Achtung: Motor- und Verstärkertypenangaben müssen mit der. Installation übereinstimmen, sonst Schädigungsgefahr. ATTENTION! NEVER REMOVE OR INSTALL THIS. PLUG
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2TDM Starting Lockout ¥ 9.555.012.4-05 ¥4/94 ¥Title:Type of Documentation:Doc. No.:Internal File Ref.:Replaces:The purposeof this documentCopyright:Validity:Copying of this document, and giving it to others and the use orcommunication of the contents thereof without express authority are forbidden. Offenders are liable to the payment of damages. All rights are reserved in the event of the grant of a patent or the registrationof a utility model or design.We reserve the right to make changes to the documents and inproduct delivery.About this DocumentationStarting Lockout Function in TDM Servo Drive ModulesApplication Manual9.555.012.4-05 EN / 4/94File No. 4 / ¥startinglockout TDM EN9.555.012.4-03 DE / 3/93This document serves:Ðto define possible application and operating conditions Ðto assist in project planning and installation Ðthe commissioning and monitoring of the starting lockout function

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3¥ TDM Starting Lockout ¥ 9.555.012.4-05 ¥ 4/94Please note the guidelines outlined in Section 3 prior tocommissioning the starting lockout!Table of ContentsTable of Contents Page1. Possible applications of the starting lockout7 1.1.A safe way to power down separate working areas in machinery or plant..7 1.2.Operating individual axes during installation..10 2. How the starting lockout works11 2.1.The function of the motor control..11 2.2.Using the starting lockout signal to safely power down the motor11 3. Installation and operating guidelines14 3.1.Application guidelines for disconnecting the power mains, standstills and securing against unintentional start-ups14 3.1.1. Using the master switch to disconnect the mains.14 3.1.2. Using the mains contactor to disconnect the mains14 3.1.3. Using the starting lockout to secure against intentionalstart ups.14 3.2.Connecting terminals.15 3.3.Sequence and procedures when using the starting lockout.16 3.4.Testing19 3.5.Examples of appliations.19 4. Controller types and related plans23 4.1.Summary of the types of controllers..23 4.2.Frontal view..24 4.3.Dimensional data..29 4.4.Installation dimensions31 4.5.Terminal interconnect diagrams34

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5¥ TDM Starting Lockout ¥ 9.555.012.4-05 ¥ 4/941.1. A safe way to powerdown separate working areasin machinery or plant1. ApplicationsProduction systems, transfer lines and machine tools often consist ofspatially separated working areas, e.g., processing units, transport,handling and storage systems (see Figure 3).It is frequently necessary for personnel to either work or accesssomething in one working area while machinery is running in anadjacent working area. This means that the drive axes within an individualÕs working area must be secured against any uninten-tional motions so that an individual is not at risk from dangerous drive motions caused by a fault somewhere else in the facility.If the drive axes in adjacent working areas and in the danger zone arecentrally connected to the power mains by a supply unit (e.g., supply modules TVM, KDV, TVD, KVR), then each direct-drive motor mustbe individually secured against unintentional motions. The dangerzone is the area in which the individual is working.The starting lockout built into every INDRAMAT drive module makesit easy to safely power down the motor of each axis with a simple switch. This switch disconnects the output stage from the controlelectronics with the use of a relay in the hardware. The user gains thefollowing advantages:1. Savings in cost and spaceA single power supply unit can feed the drive axes of severalworking areas. Individual power supply units are not needed for each drive axes in every spatially separated working area.In several applications, a large three-phase motor contactor withone or two axes is built into the motor supply lines. The motorcontactors make it possible to safely switch off these axis motors,and to use only one supply unit to operate all drives.This function is now easy to perform without a power contactor onthe drive module by controlling the starting lockout input. This represents a savings in cost and space in the control cabinet.1. Possible applications of the starting lockout

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6TDM Starting Lockout ¥ 9.555.012.4-05 ¥4/94 ¥2.Increased safety and reliability: Personnel safety and facility reliability are increased because amains contactor is not needed to disconnect the motor from the drive module.ÐEliminated are breakdowns caused by frequent switching, gum- ming or burning of the contacts of this contactor due to high loadcurrents.The danger of damage to the motor mains contacts from improperhandling or commissioning is eliminated.ÐThe motors no longer brake uncontrolled with a power failure. A motor contactor without a mechanical locking mechanism isdropped in a power failure. This means the motor will idle and the DC bus energy cannot be used for braking.ÐThe existing mains contactor is presently used to secure against unintentional motions. It is switched on and off once during every duty cycle. With a starting lockout in an INDRAMAT drive modulethe mains contactor does not need to be frequently switched, i.e., with every cycle. It is only used with E-stops, for maintenance andinspection work throughout the plant, and with every total shut-down. There is less wear and tear, and failures occur less frequently.ÐIf two faults occur simultaneously, then a motor can run up uncontrolled if a motor contactor is used to secure against uninten-tional motions .Example:Ð speed command voltage at maximum due to fault in NC, and,Ð the motor contactor fails.In the unlikely event that two faults occur simultaneously in the power supply, then the motor will only jerk if an internal startinglockout is in the INDRAMAT drive amplifier.The internal control circuits and the output stage control areinternally locked for additional safety. An external motor contactordoes not ensure an additional internal locking of the drive electron- ics.1. Applications

