Technical documentation

Twin Line Drive 01x

Power electronic system for

stepper motors

TLD01x
Operating system: 1.0xx
Order no.: 9844 1113 102
Edition: d107, 09.02
 TLD01x

CAUTION!
See the “Supplement” chapter at the end of the
documentation for important information.

9844 1113 102, d107, 09.02

-2 Twin Line Drive 01x

 TLD01x Table of Contents

Table of Contents

Glossaries . . . . . . . . . . . . . . . . . . . . . . . . . . . .V-5
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . .V-5
Product name . . . . . . . . . . . . . . . . . . . . . . . . . . V-5
Technical Terms . . . . . . . . . . . . . . . . . . . . . . . . .V-6
Conventions and symbols . . . . . . . . . . . . . . . . . . . . V-7

1 The power electronic system

1.1 Scope of supply . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Documentation and literature . . . . . . . . . . . . . 1-3
1.3 Unit series . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.4 Unit overview. . . . . . . . . . . . . . . . . . . . . . 1-5
1.5 Operational function . . . . . . . . . . . . . . . . . . 1-7
1.6 Directives and standards. . . . . . . . . . . . . . . . 1-8
1.6.1 Declaration of conformity and CE mark. . . . . . . 1-8
1.6.2 Regulations and standards . . . . . . . . . . . . 1-10

2 Safety
2.1 Danger categories . . . . . . . . . . . . . . . . . . . 2-1
2.2 Safety notes . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Use for the purpose intended . . . . . . . . . . . . . 2-2
2.3.1 Ambient conditions . . . . . . . . . . . . . . . . . 2-2
2.3.2 Intended use . . . . . . . . . . . . . . . . . . . . 2-2
2.4 Qualification of the personnel . . . . . . . . . . . . . 2-3
2.5 Safety devices . . . . . . . . . . . . . . . . . . . . . 2-3

3 Technical data
3.1 Mechanical data . . . . . . . . . . . . . . . . . . . . 3-1
3.1.1 Power electronic system TLD01x. . . . . . . . . . 3-1
3.1.2 Accessories . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Electronic data . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.1 Power electronic system . . . . . . . . . . . . . . 3-3
3.2.2 UL 508C certification . . . . . . . . . . . . . . . . 3-5
3.2.3 Accessories . . . . . . . . . . . . . . . . . . . . . 3-5

4 Installation
4.1 Electromagnetic compatibility, EMC . . . . . . . . . . 4-1
4.2 System components . . . . . . . . . . . . . . . . . . 4-3
4.3 Mechanical installation . . . . . . . . . . . . . . . . . 4-4
9844 1113 102, d107, 09.02

4.3.1 Installing the power electronic system . . . . . . . 4-4

4.3.2 Fitting the unit label . . . . . . . . . . . . . . . . . 4-5
4.3.3 Attach accessory components . . . . . . . . . . . 4-6

Twin Line Drive 01x -1

Table of Contents TLD01x

4.4 Electrical installation . . . . . . . . . . . . . . . . . 4-7

4.4.1 Line connection . . . . . . . . . . . . . . . . . . 4-8
4.4.2 Motor connection . . . . . . . . . . . . . . . . . 4-9
4.4.3 Connecting the 24 V supply voltage . . . . . . . . 4-11
4.4.4 Connecting a holding brake . . . . . . . . . . . . 4-12
4.4.5 Connection to the PULSE-C interface . . . . . . . 4-13
4.4.6 Connection to the interface for speed monitoring . 4-19
4.4.7 Connecting accessories . . . . . . . . . . . . . . 4-21
4.5 Wiring example . . . . . . . . . . . . . . . . . . . . 4-23
4.5.1 Stepper motor controller without
speed monitoring . . . . . . . . . . . . . . . . . 4-23
4.6 Check wiring . . . . . . . . . . . . . . . . . . . . . 4-24
4.7 Installation troubleshooting . . . . . . . . . . . . . . 4-25

5 Commissioning
5.1 Commissioning procedure . . . . . . . . . . . . . . 5-1
5.2 Safety notes. . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 Commissioning the power electronic system . . . . . 5-3
5.3.1 Setting phase current . . . . . . . . . . . . . . . 5-3
5.3.2 Set DIP switch . . . . . . . . . . . . . . . . . . . 5-4
5.3.3 Checking the function of the limit switches . . . . 5-6
5.3.4 Checking the holding brake . . . . . . . . . . . . 5-6
5.3.5 Motor test run . . . . . . . . . . . . . . . . . . . 5-7
5.3.6 Optimizing the movement behavior of the motor . 5-8

6 Operating functions
6.1 Positioning mode . . . . . . . . . . . . . . . . . . . 6-1
6.2 Functions of the power electronic system . . . . . . 6-2
6.2.1 Monitoring functions . . . . . . . . . . . . . . . . 6-2
6.2.2 Braking function with TL HBC . . . . . . . . . . . 6-3

7 Diagnosis and troubleshooting

7.1 Operational status indicators and transitions . . . . . 7-1
7.2 Error display and troubleshooting. . . . . . . . . . . 7-2
7.3 Malfunctions in movement mode . . . . . . . . . . . 7-3

8 Service, maintenance and warranty

8.1 Service address. . . . . . . . . . . . . . . . . . . . 8-1
8.2 Shipping, storage and disposal . . . . . . . . . . . . 8-2

9 Accessories and spare parts

9.1 List of accessories . . . . . . . . . . . . . . . . . . 9-1
9844 1113 102, d107, 09.02

9.2 List of spare parts . . . . . . . . . . . . . . . . . . . 9-1

10 Unit label
10.1 Illustration of the unit label . . . . . . . . . . . . . . 10-1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1

-2 Twin Line Drive 01x

 TLD01x Glossaries

Glossaries

Abbreviations

Abbreviation Meaning
AC Alternating current
DC Direct current
DC link DC link
EC European Community
EMC Electromagnetic compatibility
EU European Union
I Incremental encoder
I/O Inputs/Outputs
Inc Increment
IT system I: isolation T: terre
System without potential to ground, not grounded
LED Light-Emitting Diode
M Motor
PELV Protective Extra Low Voltage,
Functional Extra Low Voltage (FELV) with safe isolation
RC Residual current

Product name

Abbreviation Product designation Term used

TL HBC Twin Line Holding Holding brake controller
Brake Controller
TLD01x Twin Line Drive 01x Power electronic system
9844 1113 102, d107, 09.02

Twin Line Drive 01x V-5

Glossaries TLD01x

Technical Terms

Actual position of the drive system The actual position of the drive system gives the absolute or relative
positions of moving components in the system.
Actual position of the motor See Angular position of the motor.
Angular position of the motor The angular position of the motor corresponds to the angular position of
the rotor in the motor housing, and refers to the zero point or index point
of the position sensor.
DC link The DC link generates the necessary direct current for operating the
motor and provides the amplifier with the necessary energy. The DC link
acts as a buffer for energy fed back by the motor.
Direction of rotation Rotation of the motor shaft in a clockwise or anticlockwise direction.
A clockwise direction of rotation is defined as the motor shaft rotating
clockwise as the observer faces the end of the protruding shaft.
Drive solution The drive solution comprises the drive system with the Twin Line Unit
and motor with the system mechanics forming an integral part of the
chain of motion.
Drive system The drive system consists of the Twin Line Unit and the motor.
Encoder Sensor for recording the angular position of a rotating element.
The encoder is mounted on the motor and signals the angular position
of the rotor.
High/open Signal status of an input or output signal; when no signal is present,
signal voltage is high (high level).
Incremental encoder See encoder
Incremental signals Angular steps of an encoder in the form of square-wave pulse
sequences. The pulses signal changes in position.
Index pulse Encoder signal for referencing the rotor position in the motor. The
encoder sends one index pulse per revolution.
IT system Power system with no ground potential reference, since it is not
grounded.
I: isolation T: terre
Limit switch Switches that signal an overrun of the permissible travel range.
Low/open Signal status of an input or output signal; when no signal is present,
signal voltage is low (low level)
Power amplifier This is the unit that controls the motor. The power amplifier generates
currents for controlling the motor in accordance with the positioning
signals from the control unit.
Power controller See Power amplifier
PULSE-C Pulse direction interface for recording external position presets via pulse
direction signals or Pulseforward/Pulsebackward signals for positioning the
motor.
Pulse direction signals Digital signals with variable pulse frequencies which signal changes in
9844 1113 102, d107, 09.02

position and rotation direction via separate signal wires.

