puisse ma-
nipuler les modules de sécurité.
• la documentation dans son intégralité et dans un état
lisible est mise à disposition à l’endroit où les modules
de sécurité sont utilisés.
S-DIAS STEPPER MOTOR OUTPUT STAGE ST 151
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2 Safety Conformity
2.1 Functional Safety Standards
- EN / IEC 62061:2005/A2 2015
- EN ISO 13849-1:2015
- EN ISO 13849-2:2012
2.2 EU Conformity Declaration
CE Declaration of Conformity
The SCP 011 complies with the following European directives:
• 2006/42/EG “Directive of the European Parliament and of the
Council of 17 May 2006 on Machinery and Change to the Directive
95/16/EC” (machine guideline)
• 2014/30/EU “Electromagnetic Compatibility” (EMC guideline)
• 2011/65/EU Restricted use of certain hazardous substances in
electrical and electronic equipment (RoHS Guideline)
The EU Conformity Declarations are provided on the SIGMATEK website.
Using the search function with the keyword “EU Declaration of Conformity”.
2.3 Safety-Relevant Parameters
The application of the specified parameters requires a risk analysis of the final application.
Safety parameters for 2-channel application of the ST 151
Safety Parameters
Safety Levels
EN 62061
PFHD = 4.99E-08 (1/h)
SFF = 91.92 %
SIL 3
EN ISO 13849-1
MTTFD = 3498 years
DC = 99.12 %
PL e / Cat. 4
ST 151 S-DIAS STEPPER MOTOR OUTPUT STAGE
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3 Technical Data
3.1 Stepper Motor Output Specifications
Number of phases
2
Output voltage
dependent on the supply (18-55 V)
Current controller frequency
maximum 32 kHz
Output current
maximum 5 A RMS
Output current over the environmental temperature
maximum 5 A continuous current at 45 °C
maximum 3 A continuous current at 55 °C
DC-link capacitance
10 µF
Operating modes
step frequency mode
Step resolution
full step, half step
(1)
4-/8-/16-/32-/64x micro step
Voltage measurement
15-70 V
with an under voltage < 15 V or over voltage > 70 V, the motor output is shut
down through the hardware.
Temperature measurement
0-125 °C
with temperature warning at 103 °C
with temperature warning at 108 °C
(1)
In the operation modes half and micro step, the current amplitude is raised by a factor of √2. With this current
increase, nearly 95% of the full step torque and in micro step mode, 100% of full step torque is achieved. In half
step mode, the current increase must be activated through the software.
Note on frequency resonance
Operating a stepper motor in the stepper frequency default mode can lead to resonance in certain frequency ranges. This is indicated by loss or torque reduction =>
the stepper motor loses steps. This phenomenon is a result of the stepper motor
construction and depends on the load. The problem can be minimized or avoided by
half or micro step operation.
S-DIAS STEPPER MOTOR OUTPUT STAGE ST 151
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3.2 Brake Chopper Specifications
Number
1
Output
GND switching
Maximum current
6 A
(1)
Short-circuit protection
yes
Regen resistor
External power resistor
Regen resistor switching threshold on/off
60 V/55 V
(1)
Regen braking must be dimensioned according to the application. For most applications, a 15 Ω/100 W resistor
is sufficient. If multiple motor modules are driven with one intermediate circuit supply, it is possible to equip only
one module with regen braking. The recommended regen resistor is available at SIGMATEK under the article
number 20-014-061-Z1.
Attention Hot Surface!
Note that the brake chopper heats up considerably during operation.
Attention: During operation and also a few minutes after operation there is
a risk of combustion when touching the brake chopper surface!
