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SIGMATEK S-DIAS ST 152 Instruction Manual

Stepper motor stage closed loop
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ST 152
S-DIAS Stepper Motor Stage Closed
Loop
Instruction Manual
Date of creation: 09.01.2025
Version date: 06.02.2025
Article number: 20-014-152-E

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Summary of Contents for SIGMATEK S-DIAS ST 152

  • Page 1 ST 152 S-DIAS Stepper Motor Stage Closed Loop Instruction Manual Date of creation: 09.01.2025 Version date: 06.02.2025 Article number: 20-014-152-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...
  • Page 3 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 S-DIAS Stepper Motor Stage Closed Loop ST 152 1 stepper motor output stage 50 V/5 A with Closed Loop control 1 brake chopper 1 incremental encoder input RS422/TTL switchable 2 enable inputs +24 V/3.2 mA/0.5 ms with STO functionality 2 latch/digital inputs +24 V/3.7 mA/10 µs 2-phase stepper motors with up to 5 A phase current can be...

  • Page 4: Table Of Contents

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Table of Contents 1 Introduction 1.1 Target Group/Purpose of this Operating Manual 1.2 Important Reference Documentation 1.3 Contents of Delivery 2 Basic Safety Directives 2.1 Symbols Used 2.2 Disclaimer 2.3 General Safety Directives 2.4 Designated Use 2.5 Software/Training 3 IT Security...
  • Page 5 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 6.7 Miscellaneous 6.8 Environmental Conditions 7 Mechanical Dimensions 8 Connector Layout 8.1 Applicable Connectors 8.2 Status LEDs 8.3 Label Field 9 Wiring 9.1 Wiring Example 9.2 Note 10 Additional Safety Information 10.1 STO 10.2 Function 10.3 Function Test 11 Wiring Examples...
  • Page 6 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP 12.1.7 Speed-dependent Scaling 12.1.8 Combination of Voltage PWM Mode Chopper with Current Control Mode Chopper 12.1.9 Configuration/Commissioning Voltage PWM Mode Chopper 12.2 Sensorless Load Determination 12.2.1 Configuration/Commissioning 12.2.2 Stop on Stall 12.3 Sensorless Load-dependent Motor Current Control 12.4 Closed Loop Regulator 12.4.1 Functioning of Closed Loop Regulation 12.4.1.1 Position Control...
  • Page 7 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 13.1 Check Contents of Delivery 13.2 Mounting 14 Transport/Storage 15 Storage 16 Maintenance 16.1 Service 16.2 Repair 17 Disposal 06.02.2025 Page 5...

  • Page 8: Introduction

    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. Please see our website for our hotline number and business hours.

  • Page 9: Basic Safety Directives

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 2 Basic Safety Directives 2.1 Symbols Used The following symbols are used in the operator documentation for warning and danger messages, as well as informational notes. DANGER Danger indicates that death or serious injury will occur, if the specified measures are not taken.
  • Page 10 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP CAUTION Caution indicates that moderate to slight injury can occur, if the specified measures are not taken. To avoid moderate to slight injuries, observe all guidelines. Attention indique une situation dangereuse qui, faute de prendre les mesures adéquates, peut entraîner des blessures assez graves ou légères.

  • Page 11: Disclaimer

    Please thoroughly read the corresponding documents and this operating 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 12: General Safety Directives

    Regarding the requirements for Safety and health connected to the use of machines, the manufacturer must perform a risk assessment in accordance with machine directives 2006/42/EG before introducing a machine to the market. Operate the unit with devices and accessories approved by SIGMATEK only. Page 10 06.02.2025...
  • Page 13 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 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. Empêchez les corps étrangers et les liquides de pénétrer dans l’appareil.

  • Page 14: Designated Use

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP 2.4 Designated Use The Safety functions implemented in the product are designed for use with safety applications in a PLC control and meet the required conditions for safe operation according to SIL 3 in compliance with EN IEC 62061 or EN IEC 61508 and according to PL e / Cat. 4 in compliance with EN ISO 13849-1.

  • Page 15: Software/Training

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 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 described in this operating manual or the specifications defined in the technical data.

  • Page 16: Security

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP 3 IT Security S-DIAS safety modules were developed for integration into a network protected against unauthorized 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 connections between S-DIAS modules and the integration into the overall infrastructure.