RS422 level The signal status is calculated from the differential voltage of one
positive and one inverted negative signal. Two signal wires must
therefore be connected for one signal.

V-6 Twin Line Drive 01x

 TLD01x Glossaries

Sense regulation The voltage drop on the supply lines is compensated in such a way that
the output voltage at the sense terminals has the correct value. The
output voltage is only activated once the sense lines have been
connected.
Speed monitoring Detects position deviations during motor movement. The actual position
reported by the encoder is compared with the setpoint position. If the
deviation exceeds a defined value, a following error is reported.
Watchdog Device in the unit which detects internal faults. If a fault occurs, the
Twin Line unit switches off the amplifier and outputs immediately.

Conventions and symbols

Action symbols "왘" This action symbol is used for step-by-step instructions which can be
carried out as they are described. If one of the instructions results in a
noticeable response from the unit, this will be described after the
description of the action to be carried out. This will give you direct
confirmation that a particular step has been correctly carried out.
Enumeration symbol "•" The enumeration symbol is used for listing individual points in a given
information group in summary form. If the result of steps or sequences
is described, the step to be carried out is described first.
This symbol is used for general notes which give additional
information about the unit.

Passages preceded by this symbol may have to be

discussed in more detail with the local customer service.
9844 1113 102, d107, 09.02

Twin Line Drive 01x V-7

Glossaries TLD01x

9844 1113 102, d107, 09.02

V-8 Twin Line Drive 01x

 TLD01x The power electronic system

1 The power electronic system

1.1 Scope of supply

왘 Check the parts supplied to make sure they are complete.

Keep the original packaging in case the unit has to be returned to the
manufacturer for an update or repair.
Scope of supply of The scope of supply of the TLD01x power electronic system includes:
power electronic system
Item Qty. Designation Order no.
1 1 TLD011, TLD012 type code
2 1 Hood for front cover -
3 1 or 2 SK 14 shielding terminal for motor connection 6250 1101 400
(two shielding terminals in units without
internal line filters)
4 1 Plug units for terminal strips -
5 1 Documentation on the TLD01x on CD-ROM, 9844 1113 138
multilingual

Optional equipment of the power electronic system:

Item Qty. Designation Order no.

1 1 TLD01x...RM with speed monitoring type code
1, 6 1 TLD01xNF... without internal line filter type code
9844 1113 102, d107, 09.02

Fig. 1.1 TLD01x without and with speed monitoring

Twin Line Drive 01x 1-1

The power electronic system TLD01x

Accessories Accessories for the power electronic system are:

Item Qty. Designation Order no.

1 1 Connector set for complete assembly 6250 1519 001
2 1 Motor cable 1.5 mm2 . 6250 1317 xxx 1)
- 1 Pulse direction cable for PULSE-C interface
2 x socket, 15-pin
1 x socket, 15-pin, one end open 6250 1447 yyy 2)
6250 1452 yyy 2)
3 1 Encoder cable for encoder interface 6250 1440 xxx 1)
4 1 Holding brake controller TLHBC 6250 1101 606
5 1 External line filter for units without internal
filters
for TLD011 NF, 4 A 5905 1100 200
for TLD012 NF, 10 A 6250 1101 900
1) Cable length xxx: 003, 005, 010, 020: 3 m, 5 m, 10 m, 20 m, greater lengths
on request.
2) Cable length yyy: 005, 015, 030, 050: 0.5 m, 1.5 m, 3 m, 5 m;

Fig. 1.2 Accessories for the TLD01x

9844 1113 102, d107, 09.02

1-2 Twin Line Drive 01x

 TLD01x The power electronic system

1.2 Documentation and literature

Manuals for the Twin Line HMI, manual for the Human-Machine Interface HMI, English
power electronic system Order no.: 9844 1113 091
9844 1113 102, d107, 09.02

Twin Line Drive 01x 1-3

The power electronic system TLD01x

1.3 Unit series

The power electronic system TLD01x forms part of the Twin Line device
series for controlling stepper motors and AC servomotors. The power
electronic system operates as a stand-alone power amplifier with
integrated controller and power circuitry.
The power electronic system is available with two power ratings in a
similar housing design. Electrical connections and functional scope are
identical for both units.

Fig. 1.3 Power electronic system TLD011 and TLD012,

Type code The power class of the power electronic system is indicated by the last
digit in the device name "TLD01x" of the type code.

TLD 01 x x PULSE x

Rotation monitoring on M2
Twin Line Drive x: - not fitted
with no shaft signal RM - with rotation monitoring
for stepping motors
Reference quantities on M1
Power class PULSE : P/R-, PV/PR-signals
350 W - 1 : x
Internal mains filter
750 W - 2
x: F - with mains filter (230V)
NF - no mains filter
(230V/115V)

PULSE: position setpoints as pulse direction signal or

pulse forward / pulse back signal (only with the RM option)
9844 1113 102, d107, 09.02

Fig. 1.4 Type code of the power electronic system TLD01x

1-4 Twin Line Drive 01x

 TLD01x The power electronic system

1.4 Unit overview

Fig. 1.5 Power electronic system TLD01x

Power connection The power supply for the amplifier is connected to the line power output.
A position controller with a built-in line power filter can be operated
without any further noise suppression on the supply side.
Motor connection The unit supplies the power for a stepper motor over the three-phase
connection. The maximum power output is monitored by the unit. The
motor connection is short-circuit protected and is checked for ground
faults when the amplifier is enabled.
DC link connection The DC link voltage for the unit is taken from the intermediate circuit
terminal. The capacity of the built-in DC-link capacitors at the DC-link
connection can be increased with external capacitors for short-term
absorption of excess braking energy.
PULSE-C interface The setpoint position is set incrementally as a pulse signal over this
interface. Control signals for enabling the power amplifier, changing the
step resolution and the current setpoint value are also sent over the
interface.
Output signals at the PULSE-C interface report a fault and that the unit
is ready for operation.
9844 1113 102, d107, 09.02

Speed monitoring The power electronic system receives A/B signals for position
monitoring of the stepper motor and a signal that checks the motor
temperature. The encoder electronics in the motor receive the required
operating power from the speed monitoring connection.
Speed monitoring is built into the system as an option.

Twin Line Drive 01x 1-5

The power electronic system TLD01x

Voltage selector switch The unit can be connected to 115 V or 230 V power with the voltage
selector switch. The voltage selector switch is only available with units
without line filters (NF option).
Signal interface The power for control loops and for controlling the fan must be supplied
over the signal interface by an external 24 VDC power supply. The lines
for a holding brake or the control lines for the TL HBC holding brake
controller are connected to the brake terminal.
Status display A 7-segment display shows information about the operating status of the
power electronic system. If there is an operating malfunction the display
will flash and display the error code.
DIP switch The step resolution and the controller signal functions are set by the
eight DIP switches.
Rotary switch The rotary switch limits the maximum motor r.m.s current. The value for
the maximum motor current is shown in the motor type plate.
LED for DC link voltage The LED comes on when there is voltage in the DC link.
Air outlet and fan A built-in fan extracts cold air from the bottom of the unit and removes
the unit operating heat through the upper air vents. Temperature
sensors on the power amplifier’s heat sink protect the unit from
overheating.
Circuit diagram

Fig. 1.6 Signals and function blocks of the power electronic system with
speed monitoring
9844 1113 102, d107, 09.02

1-6 Twin Line Drive 01x

 TLD01x The power electronic system

1.5 Operational function

The power electronic system moves a stepper motor in accordance with

a setpoint. The setpoint signal is generated by a positioning or NC
controller and fed to the PULSE-C interface as a pulse signal.
If speed monitoring is also installed, the power electronic system
records the position of the motor and reports step losses, which may
occur as a result of blocking or overload of the motor.
9844 1113 102, d107, 09.02

