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SIGMATEK DC 104 Instruction Manual

S-dias drive module
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DC 104
S-DIAS Drive Module
Instruction Manual
Date of creation: 09.01.2025
Version date: 10.01.2025
Article number: 20-014-104-E

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Summary of Contents for SIGMATEK DC 104

  • Page 1 DC 104 S-DIAS Drive Module Instruction Manual Date of creation: 09.01.2025 Version date: 10.01.2025 Article number: 20-014-104-E...
  • Page 2 (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.
  • Page 3 1 holding brake 1 motor temperature sensor input The S-DIAS Drive Module DC 104 is used to control a synchronous servo motor/DC motor with +48 V supply voltage and a phase current of up to 10 A. There is also a brake chopper output for connecting an external brake resistor.

  • Page 4: Table Of Contents

    DC 104 S-DIAS DRIVE MODULE Table of Contents Introduction ................5 Target Group/Purpose of this Manual ........5 Important Reference Documentation ......... 5 Contents of Delivery ..............5 Basic Safety Guidelines ............6 Symbols Used ................6 Disclaimer ..................8 General Safety Directives ............
  • Page 5 S-DIAS DRIVE MODULE DC 104 Motor Output Specifications ............18 Brake Chopper Specifications ........... 19 Universal Encoder Feedback Specifications ......20 6.3.1 Commutation Search ................ 21 Enable Inputs Specifications ............. 22 Holding Brake Specifications ............ 22 Motor Temperature Sensor Input Specifications ....22 Electrical Requirements .............
  • Page 6 DC 104 S-DIAS DRIVE MODULE Performance Level e, Category 4 or SIL 3 – Safety PLC ..42 11.1 Performance Level e, Category 3 or SIL 3 – Safety PLC ..44 11.2 Performance Level e, Category 4 or SIL 3 – Conventional ..46 11.3...

  • Page 7: Introduction

    Please see our website for our hotline number and business hours. Important Reference Documentation • Safety System Handbook This and additional documents can be downloaded from our website or obtained through support. Contents of Delivery 1x DC 104 10.01.2025 Page...

  • Page 8: Basic Safety Guidelines

    DC 104 S-DIAS DRIVE MODULE Basic Safety Guidelines Symbols Used The following symbols are used in the operator documentation for warning and danger mes- sages, as well as informational notes: DANGER Danger indicates that death or serious injury will occur, if the specified measures are not taken.
  • Page 9 S-DIAS DRIVE MODULE DC 104 DANGER Electrical voltage Tension électrique WARNING Hot Surfaces Surfaces chaudes CAUTION Danger for ESD-sensitive components. Les signes de danger pour les composants sensibles aux décharges électrostatiques. INFORMATION Information  Provides important information on the product, handling or rel- evant sections of the documentation, which require attention.

  • Page 10: Disclaimer

    It does not guarantee properties under the warranty. Please thoroughly read the corresponding documents and this instruc- tion manual before handling a product. SIGMATEK GmbH & Co KG is not liable for damages caused through, non-compliance with these instructions or applicable regulations.

  • Page 11: General Safety Directives

    S-DIAS DRIVE MODULE DC 104 General Safety Directives The Safety Directives in the other sections of this operating manual must be observed. These instructions are visually emphasized by symbols. INFORMATION According to EU Directives, the instruction manual is a component of a product.
  • Page 12 DC 104 S-DIAS DRIVE MODULE 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! Manipulez l’appareil avec précaution et ne le laissez pas tomber. Em- pêchez les corps étrangers et les liquides de pénétrer dans l’appareil.

  • Page 13: Designated Use

    The Safety functions implemented in the product are designed for use with safety applications in a SIGMATEK control and meet the required conditions for safe operation according to SIL 3, HFT 1 in compliance with EN IEC 62061 or EN IEC 61508 and according to PL e, Kat.
  • Page 14 DC 104 S-DIAS DRIVE MODULE Non-designated use consists of: • any changes made to the module or the use of damaged modules. • use of the module inconsistent with the technical margins de- scribed in this operating manual or the specifications defined in the technical data.

