SIGMA TEK DC 061-1 User manual

DC 061-1
S-DIAS Axis Module
Date of creation: 26.07.2016
Version date: 23.08.2019
Article number: 20-014-061-1E

Publisher: SIGMATEK GmbH & Co KG
A-5112 Lamprechtshausen
Tel.: [phone]
Fax: [phone]
Email: [email protected]
WWW.SIGMATEK-AUTOMATION.COM
Copyright © 2016
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 dis-
tributed 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 responsi-
ble for technical or printing errors in the handbook and assumes no responsibility for damages that occur through
use of this handbook.

S-DIAS AXIS MODULE DC 061-1
23.08.2019 Page 1
S-DIAS Axis Module DC 061-1
with 1 motor output stage
1 resolver input
1 holding brake
The S-DIAS DC 061-1 axis module is used to control a brushless DC
motor with a 48-Volt supply voltage and phase current of up to 6 A. A
resolver input is available for position feedback. A 24 V output for con-
necting a holding brake is provided. External Regen brake can also be
connected.

DC 061-1 S-DIAS AXIS MODULE
Page 2 23.08.2019
Contents
1Basic Safety Guidelines......................................................... 5
1.1 Symbols Used...............................................................................5
1.2 Disclaimer......................................................................................7
1.3 General Safety Guidelines...........................................................8
2Technical Data ........................................................................ 9
2.1 Motor Driver Specifications.........................................................9
2.2 Resolver Specifications...............................................................9
2.3 Enable Inputs Specifications.......................................................9
2.4 Holding Brake Specifications....................................................10
2.5 Regen Brake Specifications ......................................................10
2.6 Electrical Requirements.............................................................11
2.7 Miscellaneous .............................................................................14
2.8 Environmental Conditions.........................................................14
3Mechanical Dimensions........................................................15
4Connector Layout..................................................................16
4.1 Baumüller ....................................................................................16
4.2 Kollmorgen..................................................................................17
4.3 Status LEDs.................................................................................18
4.4 Applicable Connectors...............................................................19
4.5 Label Field...................................................................................21
5Wiring......................................................................................22

S-DIAS AXIS MODULE DC 061-1
23.08.2019 Page 3
5.1 Wiring Example...........................................................................22
5.2 Wiring AKM Motors.....................................................................23
5.2.1 Wiring AKM Motors with M23 Round Connectors............................. 24
5.2.2 Wiring AKM Motors with Molex Connectors...................................... 25
5.2.3 Wiring AKM Motors with Y-Tec......................................................... 25
5.3 Servo Motor and Encoder Cables .............................................26
5.4 Encoder Cable (M23 and Y-Tec)................................................27
5.4.1 M23................................................................................................... 27
5.4.2 Y-Tec ................................................................................................ 27
6Motor Overload Protection...................................................28
7Safety Conformity .................................................................28
7.1 Functional Safety Standards .....................................................28
7.2 EU Conformity Declaration........................................................28
7.3 Safety-Relevant Parameters ......................................................28
8Additional Safety Information ..............................................29
8.1 STO...............................................................................................31
8.2 Function.......................................................................................31
8.3 Function Test ..............................................................................32
9Wiring Examples ...................................................................33
9.1 Performance Level e, Category 4 or SILCL 3 –Safety PLC....33
9.2 Performance Level e, Category 3 & SILCL 3 –Safety PLC.....35
9.3 Performance Level e, Category 4 or SILCL 3 –Conventional 37

DC 061-1 S-DIAS AXIS MODULE
Page 4 23.08.2019
9.4 Performance Level d, Category 2 or SIL 2 –Conventional ....39
10 Transport/Storage..................................................................41
11 Mounting.................................................................................42
12 Maintenance...........................................................................44
12.1 Maintenance................................................................................44
12.2 Repairs.........................................................................................44
13 Disposal..................................................................................44

S-DIAS AXIS MODULE DC 061-1
23.08.2019 Page 5
1 Basic Safety Guidelines
1.1 Symbols Used
The following symbols are used in the user documentation for warning and danger mes-
sages, as well as informational notes:
DANGER
Identifies an immediate danger with high risk, which will lead to immediate
death or serious injury if not avoided.
Identifie un danger immédiat avec un risque élevé, entraînant le décès
immédiat ou des blessures graves s’il n’est pas évité.
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
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 re-
spectées.
Warning, dangerous electrical voltage.
Attention, tension électrique dangereuse.
Hot surface warning.
Avertissement de surface chaude.
Danger for ESD-sensitive components.
Les signes de danger pour les composants sensibles aux décharges élec-
trostatiques.