3.3 Incremental Encoder Input Specifications
Number
1
Input signals
Incremental encoder signals RS422 (A, /A, B, /B, R, /R)
RS422 signal (150 termination)
Incremental encoder signal TTL (A, B, R)
TTL level (1200 Pull-Up)
Input frequency
maximum 125 kHz
Counter frequency
maximum 500 kHz
Signal analysis
4x
Counter resolution
16-bit
Encoder power supply
+5 V/0.2 A short-circuit proof
ST 151 S-DIAS STEPPER MOTOR OUTPUT STAGE
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3.4 STO Enable Input Specifications
Number
2
Input voltage
+24 V DC
Input voltage range
minimum +18 V
maximum +30 V
Signal level
low: ≤ +5 V
high: ≥ +15 V
Switch hysteresis
typically +11 V
Input current
3 mA at +24 V
Input delay
typically 0.5 ms
Safety Level
complies with the requirements of Category 4, Performance Level "e"
according to EN ISO 13849-1 and SILCL 3 according to 62061
Safety function
STO according to EN61800-5-2, section 4.2.2.2
The motor is not supplied with energy, which can cause a turn. The stepper
motor output stage does not supply energy to the motor, which can gener-
ate torque.
3.5 Latch/Digital Input Specifications
Number
2
Input voltage
typically +24 V
maximum +30 V
Signal level
low: < +8 V
high: > +14 V
Switch hysteresis
typically +11 V
Input current
3.7 mA at +24 V
Input delay
typically 10 µs
S-DIAS STEPPER MOTOR OUTPUT STAGE ST 151
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3.6 Electrical Requirements
Motor supply
+18-55 V DC, NEC Class 2
Current consumption of the
motor supply
maximum 6 A (load-dependent)
Current consumption of the
+24 V supply on the S-DIAS bus
typically 45 mA
(incl. +5 V supply
of the incremental encoder)
maximum 50 mA
(incl. +5 V supply
of the incremental encoder)
Voltage supply from S-DIAS bus
+5 V DC, NEC Class 2
Current consumption on the
S-DIAS bus
-
-
Notes on Voltage Ripples in the Motor Supply
The motor supply must be connected with an appropriate DC-link capacitance (at
least 2000 µF / 100 V).
To keep the voltage ripple within the allowable range (< 2 Vss), an electrolyte capaci-
tor of the appropriate value must be connected in parallel to the motor supply termi-
nals. As a reference value for the required capacitance, approximately 2000 µF per
Ampere supply current can be assumed. To achieve optimal EMC ratio, it is recom-
mended that the capacitor be mounted near the output stage of the stepper motor
and the connection lines be as short as possible.
For USA and Canada:
The supply must be limited to:
a) max. 5 A at voltages from 0-20 V DC, or
b) 100 W at voltages from 20-60 V DC
The limiting component (e.g. transformer, power supply or fuse) must be certified by
an NRTL (Nationally Recognized Testing Laboratory).
Pour les États-Unis et le Canada:
L’alimentation doit être limitée à:
a) max. 5 A pour des tensions de 0-20 V DC, ou
b) 100 W pour des tensions de 20-60 V DC
Le composant imposant la limite (par exemple, transformateur, alimentation électrique ou fusible) doit être certifié par un NRTL (National Recognized Testing Laboratory, par exemple, UL).
ST 151 S-DIAS STEPPER MOTOR OUTPUT STAGE
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Stepper Motor Braking
When applying the brake in a stepper motor, a generative process can occur where-
by the kinetic energy of the motor is converted into electrical energy. The energy of
the motor is thereby fed back into the supply of the stepper motor output stage; this
then increases the supply voltage. It should be noted that a regenerative voltage of
65 V at the motor supply connection is not exceeded! The external capacity of the
motor supply is may be needed. If the capacitors in the power supply are insuffi-
cient, a regen resistor, which converts the excess energy into heat must be connect-
ed to the stepper motor output stage. When selecting the power supply, it is im-
portant to ensure that it is appropriately feedback-resistant up to the maximum re-
generative voltage that occurs.
The connector at X2 cannot be inserted or removed during operation!
Note on S-DIAS Supply
If this S-DIAS module is connected to an S-DIAS supply module with several S-DIAS
modules, the total current of the modules used must be determined and checked.
The total current of the +24 V supply cannot exceed 1.6 A!
The total current of the +5 V supply cannot exceed 1.6 A!
The specification for the current can be found in the module-specific technical doc-
umentation under "Electrical Requirements".