  • Page 17: Standards And Directives

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 4 Standards and Directives 4.1 Residual Risks CAUTION The following residual risks for the product must be included in the system integrator's risk assessment: Release of non-environmentally safe substances, emissions and unusual temperatures Hazardous contact voltages Effects of operational electrical, magnetic and electromagnetic fields...

  • Page 18: Directives

    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. They can be found in the download area of the respective product. Note: The issue status of the applied standards can be foundin the EU declaration of conformity.

  • Page 19: Safety-Relevant Parameters

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 4.4 Safety-Relevant Parameters ST 152 Safety parameters SIL 3, PL e / Cat. 4 Safety Function STO PFH = 1.12E-09 (the safety function STO is SFF = 99.92 % supported by the module ONLY for operation as a servo motor MTTF = 2100 years...

  • Page 20: Type Plate

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP 5 Type Plate Example: FS: Safety Version FW: Firmware Version LD: Logic Device Version HW: Hardware Version Page 18 06.02.2025...

  • Page 21: Technical Data

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 6 Technical Data 6.1 Stepper motor output specification Type stepper motor output stage Operating modes open loop mode (without incremental encoder feedback) closed loop mode (with incremental encoder feedback) Number of phases Operating voltage +18-55 V Current controller frequency...

  • Page 22: Brake Chopper Specifications

    S-DIAS Stepper Motor Stage Closed Loop 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 23: Incremental Encoder Specifications

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 WARNING 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. Avoid physical contact with the surface of the brake resistor, and for a significant time after operation as well.

  • Page 24: Latch/Digital Inputs Specifications

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP 6.4 Latch/Digital Inputs Specifications Number Input voltage typically +24 V maximum +30 V Signal level low: < +5 V high: > +15 V Switch hysteresis typically +11 V Input current 3.7 mA at +24 V Input delay typically 10 µs INFORMATION...

  • Page 25: Electrical Requirements

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 6.6 Electrical Requirements Supply from S-DIAS bus +18-55 V DC Current consumption of the maximum 6 A (load-dependent) motor supply Supply from S-DIAS bus +5 V Current consumption on the S-DIAS bus (+5 V supply) Supply from S-DIAS bus +24 V Current consumption on the...
  • Page 26 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP INFORMATION Note 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 documentation under "Electrical Requirements".
  • Page 27 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 06.02.2025 Page 25...

  • Page 28: Miscellaneous

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP 6.7 Miscellaneous Article number 20-014-152 Printed circuit board coating Standard designed according to UL Approvals Mission time 20 years 6.8 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 STEPPER MOTOR STAGE CLOSED LOOP ST 152 7 Mechanical Dimensions Measurements 37.5 x 104 x 72 mm (W x H x D) 06.02.2025 Page 27...

  • Page 30: Connector Layout

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP 8 Connector Layout INFORMATION It is not permitted to plug or unplug the motor supply connector X2 during operation! Page 28 06.02.2025...

  • Page 31: Applicable Connectors

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 8.1 Applicable Connectors X1-X4: Connectors with spring terminals (included in delivery) The spring terminals are suited for the connection of ultrasonically compacted (ultrasonically welded) stranded wire. Connection capacity: Stripping length/sleeve length 10 mm Mating direction parallel to conductor axis or to circuit board Conductor cross section rigid...

  • Page 32: Status Leds

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP 8.2 Status LEDs Module status green module active no supply available BLINKING (5 Hz) no communication User yellow adjustable by application (e.g. the module LED can be set to blinking through the visualization so that the module is easily found in the control cabinet) BLINKING (2 Hz) BLINKING (4 Hz)

  • Page 33: Label Field

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 8.3 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 06.02.2025 Page 31...

  • Page 34: Wiring

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP 9 Wiring 9.1 Wiring Example Page 32 06.02.2025...

  • Page 35: Note

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 9.2 Note The following installation guidelines should be observed: The DIN rail must have an adequate mass connection. The shielding must be connected to a shielding bus. To wire the incremental encoder, a shielded cable is required. With an RS422 encoder, the use of shielded, twisted pair cables is recommended.

