SIGMA TEK SR 011 User manual

SR 011
S-DIAS DC Motor Module
Technical Manual
Date of creation: 20.03.2019
Version date: 20.03.2019
Article number: 20-029-011-E

Publisher: SIGMATEK GmbH & Co KG
A-5112 Lamprechtshausen
Tel.: [phone]
Fax: [phone]
Email: [email protected]
WWW.SIGMATEK-AUTOMATION.COM
Copyright © 2019
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 express permission.
We reserve the right to make changes in the content without notice. SIGMATEK GmbH & Co KG is not responsible for
technical or printing errors in this handbook and assumes no responsibility for damages that occur through its use.

S-DIAS DC MOTOR MODULE SR 011
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S-DIAS DC-Motor Module SR 011
with1 DC motor output stage +50 V/5 A
1 brake chopper
1 incremental encoder input switchable RS422/TTL
2 Enable inputs +24 V/3 mA/0.5 ms with STO function
(not EG type tested)
1 digital output +24 V/0.5 A/short-circuit protected
The S-DIAS motor output module SR 011 allows the connection of DC
brush motors with a phase current up to 5 A. The operating modes PWM
control, current and speed regulation via IxR compensation, as well as
speed and position regulation via incremental encoder are 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 and fed back to the motor supply, can be dissipated.
The incremental encoder input, which supports RS422 as well as TTL
encoders, is provided for position feedback.
With the two Enable inputs, the Safety function STO is implemented
(not EG type tested).
The module also has a short-circuit proof digital output (+24 V/0.5 A).
The +24 V supply voltage for the digital in- and outputs, as well as the incremental encoder
supply are monitored for under voltage.

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Contents
1Introduction............................................................................. 5
1.1 Target Group/Purpose of this Manual ........................................5
1.2 Contents of Delivery.....................................................................5
2Basic Safety Guidelines......................................................... 6
2.1 Symbols Used...............................................................................6
2.2 Disclaimer......................................................................................7
2.3 General Safety Guidelines...........................................................8
2.4 Guidelines......................................................................................9
2.4.1 EU Conformity Declaration..................................................................9
2.5 Safety-Relevant Parameters........................................................9
3Technical Data .......................................................................10
3.1 DC Motor Output Specifications ...............................................10
3.2 Brake Chopper Specifications...................................................11
3.3 Incremental Encoder Input ........................................................12
3.4 STO Enable Input Specifications ..............................................13
3.5 Digital Output Specifications.....................................................13
3.6 Electrical Requirements.............................................................14
3.7 Miscellaneous .............................................................................16
3.8 Environmental Conditions.........................................................16
4Mechanical Dimensions........................................................17
5Connector Layout..................................................................18

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5.1 Status LEDs.................................................................................19
5.2 Applicable Connectors...............................................................20
5.3 Label Field ...................................................................................21
6Wiring.....................................................................................22
6.1 Wiring Example...........................................................................22
6.2 Note..............................................................................................23
7Additional Safety Information ..............................................24
7.1 STO...............................................................................................27
7.2 Function.......................................................................................28
7.3 Function Test ..............................................................................29
8Wiring Examples ...................................................................30
8.1 Performance Level e, Category 4 or SIL 3 –Safety-SPS ........30
8.2 Performance Level e, Category 3 or SIL 3 –Safety-SPS ........32
8.3 Performance Level e, Category 4 or SIL 3 –Conventional.....34
8.4 Performance Level e, Category 2 or SIL 2 –Safety-SPS ........36
9Transport/Storage.................................................................37
10 Mounting................................................................................38
11 Maintenance...........................................................................40
11.1 Maintenance................................................................................40
11.2 Repair...........................................................................................40

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12 Disposal..................................................................................41

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1 Introduction
1.1 Target Group/Purpose of this Manual
This manual contains all information required for operating the SR 011.
This manual is intended for:
•Project planners
•Technicians
•Configurators/commissioning engineers
•Machine operators
•Maintenance/test technicians
General knowledge of automation technology is required.
Further help and training information, as well as the appropriate accessories can be found on
our website www.sigmatek-automation.com
Our support team is happily available to answer your questions.
For our support hotline and business hours, please visit our website.
1.2 Contents of Delivery
1x SR 011
4x opposing connector
This document can be downloaded from our website.
Additional documents may be included with delivery.

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2 Basic Safety Guidelines
2.1 Symbols Used
The following symbols are used in the operator 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 im-
médiat 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 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
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

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Provides user tips, informs of special features and identifies especially im-
portant information in the text.
Fournit des conseils d’utilisation, informe sur les fonctions particulaires et
souligne les informations particulièrement importantes dans le texte.
2.2 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 con-
figuration. The machine operator is responsible for safe handling, 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 devices.
The following documentation is purely aproduct description. It does notguar-
antee properties under the warranty.
Please thoroughly read the corresponding data sheets, operating instructions
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.

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2.3 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 beincluded in the sale, rental or transfer
of the product, or its online availability indicated.
Maintain this manual in readable condition and keep it accessible for refer-
ence.
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 device 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!