  • Page 15: Software/Training

    S-DIAS DRIVE MODULE DC 104 Software/Training The application is created with the software LASAL CLASS 2 and LASAL SCREEN Editor, the Safety application is created using the SAFETYDesigner. Basic information on Safety (Functional Safety) can be found in the Safety System Handbook.

  • Page 16: Security

    DC 104 S-DIAS DRIVE MODULE IT Security S-DIAS safety modules were developed for integration into a network protected against un- authorized access. For example, the following dangers can affect the network: • Unauthorized access • Data manipulation • and many other IT security violations It is the responsibility of the integrator or operator to carry out a risk analysis of the connec- tions between automation components and the integration into the overall infrastructure.

  • Page 17: Standards And Directives

    S-DIAS DRIVE MODULE DC 104 Standards and Directives Residual Risks CAUTION The following residual risks for the product must be included in the sys- tem integrator's risk assessment: • Release of non-environmentally safe substances, emissions and unusual temperatures • Possible effects of information technology devices Les risques résiduels suivants pour le produit doivent être inclus dans...

  • Page 18: Functional Safety Standards

    Functional safety – Part 3: Software requirements EN IEC 61508-3 4.3.2 EU Conformity Declaration EU Conformity Declaration The product DC 104 conforms to the following European guidelines: • 2006/42/EG Machine Directive • 2014/30/EU Electromagnetic Compatibility (EMC Directive) • 2011/65/EU “Restricted use of certain hazardous substances in electrical and electronic equipment”...

  • Page 19: Type Plate

    S-DIAS DRIVE MODULE DC 104 Type Plate FS: Safety version number FW: Firmware version LD: Logic device version HW: Hardware version 10.01.2025 Page...

  • Page 20: Technical Data

    DC 104 S-DIAS DRIVE MODULE Technical Data Motor Output Specifications Type Servo motor output stage DC motor output stage Operating modes Current regulation PWM control Speed regulation via universal en- Current regulation coder interface Speed regulation via IxR compensa- Position regulation via universal en-...

  • Page 21: Brake Chopper Specifications

    Regen braking must be dimensioned according to the application. For most applications, a 10 Ω/50 W resistor is sufficient. If multiple DC 061s are driven with one intermediate circuit supply, it is possible to equip only one module with regen braking. The recommended regen resistor (15 Ω/100 W) is available at SIGMATEK under the article number 20-014-061-Z1.

  • Page 22: Universal Encoder Feedback Specifications

    DC 104 S-DIAS DRIVE MODULE Universal Encoder Feedback Specifications Number Encoder system Sanyo Denki BiSS-C (Point to Tamagawa Point) Signals RS422 (A=ES+, RS422 (A=MA+, RS422 (A=Data+, /A=ES-) /A=MA-, B=SL+, /A=Data-) /B=SL-) RS422 level RS422 level (120  termination, in- (120  termination, inte- RS422 level (120 ...

  • Page 23: Commutation Search

    +5 V/0.2 A short-circuit proof With EnDAT2.2, only the reading of the encoder position is supported when the motor output stage is active. ATTENTION: When using SIGMATEK AKM motors with EnDAT encoders, an M-ROFF of 180° is required. 6.3.1 Commutation Search The DC 104 with incremental encoder runs a commutation search during the enable process, which can take several seconds.

  • Page 24: Enable Inputs Specifications

    DC 104 S-DIAS DRIVE MODULE Enable Inputs Specifications Number Input voltage +24 V Input voltage range +18-30 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...

  • Page 25: Electrical Requirements

    S-DIAS DRIVE MODULE DC 104 Electrical Requirements Supply voltage holding brake + +18-30 V, Class 2 universal encoder (X4) Current consumption supply volt- maximum 0.9 A age holding brake + universal en- (load-dependent holding brake + universal encoder supply) coder (X4)
  • Page 26 DC 104 S-DIAS DRIVE MODULE INFORMATION 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, e.g.
  • Page 27 S-DIAS DRIVE MODULE DC 104 10.01.2025 Page...