  • Page 36: Additional Safety Information

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP 10 Additional Safety Information The Safety function “STO” is an integrated part of the . It meets all necessary requirements for safe operation in SIL 3 according to EN IEC 62061 or EN IEC 61508 and in compliance with PL e.
  • Page 37 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 CAUTION For your own safety and that of others, the safety modules should be used for their designated purpose only. 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 described in this manual or the speciation's defined in the technical data (see chapter 6 Technical Data).
  • Page 38 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP CAUTION Pour votre propre sécurité et celle des autres, les modules de sécurité ne doivent être utilisés qu’à des fins prévues. Correct EMC installation is also included in the designated use. Une installation CEM correcte est également incluse dans l’utilisation prevue.
  • Page 39 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 DANGER Failure to follow the above safety measures can lead to severe injuries. Only trained personnel are authorized to install the "safe restart lock" STO (Safe Torque off) and set the parameters. All control devices (switches, relays, PLC, etc.) and the control cabinet must meet the requirements for EN ISO 13849.
  • Page 40 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP DANGER Le non-respect des mesures de sécurité ci-dessus peut entraîner des blessures graves. Seul un personnel qualifié est autorisé à installer le "blocage de redémarrage sûr" STO (Safe Torque off) et à régler les parameters.

  • Page 41: Sto

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 10.1 STO The ST 152 supports the safety functions STO (Safe Torque Off) 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.

  • Page 42: Function Test

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP 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 In regular intervals, or at least once a year WARNING If the function test results in an invalid machine status, the error must be...

  • Page 43: Wiring Examples

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 11 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.
  • Page 44 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Page 42 06.02.2025...

  • Page 45: Performance Level E, Category 3 Or Sil 3 - Safety Plc

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 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 46 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Page 44 06.02.2025...

  • Page 47: Performance Level E, Category 4 Or Sil 3 - Conventional

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 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 circuits between wires) as cross-circuit detection is not possible here.
  • Page 48 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Page 46 06.02.2025...

  • Page 49: Performance Level E, Category 2 Or Sil 2 - Conventional

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 11.4 Performance Level e, Category 2 or SIL 2 - Conventional This involves 1-channel wiring, whereby the Enable inputs are tested separately. Here, no cross-circuit detection is possible. 06.02.2025 Page 47...
  • Page 50 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Page 48 06.02.2025...

  • Page 51: Description Of Functions

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 12 Description of Functions 12.1 Current Regulator Modes 12.1.1 Current Control Mode Chopper The current control mode chopper is the current control mode configured by default. This mode allows for stable torque and good current control of the stepper motor over a wide speed range.
  • Page 52 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP The best setting is found by starting with a low hysteresis setting (e.g. with hysteresis off: hysteresis start value HSTRT=0, hysteresis end value HEND=0) and increasing HSTRT until the motor runs smoothly at low speed settings. This is best checked by measuring the motor current either with a current probe or by measuring the voltages across current-sensing resistors.

  • Page 53: Voltage Pwm Mode Chopper

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 Example 1 (minimum hysteresis, with hysteresis start value 4 and hysteresis end value 3): HEND=6 (sets an effective end value of 6-3=3) HSTRT=0 (sets an effective starting value with minimum hysteresis, i.e. 1: 3+1=4) Example 2 (minimum hysteresis, with hysteresis start value 7 and hysteresis end value 4): HEND=0 (sets an effective end value of -3)

  • Page 54: Automatic Tuning

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Motor current sine wave with voltage PWM mode chopper 12.1.3 Automatic Tuning The voltage PWM mode chopper integrates an automatic tuning process (AT) that automatically adjusts the most important operating parameters to the motor. In this way, the voltage PWM mode chopper enables high motor dynamics and supports the ramp-down of the motor to very low currents.
  • Page 55 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 Flow diagram of automatic tuning 06.02.2025 Page 53...
  • Page 56 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP The basic conditions for AT#1 and AT#2 are listed in the following table: Step Parameters Conditions Required duration AT#1 PWM_OFS_AUTO When the motor is at a standstill and the ≤ 130 ms current scale (CS) is identical to the operating current (IRUN).

  • Page 57: Voltage Pwm Mode Chopper Options

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 CAUTION Operating in voltage PWM chopper mode without proper tuning, especially for low resistance motors and fast deceleration settings, can result in high motor currents during a deceleration ramp. The automatic process must be followed.