DC 061-1 S-DIAS AXIS MODULE
Page 6 23.08.2019
Provides user tips, informs of special features and identifies especially
important information in the text.
Fournit des conseils d’utilisation, informe sur les fonctions particulaires et
souligne les informations particulièrement importantes dans le texte.

S-DIAS AXIS MODULE DC 061-1
23.08.2019 Page 7
1.2 Disclaimer
The contents of this document were prepared with the greatest care. How-
ever, deviations cannot be ruled out. This document is regularly checked
and required corrections are included in the subsequent versions. The
machine manufacturer is responsible for the proper assembly, as well as
device configuration. The machine operator is responsible for safe han-
dling, as well as proper operation.
The current document can be found on our website. If necessary, contact
our support.
Subject to technical changes, which improve the performance of the devic-
es. The following documentation represents a series of product descrip-
tions. It does not guarantee properties under the warranty.
Please thoroughly read the corresponding data sheets, operating instruc-
tions and this system handbook before handling a product.
SIGMATEK GmbH & Co KG is not liable for damages caused through
non-compliance with these instructions or applicable regulations.
The general and special safety instructions described in the following sec-
tions, as well as technical regulations, must therefore be observed.

DC 061-1 S-DIAS AXIS MODULE
Page 8 23.08.2019
1.3 General Safety Guidelines
According to EU Guidelines, the operating instructions are a component of
a product.
This manual must therefore be accessible in the vicinity of the machine
since it contains important instructions.
This technical documentation should be included in the sale, rental or trans-
fer of the product, or its online availability indicated.
Maintain this manual in readable condition and keep it accessible for refer-
ence.
This device contains a Li-Ion battery. For this reason, we refer you to the
manufacturer’s specification (battery safety data sheet). This can be found
on our website.
Regarding the requirements for Safety and health connected to the use of
machines, the manufacturer must perform a risk assessment in accordance
with machine guidelines 2006/42/EG before introducing a machine to the
market.
Before commissioning this product, check that conformance with the provi-
sions of the 2006/42/EG guidelines is correct. As long as the machine, with
which the with the HGW or BWH should be used does not comply with the
guideline, operating this product is prohibited.
Operate the unit with devices and accessories approved by SIGMATEK
only.
CAUTION
Handle the device with care and do not drop or let fall.
Prevent foreign bodies and fluids from entering the device.
The device must not be opened, otherwise it could be damaged!
Manipulez l’appareil avec précaution et ne le laissez pas tomber.
Empêchez les corps étrangers et les liquides de pénétrer dans l’appareil.
L’appareil ne doit pas être ouvert, sinon il risque d’être endommagé!
Regularly check the housing for mechanical damage.
Vérifier régulièrement l’absence de dommages mécaniques sur le boîtier.

S-DIAS AXIS MODULE DC 061-1
23.08.2019 Page 9
2 Technical Data
2.1 Motor Driver Specifications
Type
brushless, 4-quadrant regulator with position setting
Operating voltage
+18-55 V
Maximum continuous current
6 A
Maximum peak current (10 sec)
15 A
Overload protection
short circuit cutoff
temperature monitor
I2T monitor
over and under voltage monitor
2.2 Resolver Specifications
Type
resolver
Resolution
12-bit
Output voltage (EXC)
typically 7 Vrms
Maximum output current (EXC)
200 mA
Output frequency
4 kHz
Input voltage
typically 3.5 Vrms
Resolver transfer ratio
0.5
2.3 Enable Inputs Specifications
Number
2
Input voltage
24 V
Input voltage range
18-24 V
Signal level
low: < 5 V
high: > 15 V
Switching threshold
typically 11 V
Input current
3 mA at 24 V
Input delay
typically 0.5 ms