  • Page 28: Miscellaneous

    DC 104 S-DIAS DRIVE MODULE Miscellaneous Article number 20-014-104 Standard designed according to UL Approvals Mission time 20 years Environmental Conditions Storage temperature -25 ... +85°C Environmental temperature 0 ... +55 °C Humidity 0-95 %, non-condensing Installation altitude above sea...

  • Page 29: Mechanical Dimensions

    S-DIAS DRIVE MODULE DC 104 Mechanical Dimensions 10.01.2025 Page...

  • Page 30: Connector Layout

    DC 104 S-DIAS DRIVE MODULE Connector Layout Page 28 10.01.2025...

  • Page 31: Status Leds

    S-DIAS DRIVE MODULE DC 104 Status LEDs Module status green module active no supply available BLINKING (5 no communication User yellow can be set from the application (e.g. the module LED can be set to blinking through the visu- alization, so that it is easily found in the control cabinet)

  • Page 32: Applicable Connectors

    DC 104 S-DIAS DRIVE MODULE Applicable Connectors X1, X2: Weidmüller socket connectors with spring terminals (included in delivery) X3-X5: Phoenix connector plugs with spring terminals (included in delivery) The spring terminals are suited for the connection of ultrasonically compacted (ultrasonically welded) stranded wire.
  • Page 33 S-DIAS DRIVE MODULE DC 104 Phoenix connector capacity: Stripping length/sleeve length: 10 mm Mating direction: parallel to the conductor axis or circuit board Conductor cross section rigid: 0.2-1.5 mm Conductor cross section flexible: 0.2-1.5 mm Conductor cross-section strands ultrasonically compacted: 0.2-1.5 mm...

  • Page 34: Label Field

    DC 104 S-DIAS DRIVE MODULE 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 Page 32 10.01.2025...

  • Page 35: Wiring

    S-DIAS DRIVE MODULE DC 104 Wiring Wiring Example 10.01.2025 Page...

  • Page 36: Notes

    DC 104 S-DIAS DRIVE MODULE Notes • The DIN rail must have an adequate mass connection. • To wire the encoder, a shielded cable is required. The shield must be placed as close as possible before the module. • For the motor wiring, a shielded cable is required. The shield must be placed as close as possible to the module.

  • Page 37: Additional Safety Information

    CAUTION The instructions contained in this document must be followed. The DC 104 can only be powered by supplies that meet the require- ments for SELV or PELV in compliance with EN 60204. For error-free operation, proper transport and storage are essential.
  • Page 38 DC 104 S-DIAS DRIVE MODULE Correct EMC installation is also included in the designated use. Une installation CEM correcte est également incluse dans l’utilisation prevue. Pour votre propre sécurité et celle des autres, les modules de sécurité ne doivent être utilisés qu’à des fins prévues.
  • Page 39 S-DIAS DRIVE MODULE DC 104 DANGER Failure to follow the above safety measures can lead to severe injuries. Le non-respect des mesures de sécurité ci-dessus peut entraîner des blessures graves. • Only trained personnel are authorized to install the "safe re- start lock"...
  • Page 40 DC 104 S-DIAS DRIVE MODULE • Si des forces externes influencent les axes utilisés avec la fonction de sécurité STO (par ex. charge suspendue), des mesures supplémentaires doivent être prises (par ex. un frein à ressort électromagnétique à double surface au lieu d'un frein à...
  • Page 41 S-DIAS DRIVE MODULE DC 104 WARNING Hot surface warning! Physical contact poses a burn hazard! With unfavorable installation and operating conditions, the surface of the S-DIAS drive module can reach temperatures up to 72 °C and remain hot for some time after operation.