  • Page 58: Voltage Pwm Mode Chopper: Functionality

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP INFORMATION To reduce the jitter of the motor current amplitude, a specified PWM_ GRAD should be used and pwm_autograd = 0 should be set. The non- automatic mode (pwm_autoscale=0) should only be considered for known motor and operating conditions.
  • Page 59 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 Motor current recording with good setting for PWM_REG 06.02.2025 Page 57...
  • Page 60 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Motor current recording with too small a value for PWM_REG during AT#2 Successfully determined PWM_GRAD(_AUTO) and PWM_OFS(_AUTO) Page 58 06.02.2025...

  • Page 61: Lower Current Limit

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 12.1.6 Lower Current Limit The voltage PWM mode chopper sets a lower limit for the motor current control. Since the motor current can only be measured during the chopper's switch-on phase, the minimum chopper duty cycle that enables regulation of the coil current is given by the blanking time and the chopper frequency.The motor-specific minimum coil current therefore increases in auto- scaling mode of voltage PWM mode chopper, with the supply voltage and with the chopper...

  • Page 62: Speed-Dependent Scaling

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP 12.1.7 Speed-dependent Scaling The speed-based scaling scales the voltage PWM mode chopper amplitude based on the time between two steps (T ), measured in clock cycles. This concept basically does not STEP require current measuring, since no control loop is necessary.
  • Page 63 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 As the motor speed increases, the motor generates an increasing back-EMF voltage. The back-EMF voltage is proportional to the motor speed. It reduces the PWM voltage applied to the inductor, thereby reducing the current. The motor end stage offers a second speed- dependent factor (PWM_GRAD) to compensate for this.
  • Page 64 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Speed-based PWM scaling (pwm_autoscale=0) The values for PWM_OFS and PWM_GRAD can easily be optimized by measuring the motor current with a current probe. Alternatively, these values are determined by the automatic tuning and can be read from PWM_OFS_AUTO and PWM_GRAD_AUTO. Motor back-EMF constant The back-EMF constant is the voltage generated by a motor when it is turning at a certain speed.

  • Page 65: Combination Of Voltage Pwm Mode Chopper With Current Control Mode Chopper

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 12.1.8 Combination of Voltage PWM Mode Chopper with Current Control Mode Chopper For applications that require high-speed movement, the current control mode chopper can provide more stable operation at high speeds. To combine quiet operation with maximum dynamics, the stepper motor output stage allows the combination of voltage PWM mode chopper and current control mode chopper based on a speed threshold.

  • Page 66: Configuration/Commissioning Voltage Pwm Mode Chopper

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP winding). At low speeds (e.g. 1 to a few 10 rpm), this can be completely neglected for most motors. The switchover jerk must therefore be taken into account when selecting TPWMTHRS. If you only want to work with the voltage PWM mode chopper, TPWMTHRS must be set to zero.

  • Page 67: Sensorless Load Determination

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 When using the default settings, the module automatically determines the correct gain and offset to maintain the target current as closely as possible. In the voltage PWM mode chopper, there may be deviations in the set current setpoint at low speeds due to the principle involved.

  • Page 68: Configuration/Commissioning

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP 12.2.1 Configuration/Commissioning The goal is to configure the calculation of the sensorless load value so that at the target current and at the target speed under: idle the sensorless load value is in the range of a few hundred units full load the sensorless load value is small, without reaching zero before the motor stalls.

  • Page 69: Stop On Stall

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 12.2.2 Stop on Stall The module can provide a signal that can be used to stop the motor. Alternatively, the current sensorless load value can be read from bits 0-9 of register index 0x4000, sub-index 0x6D and the stopping without an event of the chip can be executed in the application.
  • Page 70 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP The following parameters are used to set the sensorless load-dependent motor current setting: Index SubIndex Name Meaning 0x4001 0x6E Bit 0:3 COOLCONF semin0- Output of maximum current when sensorless load value < semin3/Lower (lower threshold sensorless load value)*32 threshold sensorless...

  • Page 71: Closed Loop Regulator

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 To avoid a delayed reaction (increase in current amplitude), the lower threshold of the sensorless load value must be selected so that the maximum current is already output at high load. Conversely, the sum of the lower and upper threshold of the sensorless load value must be selected so that the minimum current is output.

  • Page 72: Functioning Of Closed Loop Regulation

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP 12.4.1 Functioning of Closed Loop Regulation The closed-loop regulation consists of three main components: 1. a position correction in conjunction with a P-regulator for the position deviation. In addition, the position correction has a component that compensates for the effects of the counter-electromotive force.
  • Page 73 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 The module offers the following settings to influence behavior based on the default settings. Index SubIndex Name Meaning 0x4000 0x5D CL gain/CL_ The CL gain is used to make the behavior of the axis stiffer or DELTA_P softer.