Si ce module S-DIAS est connecté à un module d’alimentation S-DIAS suivi de
plusieurs modules S-DIAS, le courant total des modules utilisés doit être déterminé
et vérifié.
Le courant total de l'alimentation +24 V ne peut pas dépasser 1,6 A!
Le courant total de l'alimentation +5 V ne peut pas dépasser 1,6 A!
Le cahier des charges pour le courant peut être trouvé dans la documentation
spécifique au module sous "Spécifications électriques".
Incorrectly set parameter or incorrect wiring can lead to destruction of the
motor. In particular, motor currents and the I2T settings (A-I2TT, A-I2TERR)
must be monitored, which can be parameterized in the DIAS-Drive Editor
via the LASAL Class 2 tool.
S-DIAS STEPPER MOTOR OUTPUT STAGE ST 151
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3.7 Miscellaneous
Article number
20-014-151
Hardware version
2.x
Standard
UL in preparation
Approvals
CE
3.8 Environmental Conditions
Storage temperature
-20 ... +85 °C
Environmental temperature
0 ... +55 °C
Humidity
0-95 %, non-condensing
Installation altitude above sea
level
0-2000 m without derating
> 2000 m with derating of the maximum environmental temperature by 0.5
°C per 100 m
Operating conditions
Pollution degree 2
EMC resistance
in accordance with 61000-6-7:2015 (Generic standards - Immunity re-
quirements for equipment intended to perform functions in safety-related
systems (functional safety) at industrial locations)
in accordance with EN 61000-6-2:2007 (industrial area)
(increased requirements in accordance with IEC 62061)
EMC noise generation
in accordance with EN 61000-6-4:2007 (industrial area)
Vibration resistance
EN 60068-2-6
3.5 mm from 5-8.4 Hz
1g from 8.4-150 Hz
Shock resistance
EN 60068-2-27
15 g
Protection type
EN 60529
IP20
(1)
maximal 5 A continuous current at 45 °C, maximum 3 A continuous current at 55 °C
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4 Mechanical Dimensions
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5 Connector Layout
The motor power connector X2, cannot be inserted or removed during operation!
ST 151 S-DIAS STEPPER MOTOR OUTPUT STAGE
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5.1 Status LEDs
Module Status
green
ON
module active
OFF
no supply available
BLINKING (5 Hz)
no communication
User
yellow
ON
can be set from the application
(e.g. the module LED can be set to blinking through the visuali-
zation so that the module is easily found in the control cabinet)
OFF
BLINKING (2 Hz)
BLINKING (4 Hz)
Moto phase A, A\,
B, B\
yellow
ON
Motor phase active
OFF
no phase control
Brake chopper
yellow
ON
brake chopper active
OFF
brake chopper inactive
Motor supply
green
ON
motor supply available, motor active
BLINKS
motor supply available motor inactive
OFF
motor supply not available
Motor Error
red
BLINKS
stepper motor output stage error
(motor supply < 15 V or > 70 V),
Motor output short circuit,
temperature motor output stage over 108 °C,
STO error)
OFF
no error
Encoder A, B, R
green
ON
encoder signal HIGH
OFF
encoder signal LOW
Encoder power
supply
yellow
ON
encoder supply OK
OFF
no encoder signal available
Enable input 1, 2
green
ON
input ON
OFF
input OFF
Latch / digital input
1, 2
green
ON
input ON
OFF
input OFF
S-DIAS STEPPER MOTOR OUTPUT STAGE ST 151
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5.2 Applicable Connectors
Connectors:
X1-X4: Connectors with spring terminals (included in delivery)
The spring terminals are suited for the connection of ultrasonically compacted (ultrasonically welded) wires.