Twin Line Drive 01x 1-7

The power electronic system TLD01x

1.6 Directives and standards

1.6.1 Declaration of conformity and CE mark

The EC directives define the minimum requirements - particularly safety
requirements - applicable to a product and must be complied with by all
manufacturers and dealers marketing the product in the member states
of the European Union (EU).
The EC directives describe the main requirements for a product. The
technical details are laid down in the harmonized standards, which are
published in Germany as the DIN EN standards. If there is not yet any
EC standard applicable to a particular product area, existing technical
standards and regulations will apply.
CE mark With the declaration of conformity and the CE mark on the product the
manufacturer certifies that the product complies with the requirements
of all relevant EC-directives. The unit can be used anywhere in the
world.
Machine Directive The Twin Line unit is not a machine in the sense of the EC Machine
Directive (89/392/EEC). It has no functional moving parts. The unit may
however be a component part of a machine or installation.
Provided the rest of the machine complies with the machine directive
and it has been set up in accordance with the EMC testing code of the
manufacturer, conformity with the machine directive can be certified.
EMC Directive The EC directive on electromagnetic compatibility (89/336/EEC) applies
to units which can cause electromagnetic interference or whose
operation can be impaired by such interference.
The Twin Line unit’s compliance with the EMC Directive cannot be
assessed until it has been installed into a machine or installation. The
instructions provided in "Installation" must be complied with to
guarantee that the Twin Line unit is EMC-compliant when fitted in the
machine or installation and before use of the unit is permitted.
Low Voltage Directive The EC Low-Voltage Directive (73/23/EEC) lays down safety
requirements for "electrical apparatus" as protection against the risks
that can originate in such devices and can be created in response to
external influences.
As specified by the low voltage directive the Twin Line unit conforms to
EN 50178 and to the following peripheral conditions:
• protection class 1
• pollution degree 2

Declaration of conformity The declaration of conformity certifies that the device satisfies the
requirements of the EC directive cited. A declaration of conformity in
accordance with the EC low-voltage directive has been issued for the
Twin Line unit.
9844 1113 102, d107, 09.02

1-8 Twin Line Drive 01x

 TLD01x The power electronic system

EC Declaration of Conformity 2001

BERGER LAHR GmbH & Co.KG
Breslauer Str. 7
D-77933 Lahr

o Machine Directive 98/37/EEC, Appendix IIA

ý EMC Directive 89/336/EEC
ý Low Voltage Directive 73/23/EEC
the above directives have been amended by the CE Marking Directive 93/68/EEC

We hereby declare that the products designated below correspond, in their design and
construction as well as in the version marketed by us, to the requirements of the listed EC
directives. This declaration loses its validity if changes are made to the products which
have not been agreed with us.

Designation: 3-phase motor amplifiers with/without electronic control and accessories

Type: TLDx1x, TLCx1x, TLDx3x, TLCx3x, TLCx1xP, TLCx3xP,

TLBRC, TLHBC

Product number: 634xxxxxxxx, 635xxxxxxxx, 62501101706, 62501101606,

Harmonised norms EN 50178 Classification VDE 0160: 1998.04

applied, EN 61800-3 Classification VDE 0160: 1997.08, category 2
especially:
according to BERGER LAHR test conditions

national norms and UL 508C

technical
specifications BERGER LAHR test conditions 200.47-01 EN
applied,
especially:

Company stamp:

Date/Signature: 27.04.2001
9844 1113 102, d107, 09.02

Name/Department: W. Brandstätter / MOM-E

Fig. 1.7 Conformity to the EC low-voltage directive

Twin Line Drive 01x 1-9

The power electronic system TLD01x

1.6.2 Regulations and standards

Standards concerning safe EN 60204-1 (VDE 0113 Part 1: 1998): Electrical equipment of
operation of the Twin Line units machines, General requirements
DIN VDE 0100, Regulations regarding the installation of high-voltage
systems with voltages up to 1000 V
DIN VDE 0106-100, 1983, Protection against electrical shock; Location
of actuation elements in the vicinity of operating resources liable to
accidental contact
DIN VDE 0470-1,1992, IP protection types
EN 954-1: Safety of machines, safety of components of control devices,
Part 1: General design principles
Standards regarding EN 61000-4-1 (IEC 1000-4-1: 1992): Testing and measurement
compliance with procedures, section 1: Overview of noise suppression test procedures
EMC limiting values
EN 61800-3:1996 and prA11:1999: Variable-speed electric drives

9844 1113 102, d107, 09.02

1-10 Twin Line Drive 01x

 TLD01x Safety

2 Safety

2.1 Danger categories

Safety notes and general information are indicated by special symbols

in the manual. In addition you will find symbols and instructions affixed
to your Twin Line unit which warn you of possible dangers and help you
to operate the unit safely.
Danger symbols are divided into three danger categories classified by
how serious a danger is. The symbols shown emphasize the danger
situation to which the warning applies.
DANGER!
This indicates direct personal danger.
Can lead to serious injuries with fatal consequences if not
observed.
WARNING!
Indication of a recognizable danger.
If the warning is ignored, the danger can lead to serious
injury with fatal consequences, and to the unit or system
parts being permanently damaged.
CAUTION!
Indication of a danger.
If this is ignored, minor personal injury and light damage to
the unit or system may be the result.

2.2 Safety notes

DANGER!
Electric shock from high voltage!
Follow safety rules when working on electrical systems:
• Switch off the power to the unit.
• Make sure the unit cannot be switched on again inadvertently.
• Confirm that no voltage is present.
• Cover or shield any neighboring system parts which are live.

DANGER!
Electric shock from high voltage!
> 4 min Before starting work on the connections of the power unit
(or 10 min) or on the motor terminals, wait for the 4 minutes discharge
time and then measure the residual voltage on the DC-link
terminals DC+ and DC-. The residual voltage must not
exceed 48 VDC before you start work on the connections.
If additional DC-link capacitors are connected, the
discharge period is increased to 10 minutes. Wait for this
period and then measure the residual voltage.
9844 1113 102, d107, 09.02

Twin Line Drive 01x 2-1

Safety TLD01x

2.3 Use for the purpose intended

2.3.1 Ambient conditions

Ambient temperature 0 °C to +50 °C
Transport and storage temperature -40 °C to +70 °C
Relative humidity 15% to 85%
(no condensation permissible)
Installation height, operation with no
reduction in performance h<1000 m above m.s.l.
Vibration stress during operation to DIN IEC 68-2-6
Number of cycles: 10
Frequency range: 10Hz to 500Hz
Acceleration: 20m/s2
Continuous shocks to DIN IEC 68-2-29
Number of shocks: 1000/direction
(directions: X, Y, Z per pos. and neg. direction, total 6000)
Peak acceleration: 150m/s2
Protection grade IP20

2.3.2 Intended use

The power electronic system is an electrical device for controlling a
variable-speed drive with stepper motor.
Only an AC stepper motor may be operated with the power electronic
system. The motor must be approved by your local representative for
operation with the unit.
The motor connections of multiple units may not be connected to each
other.
Multiple units must not be connected in parallel over the DC-link output.
The power electronic system may be used for industrial applications in
the system configuration described with a fixed connection only.
The power electronic system may only be set up and operated after
correct EMC installation.
The power electronic system must be installed and properly mounted in
a switch cabinet. It may only be used with the cables and accessories
specified by your local representative.
The power electronic system may not be used in IT networks, as they
have no ground potential. Interference suppression filters for correct
EMC installation will only work properly with a ground potential
connection.
9844 1113 102, d107, 09.02

2-2 Twin Line Drive 01x

 TLD01x Safety

2.4 Qualification of the personnel

Only personnel qualified as electrical technicians and controller

technicians in accordance with IEV 826-09-01 (modified) and who are
familiar with the contents of this manual are permitted to set parameters,
commission and operate the TL unit. The technicians must be able to
detect potential dangers that may be caused by setting parameters,
changing parameter values and generally by the mechanical, electrical
and electronic equipment.
Qualified personnel can use their technical training, knowledge and
experience to assess the work to be done and to recognize and avoid
possible dangers or non-qualified personnel can have the same
knowledge as qualified personnel after several years of work in the
same area.
Qualified personnel must be familiar with the current standards,
regulations and accident prevention regulations which have to be
observed when working on the unit.