DC 061-1 S-DIAS AXIS MODULE
Page 10 23.08.2019
2.4 Holding Brake Specifications
Output voltage
24 V
Maximum continuous current
500 mA
Short-circuit protection
yes
Maximum switch-off energy
(inductive load)
50 mJ
2.5 Regen Brake Specifications
Type
external power resistor
Output
GND switching
Maximum current
10 A (1)
Lowest possible resistance
6 Ω (2)
Short-circuit protection
yes
Threshold regen braking on/off
60 V/55 V
(1) Regen braking must be dimensioned according to the application. For most applications, a 10 Ω/50 W resistor is
sufficient. If multiple DC 061-1s 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.
(2) The resistor must be dimensioned with regard to its maximum power dissipation in accordance with the braking
power occurring in the application. However, the permissible short-term power must be at least P=U2/R, i.e.
602/R.
Hot surface warning!
Danger of burns if touched!
The surface of the braking resistor can become very hot during operation
and is still hot some time after operation.
Avoid touching the surface of the braking resistor even some time after
operation.

S-DIAS AXIS MODULE DC 061-1
23.08.2019 Page 11
2.6 Electrical Requirements
Power supply +24 V (X4)
+18-30 V, Class 2 (1)
Current consumption of the
+24 V supply
load-dependent (holding brake)
Supply voltage motor (X2)
+18-55 V (2)
Switching threshold for motor
voltage monitor
minimum 18 V
maximum 65 V
Current consumption of motor
supply
load-dependent (motor)
Voltage supply from S-DIAS bus
+24 V
Current consumption on the
S-DIAS bus (+24 V supply)
typically 70 mA
maximum 80 mA
(1) For USA and Canada:
The supply (X4) 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).
(2) Pour les États-Unis et le Canada:
L’alimentation (X4) 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 élec-
trique ou fusible) doit être certifié par un NRTL (National Recognized Testing Labora-
tory, par exemple, UL).
(2) The motor supply (X2) must be connected with an intermediate circuit capacitance
appropriate for the application (at least 2000 µF/100 V).

DC 061-1 S-DIAS AXIS MODULE
Page 12 23.08.2019
DC Motor Braking
When applying the brake in a servo motor, a generative process can occur
whereby 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 servo
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 insufficient, a regen resistor, which
converts the excess energy into heat must be connected to the servo motor
output stage. When selecting the power supply, it is important to ensure
that it is appropriately feedback-resistant up to the maximum regenerative
voltage that occurs.
Use wires only that are allowed for at least 75 °C!
There is no motor thermostat evaluation in the motor output stage.
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.
Only motors in a star connection can be used.

S-DIAS AXIS MODULE DC 061-1
23.08.2019 Page 13

DC 061-1 S-DIAS AXIS MODULE
Page 14 23.08.2019
2.7 Miscellaneous
Article number
20-014-061-1
Hardware version
1.x
Standard
UL 508C (E336350)
Approvals
CULUS, CE, TÜV-Austria EG-type-examined
2.8 Environmental Conditions
Storage temperature
-20 ... +85 °C
Environmental temperature
0 ... +50 °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
1 g from 8.4-150 Hz
Shock resistance
EN 60068-2-27
15 g
Protection type
EN 60529
IP20

S-DIAS AXIS MODULE DC 061-1
23.08.2019 Page 15
3 Mechanical Dimensions

DC 061-1 S-DIAS AXIS MODULE
Page 16 23.08.2019
4 Connector Layout
4.1 Baumüller
* Both holding brake outputs (BR) are internally connected in parallel. Therewith, the hold-
ing brake can be wired optionally to X3 (pin 7-pin 8) or X4 (pin 3-GND).
With the layout, and M-ROFF of 270 results.

S-DIAS AXIS MODULE DC 061-1
23.08.2019 Page 17
4.2 Kollmorgen
*Both holding brake outputs (BR) are internally connected in parallel. The holding brake can
therewith be optionally connected to X3 (pin 7- Pin 8) or X4 (pin 3-GND).

DC 061-1 S-DIAS AXIS MODULE
Page 18 23.08.2019
4.3 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)
Motor Error
red
BLINKING
motor output stage error
OFF
normal operation
Motor DC OK
green
OFF
no motor supply voltage
BLINKING
power applied, but motor inactive
ON
power applied and motor active
Enable 1
green
ON
enable 1 high
OFF
enable 1 low
Enable 2
green
ON
enable 2 high
OFF
enable 2 low
Holding brake
yellow
ON
output active
OFF
output inactive
DC OK
green
ON
24 V supply OK
OFF
24 V missing or voltage too low
BLINKING
24 voltage supply too high