Connections:
Stripping length/sleeve length:
10 mm
Mating direction:
parallel to the conductor axis or circuit board
Conductor cross section rigid:
0.2-1.5 mm2
Conductor cross section flexible:
0.2-1.5 mm2
Conductor cross section strands ultrasonically compacted:
0.2-1.5 mm2
Conductor cross section AWG/kcmil:
24-16
Conductor cross section flexible with ferrule without plastic
sleeve:
0.25-1.5 mm2
Conductor cross section flexible with ferrule with plastic sleeve:
0.25-0.75 mm2 (reason for reduction d2 of the
ferrule)
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5.3 Label Field
Manufacturer
Weidmüller
Type
MF 10/5 CABUR MC NE WS
Article number Weidmüller
1854510000
Compatible printer
Weidmüller
Type
Printjet Advanced 230V
Article number Weidmüller
1324380000
S-DIAS STEPPER MOTOR OUTPUT STAGE ST 151
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6 Wiring
6.1 Wiring Example
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6.2 Note
The following installation guidelines should be observed:
• The DIN rail must have an adequate mass connection.
• To wire the incremental encoder, a shielded cable is required. With an RS422 encoder,
the use of shielded, twisted pair cables is recommended. The shield must be placed in
front of the module as close as possible.
• For the motor wiring, a shielded cable is required. The shield must be placed as close
as possible to the module.
• The shielding must be connected to a shielding bus.
The ground bus should be connected to the control cabinet when possible!
Si possible la terre doit être connectée à l'armoire de commande!
The maximum length of the encoder and motor cables is 30 m.
La longueur maximale des câbles codeur et moteur est de 30 m.
IMPORTANT:
The S-DIAS module CANNOT be connected/disconnected while voltage is applied!
IMPORTANT:
Le module S-DIAS ne peut pas être inséré ou retiré sous tension.
S-DIAS STEPPER MOTOR OUTPUT STAGE ST 151
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7 Description of Functions
7.1 Stepper Motor Output Stage Operating Modes
7.1.1 Full Step Mode
In full step mode, Current is applied to the winding as shown below. The motor rotates in full
steps only. This means that in one turn the rated number of steps is taken.
7.1.2 Half Step Mode
In half step mode, Current is applied to the winding as shown below. Between each full
step, an intermediate step is taken. The resolution per turn is thereby doubled.
In half step mode, a current increase can be activated by the software to reach 95% of the
full step torque.
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7.1.3 Micro Step Mode
In micro step mode, a nearly sine wave formed current is applied to the individual windings.
With the ST 151, the resolution of the sine oscillation is 256 steps. 64 micro steps per full
step are thereby produced.
S-DIAS STEPPER MOTOR OUTPUT STAGE ST 151
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7.2 Stepper Motor Current Regulator
The current regulation for the stepper motor is influenced by the current rise and/or fall time
in the motor windings. These times are critically dependent on the supply voltage level,
inductivity and the resistance of the motor windings.
The current rise time can be influenced by the supply voltage level. The higher the supply
voltage, the faster the motor winding current rises.
The current regulator functions so that the H-bridge actively energizes the motor windings
until the value setting of the current (I
TRIP
) is reached. Afterwards, the current reduction
process (decay) is started. The current fall time in the motor windings is affected by the
decay mode.
In slow decay mode, the motor windings are shorted over the H-bridge.
The energy stored in the windings is dissipated over the internal resistance of the motor
and the H-bridge of the output stage.
In fast decay mode, the current sinks significantly faster since the windings are shorted by
reversing the polarity. The energy stored in the windings is thereby fed back to the supply.
If both variants are used during reduction of the motor current, the motor is in mixed decay
mode. In this mode, the advantages of both processes are unified. The current is first reduced to a threshold with fast decay and then switched to slow decay to keep the current
ripple low.
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The ST 151 has an adaptive fast decay current controller, by which the optimal decay mode
is automatically used. Using the time required to reach the preset current value and the
configured ChopperOnTimeMin (T
ONMIN
) value, the current controller decides which decay
mode is used and whether FastDecayTime (TFD) is reduced, increased or maintained. The
ChopperOnTimeMin, maximum FastDecayTime and maximum FastDecayTimeFallingStep
for negative current value jumps can be configured via parameters. With the ChopperOffTime (T
CHOPPEROFF
) parameter, the current controller base frequency is defined.
When the motor windings are switched over the H-bridge, parasitic capacitances generate
current spikes during charging/discharging. For this reason, the current measurement is
deactivated for a constant time (Blanking Time T
BLANK
).