2.5 Safety devices

The power electronic system unit monitors a range of signals from

system and installation components.
Safety devices coupled with the unit protect the system and operating
personnel. The following components and limit values are monitored
internally:

Monitoring Task and protective functions

Short-circuit Monitor motor cable for short-circuits between
phases, functional safety and device protection
Overvoltage and Monitor DC link for overvoltage and undervoltage,
undervoltage functional safety and device protection
Temperature Monitor power amplifier and motor 1) with sensors for
excess temperature, device protection
Speed error Following error indicated in units with speed
monitoring if position deviation is too great,
functional safety
1) Motor monitoring only with devices with optional speed monitoring
9844 1113 102, d107, 09.02

Twin Line Drive 01x 2-3

Safety TLD01x

9844 1113 102, d107, 09.02

2-4 Twin Line Drive 01x

 TLD01x Technical data

3 Technical data

3.1 Mechanical data

3.1.1 Power electronic system TLD01x

Weight TLD011 and TLD012 with speed monitoring 2.2 kg
Device protection Protection grade to DIN EN 60529: 1991 IP 20
Dimensions
TLD01x
Width [mm] 81
Height [mm] 212.5
Depth [mm] 184.5

Fig. 3.1 Dimensions TLD011 and TLD012

9844 1113 102, d107, 09.02

Twin Line Drive 01x 3-1

Technical data TLD01x

3.1.2 Accessories
Holding brake controller Dimensions (H x W x D) 107 mm x 104 mm x 76 mm
TL HBC
Installation on top-hat rail 55 mm

Fig. 3.2 Holding brake controller

9844 1113 102, d107, 09.02

3-2 Twin Line Drive 01x

 TLD01x Technical data

3.2 Electronic data

3.2.1 Power electronic system

Line connection
TLD011/TLD011P TLD012/TLD012P
Line voltage [VAC] 1x 1x
230 -20%/+15% 230 -20%/+15%
only with TLD01xNF: 1x 1x
115 -20%/+15% 115 -20%/+15%
Line frequency [Hz] 47 - 63 47 - 63
Current consumption 2 (230 V) 5 (230 V)
[A] 4 (115 V) 10 (115 V)
Starting current [A] < 60 < 60
Power factor cosϕ > 0.6 > 0.6
Power loss [W] ≤ 40 ≤ 60
Line buffering [ms] <5 <5
Overvoltage strength between phases: 1 kV, phases to ground: 1 kV
(DIN EN 61800-3)
Leakage current 1) < 30 < 30
[mA]
Fuse, external [A] /
characteristics
at 230 V 10 C, K or similar 10 C, K or similar
at 115 V 10 C, K or similar 10 C, K or similar
1) Leakage currents are measured with an RC circuit in accordance with IEC60990.
The value can be higher if measured directly. Notes on using ground leakage
circuit-breakers on request.

Motor connection
TLD011/TLD011P TLD012/TLD012P
1)
Power class [kW] 0.35 0.75
Switching frequency [kHz] 16 16
Rated current [A.r.m.s.], r.m.s. 3 7
Max. speed [rpm] 3000 3000
Cable length 2) [m] 20 20
Cable cross-section [mm2] 1.5 1.5
1) Max. electrical effective power of the unit at rated current and 115 VAC or
230 VAC line voltage
2) Longer cables on request
9844 1113 102, d107, 09.02

Twin Line Drive 01x 3-3

Technical data TLD01x

24 VDC supply PELV, DIN 19240, reverse-polarity-protected

Input
Voltage range 20 V to 30 V
Ripple < 2 VSS
Power consumption ≤ 1.5 A
Stored energy time with power failure (at 24 V)
without brake connection ≥ 20 ms
PULSE-C interface Signal inputs
Symmetrical compatible with RS422-voltage
Asymmetrical 4.5V to 30 V
connected electrically to 24VGND
Input resistance 5 kΩ

Input frequencies:
Stepping frequency (PULSE/PV, DIR/PR) ≤ 200 kHz
Motor current controller (PWM) 6 kHz to 25 kHz
Step count 200, 400, 500, 1000,
2000, 4000, 5000, 10000
Signal outputs (ACTIVE, FUNCT_OUT) open collector outputs
short-circuit-proof,
Output voltage ≤ 30 V
Output current, maximum 50 mA
Speed monitoring (optional) Signal inputs (A, B) RS422-level
connected electrically to 24VGND

Input frequency ≤ 400 kHz

1 600 000 Inc/s

Encoder pitch 1000 lines

Output
Encoder power supply (SENSE) 5 V ± 5%, ≤ 300 mA
sense-controlled
short-circuit and overload-proof
Brake control Signal output (ACTIVE_CON) short-circuit-proof
Output voltage ≤ 30 V
Output current, maximum 1.7 mA
Voltage drop at 0.5 A ≤1V
Reference potential (ACTIVE_GND) GND of 24 V
9844 1113 102, d107, 09.02

3-4 Twin Line Drive 01x

 TLD01x Technical data

3.2.2 UL 508C certification

The power electronic system TLD01x is certified to UL 508C with the
following data.
Line connection

Unit Line voltage [V] Line frequency Current [A] Phases

[Hz]
TLCX11 230 47-63 2 1
115 4
TLCX12 230 47-63 5 1
115 7.5

Motor data

Unit Motor voltage Motor Motor current Phases

[V] frequency [Hz] [A]
TLCX11 0-230 0-2500 3 3
TLCX12 0-230 0-2500 7 3

Accessories • holding brake controller, TL HBC

power supply 24 V

3.2.3 Accessories
TL HBC holding brake controller Supply voltage, input 20 V to 30 V
Input current Input current = 0.5 A + brake current
Output, brake
DC voltage 20 V to 30 V
Current at 24 V for 100 ms 0.5 A to 2.5 A
Continuous current 0.5 A to 1.25 A

DC voltage with voltage drop 9.5 V to 15 V

Current at 12 V 0.5 A to 2 A
Safe electrical isolation between 24 V input, control input and brake
output
9844 1113 102, d107, 09.02

Twin Line Drive 01x 3-5

Technical data TLD01x

9844 1113 102, d107, 09.02

3-6 Twin Line Drive 01x

 TLD01x Installation

4 Installation

4.1 Electromagnetic compatibility, EMC

Strong electromagnetic interference occurs in the power area of the

power electronic system which can influence signals coming from
control cables and system parts and endanger the operational reliability
of the system if suitable protective measures are not taken.
The power electronic system meets the requirements of the EC
directives on EMC noise resistance and on noise output as specified in
EN 61800-3, as long as the following steps have been taken during
installation.
Control cabinet setup
EMC measures Effect
Use galvanized or chrome-plated mounting plates, Good conductivity due to
make large contact surface connections for metal two-dimensional
parts, remove paint from contact surfaces contacts
Ground the control cabinet, door and mounting plate Reduction of EMC
with metal tapes or cables with a cross section area emissions
greater than 10 mm2
Mount power components and control components Reduction of mutual
separately, minimum distance 25 cm, reduce interference
interference injection from either component by
using multiple-ground dividing plates
Fit switching devices such as contactors, relays or Reduction of mutual
solenoids with interference suppressors or spark interference
suppressors (e.g. diodes, varistors, RC elements)

Cabling
EMC measures Effect
Keep cables as short as possible, no "safety loops", Avoidance of capacitive
short cables from the star point in the control cabinet and inductive
to outlying ground connection interference injection
Use cable clamps to connect a large surface area of Reduction of EMC
the shield of all shielded cables to the mounting emissions
plate at the control cabinet entry.
Lay the cables spatially separated from each other: Reduction of mutual
- Signal cables and power cables interference, reduction of
- Power and motor cables emissions, increasing
- Line filter input and output cables resistance to
interference
Connect large surface areas of cable shields, use Low shielding effect if
cable clamps and tapes the connection is not
made over large surface
area, reduction of
emissions
Ground a large surface area of the shields of digital Preventing interference
signal cables at each end or via sub-D housing on control cables,
reduction of emissions
Shield analog signal lines at one end only at the Preventing ripple loops
9844 1113 102, d107, 09.02

power controller, at the other end via capacitor, due to low-frequency

e.g. 10 nF/100V MKT interference
Use only shielded motor cables with copper braiding Controlled discharge of
and at least 85% covering, ground a large surface interference currents,
area of the shield at each end. reduction of emissions
Use motor and encoder cables recommended by
your local representative.

Twin Line Drive 01x 4-1

Installation TLD01x

EMC measures Effect

If the motor and machine are not conductively Reduction of emissions,
connected, for example by an insulated flange or a increase in resistance to
non-flat connection, ground the motor with a interference
grounding wire (> 10 mm2) or ground strap.
Ground unused cable wires from control circuits at Additional shielding
both ends of the cable (does not apply to motor effect
cable)

Fig. 4.1 EMC measures

WARNING!
Malfunctions and risk of injury!
The EMC of cables must be guaranteed if the unit is to
function reliably and free of faults. The use of unsuitable,
non-EMC-secure cables can damage the unit and lead to
malfunctions.
9844 1113 102, d107, 09.02

Motor leads and encoder cables are especially critical signal circuits.
Use the cables recommended by your local agent. They tested for EMC
safety. They are also suitable for movement.
You can find information on the cables in section "Accessories and spare
parts" on page 9-1.

