SIGMA TEK ST 151 User manual

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.: [phone]
Fax : [phone]
Email: [email protected]
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 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 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
Page 2 02.12.2019
Contents
1Basic Safety Guidelines......................................................... 5
1.1 General Information on Safety ....................................................5
1.2 Further Safety Guidelines............................................................6
1.3 General Requirements .................................................................7
2Safety Conformity..................................................................11
2.1 Functional Safety Standards.....................................................11
2.2 EU Conformity Declaration........................................................11
2.3 Safety-Relevant Parameters......................................................11
3Technical 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
4Mechanical Dimensions........................................................18
5Connector Layout..................................................................19
5.1 Status LEDs.................................................................................20
5.2 Applicable Connectors...............................................................21

S-DIAS STEPPER MOTOR OUTPUT STAGE ST 151
02.12.2019 Page 3
5.3 Label Field ...................................................................................22
6Wiring.....................................................................................23
6.1 Wiring Example...........................................................................23
6.2 Note..............................................................................................24
7Description 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
8Additional Safety Information ..............................................31
8.1 STO...............................................................................................33
8.2 Function.......................................................................................33
8.3 Function Test ..............................................................................34
9Wiring 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
Page 4 02.12.2019
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
02.12.2019 Page 5
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
Page 6 02.12.2019
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 infor-
mation 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
02.12.2019 Page 7
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 im-
portantes.
•Distribuez la documentation technique aux secteurs de
la vente et/ou de la location du produit.
Acceptance of the Safe-
ty 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
Page 8 02.12.2019
Prendre connaissance
de consignes de sécu-
rité
Avant toute manipulation on doit impérativement prendre con-
naissance 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, opera-
tion, maintenance and decommissioning of control and automa-
tion technology products in general, as well as safety-related
products especially, can only be performed by qualified person-
nel.
Qualified personnel in this context are people, who have com-
pleted 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'exploi-
tation, 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 quali-
fié.
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
02.12.2019 Page 9
Designated Use
The Safety modules are designed for use in safety-oriented
applications and meet the required conditions for safety opera-
tion in compliance with Performance level e (PL e), in accord-
ance with EN ISO 13849-1/-2 and SIL3 or SIL CL 3 in accord-
ance with EN 62061.
For your own safety and the safety of others, use safety mod-
ules for their designated purpose. Correct EMC installation as
well as proper transport and storage are also included in desig-
nated 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
Page 10 02.12.2019
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
02.12.2019 Page 11
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
Page 12 02.12.2019
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 environ-
mental 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 reso-
nance 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
02.12.2019 Page 13
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 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.
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
Page 14 02.12.2019
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
02.12.2019 Page 15
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 élec-
trique ou fusible) doit être certifié par un NRTL (National Recognized Testing Labora-
tory, par exemple, UL).

ST 151 S-DIAS STEPPER MOTOR OUTPUT STAGE
Page 16 02.12.2019
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
02.12.2019 Page 17
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

ST 151 S-DIAS STEPPER MOTOR OUTPUT STAGE
Page 18 02.12.2019
4 Mechanical Dimensions