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8TDM Starting Lockout ¥ 9.555.012.4-05 ¥4/94 ¥1.2. Operating individual axesduring installationDrives are frequently run individually during installation. In this caseas well, personnel is often found within the danger zone. Generally,the acknowledgement switch is used to switch on the mains contactorto operate the axes. The mains contactor is then switched off again if unwanted movement occurs, or at the end of an operation.The safety of personnel within a danger zone is increased, if thestarting lockout is additionally built into INDRAMATÕs drive modules.It helps to secure against unwanted starts during installation. Thisis possible because the internal, forcibly-connected contacts mean that the axes not being run can be additionally blocked.In addition, using this relay to switch the motors on and off reduceswear and tear. In effect, it also increases reliability and safety.1. Applications

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9¥ TDM Starting Lockout ¥ 9.555.012.4-05 ¥ 4/942.1. Motor controller function2. How the StartingLockout Works 2. How the Starting Lockout WorksThe power for motor current and thus the torque are advanced via thefinal output stage (driver) of the drive module. The extent of the current in the three phases of the three-phase motor is transmitted bythe controller electronics to the final output stage in the form of aswitch-mode pulse-width modulated signal.In this case, the controller electronics serve the following purpose:The greater the width of the pulse or the switch-mode ratio, thegreater the motor current. The three currents in the three phases ofthe motor must additionally be adjusted, in terms of amount and phase position, to the rotor position given at that point in time, forsufficient torque to be produced.There can be no motor revolutions at the motor shaft if there is nopulse-width modulated signal at the final output stage.The signal at terminals AS1-AS2 of INDRAMATÕs drive moduleactivates an internal relay which has two forcibly-connected contacts (see Fig. 1). The relay has been quality controlled.ÐThe first contact of this relay separates the internal controller voltage of the final output stage in the hardware.ÐThe control and controller electronics are simultaneously and addi- tionally blocked. This achieves double redundancy.ÐThe second contact (acknowledgement contact) signals the activa- tion of the first contact to the outside.A disconnection of the output stage controller is signalled via thisadditional acknowledgement contact (contact) ASQ-ASQ, to verify whether the relay has actually been activated or not. This contact is forcibly-connected to the primary contact.A relay failure or a wire break in the conductors to the starting lockoutinputs AS1-AS2 is immediately recognized by this zero-potentialacknowledgement contact in the external control. The central mains contactor is then immediately disconnected.This means it is not possible, in the event of a fault and given allconceivable possibilities, that a switch-mode motor current (alternat-ing current) could be produced within the electrical facilities of themachine which could make the motor move.It is also not possible for a current to flow through the motor even whena fault occurs in one of the six final output stages. The drive does not move. This fault is immediately acknowledgedÐas soon as personnel has moved out of the danger zone, Ðwhen the machine or sector of the facility has been properly reblocked.2.2. Using the starting lock-out signal to secure poweroff

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10TDM Starting Lockout ¥ 9.555.012.4-05 ¥4/94 ¥and the drive is reactivatedÐby disconnecting starting lockout inputs AS1-AS2, Ðby electronically enabling the controller amplifier, and, Ðby entering the speed set-point. This fault causes an excessively high current which triggers aresponse from the fuses in the drive module. Then the mainscontactor disconnects all drives from the mains. Message ãBSÒ on the defective drive module also displays the fault overccurrent.2. How the Starting Lockout Works

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11¥ TDM Starting Lockout ¥ 9.555.012.4-05 ¥ 4/94MSupply moduleControllerController voltage USTDrive moduleDrive moduleLink circuitAS1AS2 ASQASQ AS1AS2ASQASQ ~M~~MainsMaster switchMains contactor (K1)AS/AnwendApplications of the starting lockoutController voltage USTMController voltage USTDrive moduleAS1AS2 ASQASQ Figure 1: How the starting lockout works2. How the Starting Lockout Works

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