4-2 Twin Line Drive 01x

 TLD01x Installation

4.2 System components

Besides the components included in the scope of delivery, other system

components are required for connecting the power electronic system:
• three-phase stepper motor
• motor cable
• signal cable
• encoder cable when unit fitted with speed monitoring
• line cable and line fuses
• external power supply, 24 VDC with safe separation - PELV
• external line filter for units with no built-in line filter
• control cabinet
• additional filters and chokes for line connection and motor
connection, depending on system configuration
• NC control or PLC for automatic operation
9844 1113 102, d107, 09.02

Twin Line Drive 01x 4-3

Installation TLD01x

4.3 Mechanical installation

4.3.1 Installing the power electronic system

Before installation... 왘 Check the unit for external damage such as dents in the housing or
broken connection terminals. Do not install damaged units.

DANGER!
Danger from high voltages, possibility of permanent
damage to the unit’s electronic circuitry.
During installation ensure that no loose parts such as
pieces of wire or mounting parts fall into the unit. Loose
conductive parts inside the unit can endanger life by
forming parasitic voltages and permanently damage the
unit through short-circuits.
Control cabinet The control cabinet must be big enough to allow both unit and
accessories such as ballast resistor controller and holding brake
controller to be firmly mounted and connected in line with EMC
requirements.
It must be possible to extract the heat generated by the unit and
components during operation through the switch cabinet vents.
Installation clearances The unit is fitted with a built-in fan. Ventilation slots on and under the unit
must be kept at least 70 mm away from neighboring units or walls.

Fig. 4.2 Installation clearances, dimensions in mm

왘 Position the unit in the control cabinet such that the heated air flow
from other units, for example from an external ballast resistor, does
not result in undesired heating of the cooling air.
왘 Mount the unit vertically with the power connection at the top.
왘 Fasten the unit to a galvanized metal plate. The back wall of the unit
must have good contact with the metal plate across its whole
surface area.
9844 1113 102, d107, 09.02

Painted surfaces have an insulating effect. Before fixing the

unit to a painted mounting plate, scratch off the paint over
a wide surface area in the places where the unit is to be
mounted, to ensure that it has a good connection with the
grounded plate.

4-4 Twin Line Drive 01x

 TLD01x Installation

4.3.2 Fitting the unit label

The unit label provides information on the meaning of all operating
states displayed on the 7-segment display, and on signal interface
assignment. An example of the unit label for copying is provided in
section "Unit label", page 10-1.
왘 Attach the unit label inside the hood of the Twin Line unit on the side
where the signal plugs are connected.

Fig. 4.3 Attach unit label to the side of the hood

After the electrical installation has been completed and the unit hood
installed, the cables for connection to power and the cables for both
upper signal connections are led out through the top of the hood, while
the motor cable and other signal cables are taken out through the
bottom.
9844 1113 102, d107, 09.02

Twin Line Drive 01x 4-5

Installation TLD01x

4.3.3 Attach accessory components

Line filter The power electronics are supplied with a line filter built in in the
standard design. A special version of the unit can also be ordered
without a line filter.
Do not use the units with external line filters unless you can make test
measurements at the unit of the functioning and the EMC of a selected
line filter.
An external line filter is required for a standard unit without
a built-in line filter. The user must ensure that the EMC
directives are observed in this case.

The type plate on the front of the unit states whether a line filter is built
in or not:
• "F": with line filter, e.g. TLD01x F
• "NF": without line filter, e.g. TLD01x NF

Select a two-stage line filter, e.g. for a frequency converter. The size and
selection of a suitable filter is for the system designer to decide.
왘 Fit the line filter near the mains connection and on the same
mounting plate. The length of the cable to the power electronic
system must not exceed 50 cm. The cable must be shielded and
the shield must be grounded at both ends.

9844 1113 102, d107, 09.02

4-6 Twin Line Drive 01x

 TLD01x Installation

4.4 Electrical installation

WARNING!
Malfunctions and danger of injury arising from interference
with other units!
Connect the unit correctly to meet EMC requirements.
Control signals suffering interference can generate
unexpected signal states which can impair the functioning
of the unit.
DANGER!
Electric shock from high voltage!
Follow safety rules when working on electrical systems:
• Switch off the power to the unit.
• Make sure the unit cannot be switched on again inadvertently.
• Confirm that no voltage is present.
• Cover or shield any neighboring system parts which are live.

DANGER!
Electric shock from high voltage!
Only work on the power system with the
power supply switched off.
Lock the main switch and lock access to it.
Only qualified electrical technicians may install the power electronic
system and other components and connect them to the power supply.
9844 1113 102, d107, 09.02

Twin Line Drive 01x 4-7

Installation TLD01x

4.4.1 Line connection

Connect power cable 왘 Connect power lines to PE, N and L screw terminals

Fig. 4.4 Line connection

• The connection cross-section for power cables is 1.5 mm2 to

2.5 mm2.
• Fit a fuse in the power phase:
at 230 V terminal: 10 A (C, K characteristic or similar)
at 115 V terminal: 10 A (C, K characteristic or similar)
• In the case of units without integrated line filter, NF types, the power
cable must be shielded and grounded at both ends between the
filter and the unit terminal if it is longer than 20 cm.
• The correct torque for the terminal screws is 0.4 Nm - 0.5 Nm.
• The individual conductors of the cable can be connected to the unit
without wire end ferrules.

• For units with a hood, the cable must be led upwards from the point
of connection.

Wire end ferrules If you use wire end ferrules, pay attention to the following:
• Do not use end ferrules with a plastic collar on wires with a cable
cross-section of 2.5 mm2.
• Only use square end ferrules to ensure that they do not work loose.
• Strip the insulation from the cable to a length of 10 mm.

Ground leakage circuit-breaker If a fault occurs, fault currents with DC component may occur. For single-
phase units, an e.l.c.b. for fault currents with a pulsating DC component
can be fitted.
9844 1113 102, d107, 09.02

4-8 Twin Line Drive 01x

 TLD01x Installation

4.4.2 Motor connection

DANGER!
Danger of high voltages from inductance!
Do not touch motor cable wires and contacts while the
motor is moving. Even when they are not connected to the
power electronic system, motors will build up dangerous
induced voltages if the motor shaft is turned. During
installation ensure that the motor cannot be driven by
another device.
Connecting motor wires 왘 Connect the motor wires and protective ground to terminals U, V, W
and PE. Wiring assignment for motor and unit must match.

Terminal Connection Color

U Motor cable brown (bn)
V Motor cable blue (bl)
W Motor cable black (bk)
PE Protective conductor (shield tracer wire) -

Fig. 4.5 Motor cable connection to unit

9844 1113 102, d107, 09.02

Fig. 4.6 Motor cable connected to motor with terminal box or plug

Twin Line Drive 01x 4-9

Installation TLD01x

• cable cross-section: 1.5 mm2

• maximum cable length: 20 m
• The correct torque for the terminal screws is 0.4 Nm - 0.5 Nm.
• The individual conductors of the cable can be connected without
wire end ferrules.

• For units with a hood, the cable must be led downwards from the
point of connection.

Fig. 4.7 Preparing the motor cable

Wire end ferrules If you use wire end ferrules, pay attention to the following:
• Only use square end ferrules to ensure that they do not work loose.
• The wire must fill the wire end ferrule over its whole length. Only
then has the connection been safely carried out, ensuring maximum
current carrying capacity and vibration resistance.

EMC measures The motor cable is a source of interference and must be carefully laid:
• The shield braiding of the motor cable must be connected to the
motor housing and to the unit housing as well as to the switch
cabinet entry with a large surface area connection. Use the
supplied shielded terminal for the connection to the housing.
• Where possible motor cables and signal wiring must laid at least 20
cm apart; if they are laid closer together, motor cables and signal
9844 1113 102, d107, 09.02

wiring must be shielded with grounded plates.

4-10 Twin Line Drive 01x

 TLD01x Installation

4.4.3 Connecting the 24 V supply voltage

왘 Route the 24 V wires to the unit over a grounded 24 VDC
transformer (PELV).