  • Page 74: Current Controller

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP To compensate for the effects of back-EMF, the output angle can also be corrected by a speed-dependent value. This means that the CL regulator only compensates for the correct deviation that results from the drive, and the increasing effect of the back-EMF with speed does not have to be compensated for.

  • Page 75: Speed Regulator

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 12.4.1.3 Speed Regulator The idea of the speed controller can be compared to the approach with the position controller. An additional speed is determined, which is added to the target speed. The total speed is the sum of the control speed and the additional speed.

  • Page 76: Closed Loop Tuning Procedure

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP 12.4.1.4 Closed Loop Tuning Procedure If the analysis of the controller quality shows that the standard settings of the module are not satisfactory, the closed loop controller can be tuned. The most important tuning factor for the CL regulator has typically already been set during commissioning, by defining “minimum current”...
  • Page 77 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 The next step is to set the back-EMF correction. To do this, it is best to accelerate the axis slowly (if possible without exciting resonant frequencies). From the speed of back-EMF correction start speed (default = 250000 pps), a reduction in encoder deviation should be visible or no further increase.
  • Page 78 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP In the case of the current controller, the user only has access to the minimum and maximum current. As with open loop mode, there is no general rule for how the current amplitude should be changed to influence vibrations and oscillations.

  • Page 79: Supported Step Operation Modes

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 12.5 Supported Step Operation Modes 12.5.1 Full step mode In full step mode, Current is applied to the winding as shown below. The motor rotates in full steps only. It therefore executes the nominal number of steps of the motor in one revolution. The step mode selection with full step, half step, 4-/8-/16-/32-/64-/128-/256-fold microstep is done automatically.

  • Page 80: Micro Step Mode

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP 12.5.3 Micro Step Mode In micro step mode, a nearly sine wave formed current is applied to the individual windings. With the ST 152, the resolution of the sine oscillation is 1024 steps. 256 micro steps per full step are thereby produced.

  • Page 81: Signal Process "Count Down

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 12.6.2 Signal Process “Count DOWN” 12.6.3 Signal Process “Reference Pulse (Zero Position)” 12.6.4 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.

  • Page 82: Object Directory Overview

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP 12.7 Object Directory Overview Index SubIndex Name Index SubIndex Name 0x1001 0x00 Error Register 0x4000 0x67 V_ENC_MEAN 0x100A 0x00 FW Version 0x4000 0x68 VSTALL_LIMIT 0x2001 0x00 FW Status 0x4000 0x7D SCALE_PARAM 0x1600 0x00 RPDO Mapping 0x4001...
  • Page 83 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 Index SubIndex Name Index SubIndex Name 0x4006 0x07 Blocking Time 0x400F 0x01 OL DRV1_SCALE_VAL / CL CL_IMAX 0x4006 0x08 Upper Voltage Limit 0x400F 0x02 OL HOLD_SCALE_VAL / 0x4006 0x09 Lower Voltage Limit CL CL_IMIN 0x4006 0x0A...
  • Page 84 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Index SubIndex Name Index SubIndex Name 0x401B 0x02 IRUN 0x6080 0x00 Motor Max Speed 0x401B 0x03 IHOLD 0x60C5 0x00 Motor Max Acceleration 0x6041 0x00 Status Word 0x60C6 0x00 Motor Max Deceleration 0x6061 0x00 Modes of Operation Display 0x6083...