S-DIAS DC MOTOR MODULE SR 011
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2.4 Guidelines
The device was constructed in compliance with European Union guidelines.
2.4.1 EU Conformity Declaration
CE Declaration of Conformity
The SR 011 conforms to the following European guidelines:
•2014/35/EU Low-voltage 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.
See: Products/downloads, or using the search function and keyword “EU
Declaration of Conformity”
In addition to these directives, the SR 011 was also designed in accordance with 2006/42/EC
and the standards EN 13849-1 and EN 62061 but was not EC type-examination tested!
2.5 Safety-Relevant Parameters
The use of the specified parameters requires a risk analysis of the end application.
Safety parameters for two channel operation of the SR 011
Safety Parameters
Safety Level
EN 62061
PFHD = 1.64E-09 (1/h)
DC = 99.77 %
SIL 3 or SIL CL3
EN ISO 13849-1
MTTFd = 631 years
DC = 99.11 %
PL e, Cat. 4

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3 Technical Data
3.1 DC Motor Output Specifications
Number
1
Supported motor type
DC brush motor
Operating modes
PWM control
Current regulation
Speed regulation via IxR compensation
Speed regulation via incremental encoder
Position regulation via incremental encoder
Supply voltage
+18-55 V
PWM frequency
32 kHz
Current controller frequency
16 kHz
Maximum PWM Switching
ratio
95 % (limited by hardware)
Maximum continuous current
5 A
Output current over the environ-
mental temperature
maximum 5 A continuous current at 45 °C
maximum 3.5 A continuous current at 50 °C
maximum 2 A continuous current at 55 °C
Maximum peak current (1 s)
15 A
DC-link capacitance
2.8 µF
Motor current measurement
0-15 A
Voltage measurement
0-65 V
Temperature measurement
0-125 °C
with temperature warning at 103 °C
with temperature warning at 108 °C
Safety functions
Short circuit cutoff
Temperature cut-off
I2t monitor
Over and under voltage monitor

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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
Article number
20-014-061-Z1
Regen resistor switching thresh-
old 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.
(2) The resistance must be dimensioned based on its maximum power dissipation corresponding to the braking power
generated in the application. However, the permissible short-term power generated must be at least P=U2/R, mean-
ing 602/R.
Hot surface warning
A burn hazard exists with physical contact!
During operation, the surface of the brake resistor can become very hot and
remain hot sometime after operation.
Avertissement de surface chaude
Il existe un risque de brûlure par contact physique !
Pendant le fonctionnement, la surface de la résistance de freinage peut
devenir très chaude et rester chaude quelque temps après le fonctionne-
ment.
Avoid physical contact with the surface of the brake resistor, and for a signif-
icant time after operation.
Éviter tout contact physique avec la surface de la résistance de freinage et
pendant une longue période après le fonctionnement.

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3.3 Incremental Encoder Input
Number
1
Input signals
Incremental encoder signals RS422 (A, /A, B, /B, R, /R)
RS422 signal (120 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 bits
Encoder power supply
+5 V/0.2 A short-circuit proof

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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" ac-
cording to
EN ISO 13849-1 and SIL CL 3 according to 62061
Not EG type tested!
Safety function
STO according to EN 61800-5-2, section 4.2.2.2
The motor is not supplied with energy, which can cause a turn. The DC mo-
tor output stage does not supply energy to the motor, which can generate
torque.
Not EG type tested!
3.5 Digital Output Specifications
Number
1
Short-circuit proof
yes
Maximum continuous current load
allowed
0.5 A
Maximum braking energy of the
output (inductive load)
maximum 0.5 Joules
Residual current output
(off)
≤ 10 µA
Turn-on delay
< 200 µs
Turn-off delay
< 200 µs

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3.6 Electrical Requirements
Supply voltage +24 V (X4)
18-30 V
Current consumption of the +24 V
supply (X4)
load-dependent (digital output + digital output supply)
maximum 0.6 A
Motor supply voltage (X2)
+18-55 V
Current consumption of motor
supply (X2)
maximum 5 A (load-dependent)
Voltage supply from S-DIAS bus
+24 V
Current consumption on the
S-DIAS bus (+24 V supply)
typically 60 mA
maximum 85 mA
Voltage supply from S-DIAS bus
+5 V
Current consumption on the S-
DIAS bus (+5 V supply)
-
-
The motor supply must be connected with an appropriate DC-link capaci-
tance (at least 2000 µF / 100 V).
Braking a DC motor
When braking a DC 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 DC motor output stage;
this then increases the supply voltage. It should be noted that the feedback
voltage supply voltage of 65 V cannot be 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 ex-
cess energy into heat must be connected to the DC motor output stage.
When selecting the power supply, it is important to ensure that it is appropri-
ately feedback-resistant up to the maximum feedback voltage.
Use only conductors that are rated for at least 75 °C!
There is no motor thermostat analysis in the motor output.
Incorrectly set parameter or incorrect wiring can lead to destruction of the
motor. It is important that the motor currents and the I2T settings (A-I2TT, A-
I2TERR), which can be defined via the LASAL Class 2 Tool in the DIAS-Drive
Editor, must be taken into account.

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3.7 Miscellaneous
Article number
20-029-011
Hardware version
1.x
Standard
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 environment temperature by 0.5 °C
per 100 m
Operating conditions
pollution degree 2
indoor use
EMC resistance
in accordance with 61000-6-7:2015 (Generic standards –immunity require-
ments for equipment designed to perform functions in safety-based systems
(functional safety) at industrial facilities)
according to 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

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4 Mechanical Dimensions

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5 Connector Layout