Fig. 4.8 24 V connection

Pin Signal Active Meaning I/O

1 24VDC - 24 VDC supply voltage, internally connected to pin 2 -
2 24VDC - 24 VDC power supply -
3 24VGND - GND for 24 VDC voltage, internally connected with pin 4 and pin 6 -
(ACTIVE_GND)
4 24VGND - GND for 24 VDC voltage -

• The second 24 VDC and GND connection can be used as a 24 V

output for further consumers or for cascading several Twin Line
units; the maximum terminal current is 7.5 A.
• In selecting your 24 V power supply unit make sure you take into
account any additional consumers, such as the holding brake and
the holding brake controller.
• To retain the position of the motor when the supply voltage to the
power amplifier is switched off, the ENABLE input signal must be
set to Low before the supply voltage is shut off. The external 24 V
supply voltage must remain switched on, and the motor must not be
subjected to external torque.
• Lay the 24 V supply line at a distance of at least 20 cm from other
lines to ensure EMC protection. For wiring longer than 2 m, make a
twisted pair of the 0 V and 24 V supply wires.
• The torque for terminal screws 1-34 is 0.22 Nm to 0.25 Nm.
9844 1113 102, d107, 09.02

Twin Line Drive 01x 4-11

Installation TLD01x

4.4.4 Connecting a holding brake

In motors with holding brakes the brake can be connected directly or to
the signal interface via the TL HBC holding brake controller. The holding
brake controller connection is described in "Connecting accessories" on
page 4-21.
Use the following circuit with direct control to protect the motor from
overheating. The circuit reduces the exciter current shortly after the
brake is opened.
The values for R1 and C1 are given for the manufacturer’s VRDM 39...
and VRDM311.. motors.

Motor VRDM 36... VRDM 39... VRDM 311...

Resistance R1 72 Ω, min. 4 W 24 Ω, min. 6 W 18 Ω, min. 8 W
Capacitor C1 4700 µF / 25 V 4700 µF / 25 V 6800 µF / 25 V

Fig. 4.9 Holding brake controller connection

For more information see section "Connecting accessories" at

page 4-21.
The static load torque for vertical loads must not exceed 25% of the
motor holding torque to ensure safe function of the holding brake.
Only use cables with the following specifications:

TLD011 TLD012
Cable cross-section 1.5 1.5
[mm2]
Max. cable length 1) 20 20
[m]
1) Longer cables on request
9844 1113 102, d107, 09.02

4-12 Twin Line Drive 01x

 TLD01x Installation

4.4.5 Connection to the PULSE-C interface

Connection The PULSE-C interface is equipped with a Sub-D plug, 15-pin with an
M3 threaded connection.

Fig. 4.10 PULSE-C interface

Pin Signal Color 1) Pair Meaning I/O

1 PULSE (PV) white 1 Motor step "Pulse" or motor step forwards "PV" I
9 PULSE (PV) brown 1 Motor step "Pulse" or motor step forwards "PV", I
inverted
2 DIR (PR) green 2 Direction of rotation "Dir" or motor step I
backwards "PR"
10 DIR (PR) yellow 2 Direction of rotation "Dir" or motor step I
backwards "PR", inverted
3 ENABLE (GATE) gray 3 Enable signal I
11 ENABLE (GATE) pink 3 Enable signal, inverted I
4 PWM blue 4 Phase current value I
12 PWM red 4 Phase current value, inverted I
5 STEP2_INV black 5 Angular resolution transfer I
6 STEP2_INV purple 5 Angular resolution transfer, inverted I
7 GND pink/pink 6 Ground, signal applied internally via resistance -
at 24VGND
8 ACTIVE red/blue 6 Drive ready O
13 FUNCT_OUT white/green 7 Following error message O
14 GND brown/green 7 Ground, signal applied internally via resistance -
at 24VGND
15 GND white/yellow 8 Ground, signal applied internally via resistance -
at 24VGND
1) Color details refer to the cable available as an accessory.
9844 1113 102, d107, 09.02

Twin Line Drive 01x 4-13

Installation TLD01x

Cable specification • shielded cable

• minimum cross-section of signal wires 0.14 mm2
• twisted-pair wires
• shield grounded at both ends
• maximum length:
100 m with RS422 connection
up to 10 m with Open Collector connection

Function Setpoint via externally fed pulse-direction signals

Reference signals for step-by-step positioning of the motor and control
signals for motor current, angular resolution and power amplifier release
are sent over the PULSE-C interface. The power electronic system
simultaneously reports that it is ready for operation and possible
operating fault over the interface.
PULSE (PV), DIR (PR) The square-wave signals PULSE (PV) and DIR (PR) can be combined
for two operating modes. The setting of DIP switch 6 sets the operating
mode:
• PULSE/DIR: Pulse-direction signal with DIP 6 ON
• PV/PR: Pulseforward - Pulsebackward signal with DIP 6 OFF

PV/PR signals can only be used with units with speed monitoring.
You can find information on the DIP switches in section "Set DIP switch"
on page 5-4.
Pulse direction mode The motor executes an angular step with the leading edge of the PULSE
signal. The direction of rotation is controlled by the DIR signal.

Fig. 4.11 Pulse direction signal

Pin Signal Function Value

1, 9 PULSE Motor step low -> high
2, 10 DIR Clockwise direction of rotation low/open
Anticlockwise direction of rotation high
9844 1113 102, d107, 09.02

4-14 Twin Line Drive 01x

 TLD01x Installation

Operating mode The PV (PULSE) signal is used to move the motor in a clockwise
Pulseforward - pulsebackward direction, and the PR (DIR) signal moves it in an anticlockwise direction.

Fig. 4.12 Pulseforward - Pulsebackward signal

Pin Signal Function Value

1, 9 PULSE (PV) PV: Step in clockwise direction of low -> high
rotation
2, 10 DIR (PR) PR: Step in anticlockwise direction low -> high
of rotation

The maximum frequency of PULSE (PV) and DIR (PR) is 200 kHz.
ENABLE (GATE) The ENABLE (GATE) input has two functions, which are set with DIP
switch 5:
• ENABLE function: enable and disable power amplifier, DIP 5 = OFF
• GATE function: enable and disable pulse input, DIP 5 = ON

You can find information on the DIP switches in section "Set DIP switch"
on page 5-4.
ENABLE function The ENABLE (GATE) signal enables the power amplifier so the motor
can be controlled. This requires DIP switch 5 to be set to OFF.

Pin Signal Function Value

3, 11 ENABLE Disable power amplifier low/open
Enable power amplifier high

An error message is also acknowledged with a negative slope at the

ENABLE input.
If there is no operating fault, the ACTIVE output displays operational
readiness for approx 100 ms after the power amplifier is enabled. Then
pulses can be fed in for units without speed monitoring and brake.
Units with brake or speed monitoring require waiting periods before
feeding in pulses to release a holding brake or to initialize the encoder.
9844 1113 102, d107, 09.02

Twin Line Drive 01x 4-15

Installation TLD01x

Fig. 4.13 Enabling and blocking the power amplifier with waiting time TW

Twin Line unit… without brake with brake

without speed monitoring TW= 0 ms TW= 100 ms
with speed monitoring TW= 300 ms TW= 300 ms

If the ENABLE signal is removed, the power amplifier remains active for
150 ms to allow a holding brake to close. If an error that results in the
power amplifier shutting down, the motor current is simultaneously shut
off with ACTIVE.
See page 5-7 for a view of the ENABLE function in motor operation.
GATE function The GATE signal blocks the pulses at the setpoint value input with
stopping it from being ready to operate. The GATE function can be used
to select individual axes in a multi-axis system. DIP switch 5 must be set
to ON for the GATE function.

Pin Signal Function Value

3, 11 ENABLE Enable power amplifier low/open
(GATE) Disable power amplifier high

The following graph shows the motor movement when the GATE
function is enabled. There must be no pulse pending for 1.5 ms before
and after switching the GATE signal.

Fig. 4.14 Signal sequence when switching on the unit with GATE function
9844 1113 102, d107, 09.02

4-16 Twin Line Drive 01x

 TLD01x Installation

STEP2_INV The resolution of the motor step count can be increased by a factor if ten
if this function is enabled by DIP switch 1 and has been activated with
the signal STEP2_INV. STEP2_INV reverses the DIP switch setting.