  • Page 85: Detaillied Object Directory

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 12.8 Detaillied Object Directory Name Error Register Index 0x1001 Sub-index 0x00 Device State Size [bytes] Shows error bits in a bit field from 0-31. Bit 0-1: Reserved. Bit 2: Voltage error (see chapter Stepper Motor Output Specifications). Bit 3: Temperature error (see chapter Stepper Motor Output Specifications).
  • Page 86 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Name FW Status Index 0x2001 Sub-index 0x00 Device State Size [bytes] Shows the FW status in bits. Bit 0: DC not OK (not used). Bit 1: Not synchronized (no sync). Bit 2: Flash error (normalization data invalid). Bit 3: RAM error (cyclic RAM check detected errors).
  • Page 87 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 Name Motion Index 0x4000 Sub-index 0x00 Controller Parameter Device State Size [bytes] Sub-index 1-128 Parameter Motion Controller. Important! Only the listed sub-indices may be used. Name REFERENCE_ Index 0x4000 Sub-index 0x02 CONF Device State Size [bytes] Application user: STOP_ON_STALL (Bit 26)
  • Page 88 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Bits 23-24: pos_comp_output 0: TARGET_REACHED is triggered by the TARGET_REACHED flag. 1: TARGET_REACHED is triggered by the VELOCITY_REACHED flag. 2: TARGET_REACHED is triggered by the ENC_FAIL flag. 3: TARGET_REACHED is triggered by the POSCOMP_REACHED flag. Default value = 0 Bit 25: pos_comp_source 0: Compares POS_COMP with the internal position (XACTUAL).
  • Page 89 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 Bit 2: clr_latch_cont_on_n 0: ENC_POS is not deleted/blocked at each N-event. 1: ENC_POS is deleted/blocked at each N-event. Default value = 0 Bit 3: clr_latch_once_on_n 0: ENC_POS is not deleted/stored at the next N event. 1: ENC_POS is deleted/stored at the next N event.
  • Page 90 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Bit 15: use_usteps_instead_of_xrange 0: X_RANGE is valid when circular motion is activated for encoders. 1: USTEPS_PER_REV is valid when circular motion is activated for encoders. Default value = 0 Bits 16-21: Default value = 0 -> must not be changed Bits 22-23: Internal use ->...
  • Page 91 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 3: VEL_STATE = b'00: speed is zero (VACTUAL = 0). Default value = 0 4: VEL_STATE = b'01: speed is positive (VACTUAL > 0). Default value = 0 5: VEL_STATE = b'10: speed is negative (VACTUAL < 0). Default value = 0 6: RAMP_STATE = b'00: Ramp status is constant speed (AACTUAL = 0, VACTUAL is constant).
  • Page 92 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Name CL_BETA / CL_ Index 0x4000 Sub-index 0x1D GAMMA Device State Size [bytes] CL_BETA and CL_GAMMA configuration Bits 0-8 - CL_BETA: 0x0FF: Defines the maximum commutation angle for the regulation. Note: A value of 255 (0x0FF) is recommended for best performance. The setting of CL_BETA above 255 should be done with caution, especially if cl_vlimit_en is activated.
  • Page 93 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 Name ENC_POS_DEV Index 0x4000 Sub-index 0x53 / CL_TR_ TOLERANCE Device State Size [bytes] ENC_POS_DEV and CL_TR_TOLERANCE configuration: Bits 0-31 - ENC_POS_DEV (Preset: 0x00000000) read only (R): This represents the deviation between the current XACTUAL position and the encoder position ENC_POS.
  • Page 94 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Name CL_VMAX_ Index 0x4000 Sub-index 0x5C CALC_I Device State Size [bytes] PID integral configuration, default value = 0x32 Bits 0-23 - PID_I write only (W): Parameter I of the PID regulator. Integral value = (PID_ISUM / 256) × (PID_I/256). Bits 0-31 - CL_VMAX_CALC_I write only (W): Parameter I of the PI controller, which controls the maximum limitation of the catch-up speed in control operation.
  • Page 95 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 Name CL_VADD_EMF Index 0x4000 Sub-index 0x62 Device State Size [bytes] Closed loop additional velocity configuration CL_VADD_EMF (default: 0x0006DDD0) read/write (U): Additional speed value for calculating the encoder speed at which the back-EMF compensation reaches the maximum angle CL_GAMMA.
  • Page 96 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Name GCONF Index 0x4001 Sub-index 0x01 Device State Size [bytes] GCONF register, default vert = 0x00010000 Bit description: Bit 0: Recalibrate 1: Zero-crossing recalibration at driver disable (via DRV_ENN or TOFF setting). Default value = 0 Bit 1: faststandstill Timeout for step execution until standstill is detected:...
  • Page 97 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 Name IHOLD_IRUN Index 0x4001 Sub-index 0x11 Device State Size [bytes] IHOLD and IRUN configuration, default value = 0x00071003 IHOLD: Bits 0-4: This setting specifies the standstill current. It can be between 0 and 31, where 0 corresponds to 1/32 of the maximum current and 31 to 32/32 (full current).
  • Page 98 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Name TCOOLTHRS Index 0x4001 Sub-index 0x15 Device State Size [bytes] TCOOLTHRS register, default value = 0x000000C8 This is the lower limit speed for switching on the smart energy, sensorless load-dependent motor current setting and sensorless load value.
  • Page 99 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 Bits 8-11: semax0, semax1, semax2, semax3 Function: Sensorless load value hysteresis value for intelligent current control. Note: If the sensorless load value result is equal to or greater than (SEMIN + SEMAX + 1) * 32, the motor current is reduced to save energy.
  • Page 100 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Name PWM_SCALE Index 0x4001 Sub-index 0x72 Device State Size [bytes] Analysis of current control mode chopper by current scaling. This section shows the results of the current control mode chopper amplitude controller. The values can be used to monitor the automatic PWM amplitude scaling, where 255 represents the maximum voltage.