  • Page 42: Sto

    S-DIAS DRIVE MODULE 10.1 STO The DC 104 supports the safety functions STO (Safe Torque Off) when connecting to servo motors and meets the requirements for Category 4 Performance Level "e" according to EN ISO 13849-1 and SILCL 3 according to EN IEC 62061 or EN IEC 61508. (For DC motors, the safety requirement is not met!) For his purpose, the servo amplifier has two safe inputs ENABLE 1 and ENABLE 2.

  • Page 43: Function Test

    S-DIAS DRIVE MODULE DC 104 10.3 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 •...

  • Page 44: Wiring Examples

    DC 104 S-DIAS DRIVE MODULE 11 Wiring Examples In the following sub chapters, wiring examples are provided. It must be ensured that all con- structive measures etc. are taken with and applied in order to fulfill the requirements of the category used.
  • Page 45 S-DIAS DRIVE MODULE DC 104 10.01.2025 Page...

  • Page 46: Performance Level E, Category 3 Or Sil 3 - Safety Plc

    DC 104 S-DIAS DRIVE MODULE 11.2 Performance Level e, Category 3 or SIL 3 – Safety PLC To meet the requirements of safety category 3, performance level "e" for EN ISO 13849-1 and SIL 3 according to EN IEC 62061 or EN IEC 61508, an error-proof output of a safety PLC must be used.
  • Page 47 S-DIAS DRIVE MODULE DC 104 10.01.2025 Page...

  • Page 48: Performance Level E, Category 4 Or Sil 3 - Conventional

    DC 104 S-DIAS DRIVE MODULE 11.3 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 IEC 62061 or EN IEC 61508, the placement of the lines must comply with EN ISO 13849-2, table D.4 (separate placement, prohibiting of error via short...
  • Page 49 S-DIAS DRIVE MODULE DC 104 10.01.2025 Page...

  • Page 50: Performance Level E, Category 2 Or Sil 2 - Safety-Sps

    DC 104 S-DIAS DRIVE MODULE 11.4 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. Page 48 10.01.2025...
  • Page 51 S-DIAS DRIVE MODULE DC 104 10.01.2025 Page...

  • Page 52: Mounting

    DC 104 S-DIAS DRIVE MODULE 12 Mounting 12.1 Check Contents of Delivery Ensure that the contents of the delivery are complete and intact. See chapter 1.3 Contents of Delivery. INFORMATION On receipt and before initial use, check the device for damage. If the device is damaged, contact our customer service and do not install the device in your system.

  • Page 53: Mounting

    S-DIAS DRIVE MODULE DC 104 12.2 Mounting The S-DIAS modules are designed for installation into the control cabinet. To mount the mod- ules, 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.
  • Page 54 DC 104 S-DIAS DRIVE MODULE Recommended minimum distances between the S-DIAS modules and the surrounding com- ponents or control cabinet wall: a, b, c … distances in mm (inches) Page 52 10.01.2025...

  • Page 55: Supported Cycle Times

    S-DIAS DRIVE MODULE DC 104 13 Supported Cycle Times The DC 104 can be accessed via the S-DIAS bus with different bus cycle times. 13.1 Cycle Times below 1 ms (in µs) x= supported 13.2 Cycle Times equal to or higher than 1 ms (in ms)

  • Page 56: Transport/Storage

    DC 104 S-DIAS DRIVE MODULE 14 Transport/Storage INFORMATION This device contains sensitive electronics. During transport and stor- age, high mechanical stress must therefore be avoided. For storage and transport, the same values for humidity and vibration as for operation must be maintained! Temperature and humidity fluctuations may occur during transport.

  • Page 57: Maintenance

    S-DIAS DRIVE MODULE DC 104 16 Maintenance INFORMATION During maintenance as well as servicing, observe the safety instruc- tions from chapter 2. 16.1 Service This product was constructed for low-maintenance operation. 16.2 Repair INFORMATION In the event of a defect/repair, send the device with a detailed error de- scription to the address listed at the beginning of this document.

  • Page 58: Documentation Changes

    DC 104 S-DIAS DRIVE MODULE Documentation Changes Change Affected Chapter Note date page(s) Page 56 10.01.2025...