Pin Signal Function Value

5, 6 STEP2_INV Angular resolution
- as set with DIP 1 low/open
- DIP 1 setting inverted high

When operating the interface with a SIG Berger Lahr WPxxx positioning
controller STEP2_INV is at low level.
The following graph shows the motor movement with the STEP2_INV
signal enabled. There must be no pulse pending for 1.5 ms before and
after switching the STEP2_INV signal.

Fig. 4.15 Signal sequences when switching the step number

PWM The preset motor phase current and therefore the motor torque can be
reduced to between 0% and 100% with the pulse-width-modulated
signal.

Pin Signal Function Value

4, 12 PWM maximum motor phase current low/open
reduced motor phase current high

If there is constant high level at the PWM input, phase current does not
flow and the motor has no current. If there is constant low level the motor
operates at the set maximum phase current.
Only set the PWM controller together with the ENABLE
function, not with the GATE function. The motor receives
the full motor current with the GATE function if the PWM
controller is switched off or fails.

ACTIVE The output shows that the power electronic system is ready for
operation.

Pin Signal Function Value

9844 1113 102, d107, 09.02

8 ACTIVE power amplifier is disabled high

power amplifier is enabled low

ACTIVE is an open collector output to GND.

Twin Line Drive 01x 4-17

Installation TLD01x

FUNCT_OUT The output signals a following error if an encoder is connected and the
encoder monitoring is enabled.

Pin Signal Function Value

13 FUNCT_OUT standard operating status low
following error message high

If FUNCT_OUT signals a following error, the signal must be reset before

continuing to operate. You will find information in "Error display and
troubleshooting" on page 7-2.
FUNCT_OUT is an open collector output to GND.
Circuit of the signal inputs It is recommended that signal inputs be switched via the RS422
interface.
The diagram shows the circuitry of the signal inputs PULSE (PV),
DIR (PR) and ENABLE. Up to 10 inputs of the PULSE-C module can be
connected to an RS422-C transmitter.

Fig. 4.16 Circuit of the signal inputs, L: Cable length

For cable lengths ≤10 m and frequencies ≤50 kHz, Open Collector
outputs can be used if interference resistance requirements are low. 9844 1113 102, d107, 09.02

4-18 Twin Line Drive 01x

 TLD01x Installation

4.4.6 Connection to the interface for speed monitoring

The optional encoder interface is only built-in in units with speed
monitoring.
Connection The interface is equipped with a Sub-D socket, 15-pin with an M3
threaded connection.

Fig. 4.17 Interface for speed monitoring, motor plug view: solder side

Pin Signal Color 1) Pair Meaning I/O

1 A white 1 Encoder signal channel A I
9 A brown 1 Channel A, negated I
12 B green 2 Channel B I
5 B yellow 2 Channel B, negated I
2 5VDC red 3 Encoder supply, 5V, max. 300mA O
3 5VGND blue 3 Encoder supply, ground O
10 +SENSE purple 4 Sense line positive 2) I
11 -SENSE black 4 Sense line negative 2) I
7 TEMP_MOT grey/pink 6 Temperature error, inverted I
4 - red/blue 6 not assigned -
6 - - 5 not assigned -
8 - - 5 not assigned -
13 - - - not assigned -
14 - - - not assigned -
15 - - - not assigned -
1) Color details refer to the cable available as an accessory.
2) Sense line must be connected for activating the 5VDC.

Cable specification • shielded cable

• minimum cross-section of the signal conductors is 0.25 mm2, 5VDC
and 5VGND 0.5 mm2
• twisted-pair wires
9844 1113 102, d107, 09.02

• shield grounded at both ends

• maximum length 100 m

Twin Line Drive 01x 4-19

Installation TLD01x

Function The angular position of the motor is transferred incrementally over the
connection with A/B rectangular signals. The unit detects stepper errors
by comparison with the setpoint position and reports a following error if
the limit value of 6.4° is exceeded.
The power electronic system does not evaluate index pulses.

Fig. 4.18 Timing diagram with positive A and B signal, counting forwards and
backwards

Temperature monitoring The motor winding temperature is monitored with the TEMP-MOT
signal. The signal also indicates whether the encoder is connected.

Pin Signal Function Value

7 TEMP_MOT Temperature range OK high
Overheating of motor or break in low
cable

Encoder type An encoder with 1000 lines must be connected to use the speed
monitoring.

9844 1113 102, d107, 09.02

4-20 Twin Line Drive 01x

 TLD01x Installation

4.4.7 Connecting accessories

Holding brake controller In motors with holding brakes the brake can be connected directly or via
the TL HBC holding brake controller.
The ACTIVE-CON control signal is amplified with the holding brake
controller to ensure that the brake switches quickly and generates as
little heat as possible.

Fig. 4.19 Connection of the TL HBC holding brake controller

Connection The connection of the motor cable is described on page 4-9.

왘 Connect the control connections to the holding brake terminals B+
and B-.
왘 Connect the control terminals ACTIVE_CON and ACTIVE_GND of
the brake controller and the signal interface.
왘 Connect the 24 VDC power supply to the holding brake controller.

The holding brake controller’s power requirement depends on the

switching current for the holding brake:
Brake controller input current [A] = 0.5 A + switching current [A]
왘 Set the switch for voltage reduction to 1.

The voltage reduction function is described in "Braking function with

TL HBC", page 6-3.
9844 1113 102, d107, 09.02

Twin Line Drive 01x 4-21

Installation TLD01x

External capacitors The power control can store superfluous braking energy on an external
electrolytic capcitor viaq the DC link connection. This enables any
increase in the DC link voltage to be reduced in the event of frequent
braking.
Only use cables with the following specifications:

TLD011 TLD012
dielectric strength ≥ 450 V ≥ 450 V
external capacity < 500 µF < 1000 µF

Cable specification • shielded cable

• shield grounded at both ends
• maximum cable length 3 m
• minimum cross-section: 1.5 mm2

Connection 왘 Connect the cable from the DC link connection to the capacitor
connections. Observe correct polarity: DC+ to + and DC- to -.
Otherwise the unit and capacitor can be destroyed.

Fig. 4.20 Connection of an external capacitor

9844 1113 102, d107, 09.02

4-22 Twin Line Drive 01x

 TLD01x Installation

4.5 Wiring example

4.5.1 Stepper motor controller without speed monitoring

Fig. 4.21 Wiring example for stepper motor controller

Signal interface:

Pin Signal Active Meaning I/O

1/9 PULSE (PV) 1) high/low Pulse signal or pulse forward signal I
2/10 DIR (PR) 1) high/low Direction signal or pulse backward signal I
1)
3/11 ENABLE (GATE) high/low Enable signal for power amplifier, DIP switch 5 to OFF I
4/12 PWM high/low Phase current value I
5/6 STEP2_INV high/low Angular resolution, inversion of DIP switch setting I
7,14,15 GND 1) - Ground I
8 ACTIVE low Drive ready O
13 FUNCT_OUT low Following error message O
1) Minimum pin assignment of signal interface for commissioning

Power supply and brake connection:

Pin Signal Active Meaning I/O

1.2 24VDC 1) - + 24 VDC power supply I
9844 1113 102, d107, 09.02

1)
3.4 24VGND - GND for 24 VDC power supply I
5 ACTIVE_CON high Drive ready, brake/relay control signal O
6 ACTIVE_GND - GND for brake and relay control voltage O
1) Minimum pin assignment of signal interface for commissioning

Twin Line Drive 01x 4-23

Installation TLD01x

4.6 Check wiring

왘 Carry out these checks:

• Are all cables and connectors safely installed and connected?

• Are any live cable ends exposed?
• Are the control lines connected correctly?

System check and initialization The motor must not be controlled for the wiring test.
WARNING
Destruction of motor!
The motor must only be operated with the correct phase
current. Controlling the motor with excessively high phase
current will destroy the motor immediately.
왘 Remove the plug for the PULSE-C interface to test the wiring.
왘 Select the ENABLE(GATE) function with DIP switch to OFF.

Fig. 4.22 Wiring test without PULSE-C plug; DIP 5 ENABLE to OFF

왘 Switch on the primary power supply.

왘 Switch on the 24 V power supply.

Unit OK The status display first changes from "1" to "2", then to "3".
The unit carries out a self-test and checks the internal operating data,
the internal monitoring devices and the connected sensing equipment.
The DC link is loaded. The DC link LED D2 lights.
왘 Switch off the power supply again.

왘 Connect the PULSE-C plug again for commissioning.