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7.3 Incremental Encoder
7.3.1 Signal Process “Count UP”
7.3.2 Signal Process “Count DOWN”
7.3.3 Signal Process “Reference Pulse (Zero Position)”
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7.3.4 Latch Function
This function is primarily used for the reference motion.
The incremental encoder data and frequency counter values can be stored (latched) in a
selected input at the time of an event. The event source (input) and event type (edge) can
be set via latch registers.
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8 Additional Safety Information
The Safety function “STO” is an integrated component of the stepper motor output stage. It
meets all necessary requirements for safe operation in SIL 3 according to EN 62061 and in
compliance with PL e. Cat. 4 in accordance with EN ISO 13849-1.
Safety modules can only be powered by supplies that meet the requirements for
PELV in compliance with EN60204.
Installation, mounting, programming, initial start-up, operation, maintenance and
discarding of safety modules can only be performed by qualified personnel.
Qualified personnel in this context are people who have completed training or
have trained under supervision of qualified personnel and have been authorized
to operate and maintain safety-related equipment, systems and facilities in compliance with the strict guidelines and standards of safety technology.
Installation, montage, programmation, mise en service, l'exploitation, l'entretien
et mise hors service de produits de commande et d'automatisation en général, et
de produits liés à la sécurité, en particulier, ne peut être effectuée que par le
personnel qualifié.
On entend sous terme personnel qualifié les personnes ayant acquis une for-
mation professionnelle dispensé par un spécialiste sur l’utilisation et surveillance
des composants et des systèmes de sécurité, ceci conformément aux lignes
directrices et les normes en vigueur.
For your own safety and the safety of others, use Safety modules for their
designated purpose only.
Correct EMC installation is also included under designated use.
Utilisez le module de sécurité conformément à son mode d’emploi pour
votre propre sécurité et celle d'autres personnes. L'utilisation conforme
comprend également une installation conforme CEM ainsi que le transport
et le stockage conforme
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Non-designated use consists of
• any changes made to the Safety modules or the use of damaged mod-
ules
• the use of the Safety modules inconsistent with the technical margins
described in these operating instructions.
• the use of the Safety modules inconsistent with the technical data de-
scribed in these operating instructions (see the "Technical data" sections of the respective production).
L'utilisation abusive comprend entre autres:
• Les modifications quelconques apportées aux modules de sécurité.
• Utilisation de modules de sécurité endommagés.
• Utilisation de modules de sécurité en dehors du cadre décrit dans ce
mode d’emploi.
Utilisation de modules de sécurité en dehors des spécifications décrites
dans ce mode d’emploi.
In addition, observe the warnings in the other sections of these instruc-
tions. These instructions are visibly emphasized by symbols.
Respectez également les avertissements des autres sections de ces in-
structions. Ces instructions sont mises en évidence par des symboles.
• Only trained specialists are authorized to install the "safe restart" STO
(Safe Torque off) and set the parameters.
• All control devices (switches, relays, PLC, etc.) and the control closet
must meet the requirements for EN ISO 13849. This consists of:
– Door switches, etc. with at least IP54 protection.
– Control classes with at least IP54 protection.
• The proper cables and end-sleeves must be used
• All cables that affect safety (e.g. control cables for the ENABLE 1 and
ENABLE 2 inputs) must be laid in a cable duct outside of the control cabinet. Short or crossed circuits in the signal lines must be avoided! See EN
ISO 13849
• If external forces influence axes that are used with the STO safety func-
tion (e.g. hanging load), additional measures must be taken (such as an
electromagnetic double-surface spring brake, instead of a permanent
magnet brake).
Failure to follow the above safety measures can lead to severe injuries.
S-DIAS STEPPER MOTOR OUTPUT STAGE ST 151
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The main power supply for the servo amplifier must be disconnected using the main switch
for the following instances:
• Cleaning, maintenance or repairs
• Extended still-stand periods
Failure to follow the above safety measures can lead to severe injuries.