  • Page 101 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 Name Act Device Index 0x4004 Sub-index 0x00 State Device State Size [bytes] Returns the current device state of the module. 0: BootUp 1: Init 2: PreOP 8: Operational Name Position Mode Index 0x4005 Sub-index 0x00...
  • Page 102 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Name Time Constant Index 0x4006 Sub-index 0x04 of Resistor Device State PreOP Size [bytes] Time constant for brake resistor [ms] Value range: 1-100000 Default: 1000 Name Utilisation Index 0x4006 Sub-index 0x05 Resistor Device State PreOP Size [bytes]...
  • Page 103 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 Name Warning Index 0x4006 Sub-index 0x0A Threshold Utilisation Device State PreOP Size [bytes] Warning threshold braking resistor [‰] Value range: 1-1000 When the value is reached, the warning flag is set in StateWord. Default: 980 Name Motion Profile...
  • Page 104 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Name Latch Config Index 0x4008 Sub-index 0x01-0x02 Input 1/2 Device State PreOP Size [bytes] Specifies the behavior for the position latch trigger of input 1/2. 0: Deactivated 1: With rising edge 2: With falling edge 3: With rising and falling edge Name Chopper Values Index...
  • Page 105 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 Name HEND Index 0x400D Sub-index 0x03 Device State PreOP Size [bytes] Value range: 0-15 HEND (3:0): These four bits define the lower hysteresis value (HEND). Hysteresis values: The setting ranges from -3 to 12 (0-15) and allows fine-tuning of the current control by adjusting the hysteresis window. Hysteresis functionality: This hysteresis value is used by the chopper for current control.
  • Page 106 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Name PWM_ Index 0x400E Sub-index 0x03 AUTOSCALE Device State PreOP Size [bytes] pwm_ autoscale PWM automatic amplitude scaling Value range: 0-1 0: User-defined forward PWM amplitude. The current settings IRUN and IHOLD are not enforced by the regulation, but only scale the PWM amplitude! The resulting PWM amplitude (limited to 0-255) is: PWM_OFS * ((CS_ACTUAL+1) / 32) + PWM_GRAD * 256 / TSTEP 1: Release of the automatic current regulation (preset)
  • Page 107 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 Name OL DRV1_ Index 0x400F Sub-index 0x01 SCALE_VAL / CL CL_IMAX Device State Size [bytes] Scaling in [‰] with use depending on the selected “Controller Mode” (Index 0x4002). Value range: 0-1000 Controller Mode Open Loop: OL DRV1_SCALE_VAL * first drive scaling value Controller mode closed loop: CL CL_IMAX * maximum scaling value...
  • Page 108 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Name Digital Inputs Index 0x4009 Sub-index 0x00 Device State Size [bytes] Shows the state of the inputs in a bit field. Bit 0: Enable input 1 Bit 1: Enable input 2 Bit 2: Latch input 1 Bit 3: Latch input 2 Bit 4-7: Reserved Bit 8: Motor supply OK...
  • Page 109 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 Name Motion Index 0x4018 Sub-index 0x01 Controller Status Device State Size [bytes] Specifies the status information of the motion controller in a 32-bit variable. Bit 0: TARGET_REACHED_F - XACTUAL = XTARGET (target reached). Default value = 0 Bit 1: POS_COMP_REACHED_F - XACTUAL = POS_COMP (Position comparison reached).
  • Page 110 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Name Motor Index 0x4018 Sub-index 0x02 Controller Status Device State Size [bytes] In a 32-bit variable, indicates the status information of the motor controller. Bits 0-19: LOST_STEPS - Number of skipped steps due to load. After 2 steps, the counter restarts.
  • Page 111 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 Name RPDO Mapping Index 0x4019 Sub-index 0x01 Size Device State Size [bytes] Size of RPDO data (from ST 152 perspective) in [byte] Name TPDO Mapping Index 0x4019 Sub-index 0x02 Size Device State Size [bytes] Size of TPDO data (from ST 152 perspective) in [byte] Name...
  • Page 112 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Name Motor Current Index 0x401B Sub-index 0x00 Device State Size [bytes] Number of sub-indices = 3 Name Global Scaler Index 0x401B Sub-index 0x01 Device State Size [bytes] Value for global scaler (0-255) can only be read. Is calculated from “Max Motor Current”...
  • Page 113 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 Bit 9: remote - remote control active. Bit 10: target_reached. Bit 11: internal_limit_active. Bit 12: opSpecific1 - operating mode specific: Target mode = set point acknowledge flag. Bit 13: opSpecific2 - operating mode specific Bit 14: latchInput1 - latch input 1.
  • Page 114 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Name Control Word Index 0x6040 Sub-index 0x00 Device State Size [bytes] Shows the DS402 control word in a 16-bit bit field. Bit 0: switch_on. Bit 1: enable_voltage. Bit 2: quick_stop. Bit 3: enable_operation. Bit 4: opSpecific1 - operating mode specific: Target mode = New setpoint specification Bit 5: opSpecific2 - operating mode specific.
  • Page 115 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 Name Motor Max Index 0x6080 Sub-index 0x00 Speed Device State Size [bytes] Specifies the maximum speed in [µSteps] for the motor. Is only active when modes of operation is "-1 .. Target Mode". Name Motor Max Index...
  • Page 116 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Name Encoder Index 0x6410 Sub-index 0x02 Resolution Device State PreOP Size [bytes] Resolution of the encoder for one revolution. Value range: 0-4,294,967,295 Default: 0 Name Encoder Index 0x6410 Sub-index 0x03 Direction Device State PreOP Size [bytes] Specifies the direction of rotation for the encoder.