8.1 STO
The stepper motor output stage supports the safety functions STO (Safe Torque Off), and
meets the requirements for Category 4 Performance Level "e" according to EN ISO 138491 and SIL3 according to EN 62061.
For his purpose, the output stage has two safe inputs ENABLE 1 and ENABLE 2.
For the 24 V supply, only PELV/SELV can be used.
8.2 Function
The safety functions in the stepper motor output stage are controlled over two digital inputs.
The following table shows the status that the safe inputs ENABLE 1 and ENABLE 2 must
assume to enable normal operation or trigger the safety function.
Input Status
Description
ENABLE 1
ENABLE 2
Open
Open
Safe status of
the drive system
Open
Low
Low
Open
Low
Low
High
High
Drive system ready
If the ENABLE 1 and ENABLE 2 are changed from any status to the "Drive Ready" status,
the stepper motor output stage is not enabled immediately. In order to set the system to
“Drive system ready” status, a change from “Low - Low” to “High - High” must occur.
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8.3 Function Test
The safety function test is required to ensure correct operation. The entire
safety circuit must be tested for full functionality.
Tests must be performed at the following times:
• After installation
• In regular intervals, or at least once a year.
If the function test results in an invalid machine status, the error must be found and
corrected before the safety function is retested. If the error reoccurs during the func-
tion test, the machine can no longer be operated.
Failure to follow the above safety measures can lead to severe injuries and damage.
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9 Wiring Examples
In the following sub chapters, wiring examples are provided. It must be ensured that all
constructive measures etc. are complied with and applied in order to fulfill the requirements
of the category used.
9.1 Performance Level e, Category 4 or SIL 3 – Safety-SPS
To meet the requirements of category 4, performance Level "e" for EN ISO 13849-1 and
SIL 3 according to EN 62061, two error-proof output of a Safety PLC must be used. Crosscircuit detection between the two lines via the output tests of the STO 081 is hereby possible.
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9.2 Performance Level e, Category 3 or SIL 3 – Safety-SPS
To meet the requirements of safety category 3, performance level "e" for EN ISO 13849-1
and SIL 3 according to EN 62061, an error-proof output of a safety PLC must be used. The
reason of category 3 here, is that cross-circuit detection between the two lines is not possible.
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9.3 Performance Level e, Category 4 or SIL 3 – Conventional
To meet the requirements of safety category 4, performance level "e" for EN ISO 13849-1
and SIL 3 according to EN 62061, the placement of the lines must comply with EN ISO
13849-2, table D.4 (separate placement, prohibiting of error via short circuits between
wires) as cross-circuit detection is not possible here.
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9.4 Performance Level e, Category 2 or SIL 2 – Safety-SPS
This involves 1-channel wiring, whereby the Enable inputs are tested separately. Here, no
cross-circuit detection is possible.
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10 Mounting
The S-DIAS modules are designed for installation into the control cabinet. To mount the
modules a DIN-rail is required. The DIN rail must establish a conductive connection with the
back wall of the control cabinet. The individual S-DIAS modules are mounted on the DIN rail
as a block and secured with latches. The modules must be mounted horizontally (module
label up) with sufficient clearance between the ventilation slots of the S-DIAS module blocks
and nearby components and/or the control cabinet wall. This is necessary for optimal cooling and air circulation, so that proper function up to the maximum operating temperature is
ensured.
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Recommended minimum distances of the S-DIAS modules to the surrounding components
or control cabinet wall:
a, b, c … distances in mm (inches)
11 Disposal
For the disposal of the product, the respective guidelines, possibly country-specific, must be
observed and followed.
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Documentation Changes
Change date
Affected page(s)
Chapter
Note
05.02.2018
21
6.2 Stepper Motor
Current Regulator
Expansion and Edit
18.06.2018
7
1.6 Electrical Requirements
Notes updated
02.04.2019
18
17
all
4.3 Safety-Relevant
Parameters
3.8 Environmental
Conditions
Correction of the safety-relevant parameters
Corrections environmental conditions
Corrections due to CE
29.07.2019
20
5.1 Status LEDs
Enable inputs corrected
02.12.2019
2.3 Safety-Relevant
Parameters
Values updated
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