  • Page 117: Asynchronous Parameters - Error Codes

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 12.9 Asynchronous Parameters - Error Codes Error code Description SDO Abort Code 0x00000000 No error occurred or error was reset SDO_ERROR_RESET_NO_ERROR 0x05040000 Internal timeout when creating the response to an SDO SDO_ABORT_SDOTIMEOUT 0x06010000 Unsupported access to object SDO_ABORT_UNSUPPORTED...

  • Page 118: Assembly/Installation

    ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP 13 Assembly/Installation 13.1 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 119 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 13.2 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.
  • Page 120 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP Recommended minimum distances between the S-DIAS modules and the surrounding components or control cabinet wall: a, b, c … distances in mm (inches) Page 118 06.02.2025...
  • Page 121 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 14 Transport/Storage INFORMATION This device contains sensitive electronics. During transport and storage, 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 122 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP 15 Storage INFORMATION When not in use, store the operating panel according to the storage conditions. See chapter 14 Transport/Storage. During storage, ensure that all protective covers (if available) are placed correctly, so that no contamination, foreign bodies or fluids enter the device.

  • Page 123: Maintenance

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 16 Maintenance INFORMATION During maintenance as well as servicing, observe the safety instructions from chapter 2 Basic Safety Directives. Lors de l'entretien et de la maintenance, respectez les consignes de sécurité du chapitre 2 Basic Safety Directives. 16.1 Service This product was constructed for low-maintenance operation.
  • Page 124 ST 152 S-DIAS STEPPER MOTOR STAGE CLOSED LOOP 17 Disposal INFORMATION Should you need to dispose of the device, the national regulations for disposal must be followed. The device appliance must not be disposed of as household waste. Page 122 06.02.2025...

  • Page 125: Change History

    S-DIAS STEPPER MOTOR STAGE CLOSED LOOP ST 152 Change History Change Affected Chapter Note date page(s) 24.10.2024 6.4 Latch/Digital Inputs Signal level values changed Specifications 3 IT Security Chapter added 25.10.2024 12 Description of Functions Separated in different chapters 12.1 Current Regulator Modes Chapter added 12.4 Closed Loop Regulator 12.5 Supported Step Operation...

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