9844 1113 102, d107, 09.02

4-24 Twin Line Drive 01x

 TLD01x Installation

4.7 Installation troubleshooting

Operational status indicator "2" If the power electronic system hangs in the switching-on state "2", this
indicates an internal fault in the unit which can only be identified and
corrected by your local representative.
Operational status indicator "3" If the display does not change from "3" to "4", check whether the line
voltage is switched on and the line voltage connections are correctly
wired.
Operational status The unit has detected a fault. In "Diagnosis and troubleshooting" from
indicator flashing page 7-1 you will find a list of the causes of faults.
9844 1113 102, d107, 09.02

Twin Line Drive 01x 4-25

Installation TLD01x

9844 1113 102, d107, 09.02

4-26 Twin Line Drive 01x

 TLD01x Commissioning

5 Commissioning

5.1 Commissioning procedure

The following commissioning steps are also required if you

are using a configured unit under changed operating
conditions. Incorrectly set values could cause permanent
damage to the power electronic system, motor and system
parts.

What you need to do... Info

Make sure the Twin Line unit is correctly installed and Chapter
wired up. "Installation" from
When carrying out this check, use the wiring diagrams page 4-1
for the system layout or the sample circuits in "Wiring
example", page 4-23.
Setting phase current Page 5-3
Set DIP switch Page 5-4
Check the functioning of the holding brake controller if it Page 5-6
is wired for that
Test run Page 5-7
Optimizing the movement behavior of the motor Page 5-8
9844 1113 102, d107, 09.02

Twin Line Drive 01x 5-1

Commissioning TLD01x

5.2 Safety notes

Only qualified electrical technicians may commission the system.

WARNING!
Incorrectly set parameters can cause the motor to start
unexpectedly with risk of crushing and damage to the
system!
Close off the danger area and start up the motor when it is
disconnected mechanically from the system and not under
load.
WARNING!
Danger of injury and permanent damage to system parts
by runaway motor!
In error class 3 or 4, or if the unit fails, the motor will no
longer be actively braked and it will run at high speed
against a mechanical stop.
WARNING!
Permanent damage to the power controller!
Only change the settings for the phase current and the DIP
switch settings with the power supply switched off.
WARNING!
Danger of damage and destruction of system components
by motor without braking if the device fails or error class
3 or 4!

WARNING!
Incorrectly set parameters can cause the motor to start
unexpectedly with risk of crushing and damage to the
system!
Close off the danger area and start up the motor when it is
disconnected mechanically from the system and not under
load.

9844 1113 102, d107, 09.02

5-2 Twin Line Drive 01x

 TLD01x Commissioning

5.3 Commissioning the power electronic system

5.3.1 Setting phase current

The power electronic system controls the motor torque with the phase
current. A high phase current generates a high motor torque. To prevent
damage to the motor, the maximum permissible phase current at the
unit must be limited.
WARNING!
Phase current that is set too high can damage or destroy
the motor!
The phase current at the unit must not be set higher than
the rated phase current of the motor. If no value for the
rated current is given, select the next lower phase current
on the unit.
Rotary switch Phase current

Fig. 5.1 Setting phase current

왘 Select the rotary switch position for the maximum phase current
from the table.

Rotary switch r.m.s. value of the max. phase current [A]

TLD011 TLD012
0 0.40 1.75
1 0.50 2.00
2 0.60 2.25
3 0.70 2.50
4 0.80 2.75
5 0.90 3.00
6 1.00 3.25
7 1.20 3.50
8 1.40 3.75
9 1.60 4.00
A 1.80 4.25
B 2.00 4.50
C 2.25 4.75
9844 1113 102, d107, 09.02

D 2.50 5.00
E 2.75 6.00
F 3.00 7.00

Twin Line Drive 01x 5-3

Commissioning TLD01x

5.3.2 Set DIP switch

The DIP switch is used to set control signals for current reduction,
enabling the power amplifier, pulses and speed monitoring.
DIP 1, 2 and 3 Increment count

Fig. 5.2 Setting increment count

Setting increment count 왘 Set the increment count with DIP switches 3, 2 and 1. The
increment count that you selected with STEP0 and STEP1 can be
increased by 10 times with STEP2.

The STEP2 setting can be inverted with the PULSE-C interface

STEP2_INV input signal. See page 4-17 for the signal settings.
DIP 4 and 5 Current reduction and ENABLE/GATE function

Fig. 5.3 Setting current reduction and ENABLE/GATE function

Current reduction Current reduction reduces the motor current to approximately 70%
100 ms after the last pulse slope is received. This allows the motor to
cool while at a standstill.
If the motor drives a vertical axis, the current reduction may
result in loads sinking because the torque is reduced to
about 70% along with the phase current.
9844 1113 102, d107, 09.02

5-4 Twin Line Drive 01x

 TLD01x Commissioning

ENABLE (GATE) The ENABLE (GATE) signal at the signal interface can carry out two
functions:
• ENABLE function: enable and disable power amplifier, DIP 5 = OFF
• GATE function: enable and disable pulse input, DIP 5 = ON

An error message is also acknowledged with a positive slope at the

ENABLE/GATE input.
In a multi-axis system the GATE function enables switching between
individual axes by enabling the pulses for the active axis and leaving
them blocked for the remaining axes.
DIP 6 and 8 Pulse mode and speed monitoring

Fig. 5.4 Setting the function of the PULSE/DIR signals and speed monitoring

Pulse mode The position setpoint values can be fed to the signal interface as a pulse-
direction signal or as a pulse-forward and pulse-backward signal. The
power electronic system converts input signals to a motor movement in
accordance with the DIP switch setting.
Only pulse/directions signals are evaluated in the unit
without speed monitoring. The DIP switch setting is not
relevant.

Speed monitoring Speed monitoring can be disabled with the DIP switch. Then the unit no
longer monitors following errors, even with persistent encoder signals.
The DIP switch setting is not relevant in the unit without speed
monitoring.
9844 1113 102, d107, 09.02

Twin Line Drive 01x 5-5

Commissioning TLD01x

5.3.3 Checking the function of the limit switches

The motor traverse range can be secured with limit switches. The limit
switch signals must be monitored by the external controller and
interrupted for power control if the setpoint pulses are triggered.
왘 Check the functioning of the limit switches before commissioning
the motor in the system.

5.3.4 Checking the holding brake

Carry out this test when you are using a motor with a holding brake.
WARNING!
Danger of injury if the brake function fails!
Protect the danger zone before starting up, and carry out
function test with no load.

Check the brake function with the push-button switch on the holding
brake controller.
If the holding brake controller is to enable the button, the controller must
not be switched by the power electronic system:
왘 Disconnect the ACTIVE_CON control cable at the power electronic
system or switch off the 24 V supply to the power electronic system.
왘 Press the button on the holding brake controller several times to
alternately release and re-apply the brake. The LED on the
controller will light up when the brake has been activated and
thereby released.
왘 Check the brake function: the shaft can be moved by hand when the
brake is not applied, but not when the brake is applied.

9844 1113 102, d107, 09.02

5-6 Twin Line Drive 01x

 TLD01x Commissioning

5.3.5 Motor test run

WARNING!
Danger of injury and damage to system parts resulting
from unexpected motor acceleration!
Run the first test run with no coupled load.
If the motor is already installed in the plant, ensure that any
unexpected motor movements will not cause any damage.
Checking motor direction of rotation 왘 Switch on the external 24 VDC power supply and the 230 V power
for the power circuit.
왘 Enable the ENABLE signal if the ENABLE function has been
selected with DIP switch 5=OFF.

The operational status indicator changes to "4". Power amplifier is

enabled.
왘 Start the first test with low pulse frequency. If the DIR signal is
disabled, the motor must rotate in the clockwise or positive
direction.

Fig. 5.5 Direction of rotation of motor

In the model without encoder the motor direction of rotation can be

reversed by switching two motor phases.
If the motor follows the pulse signals, the control of the motor is correct.
왘 Switch off the power supply and install the motor in the system.
9844 1113 102, d107, 09.02

Twin Line Drive 01x 5-7

Commissioning TLD01x

5.3.6 Optimizing the movement behavior of the motor

Calculating and testing For optimum operation of the motor with the power electronic system the
cut-off frequencies cut-off frequencies must be set for the start/stop and the acceleration
phase at the NC controller.
The cut-off frequencies of a motor are determined from the motor torque
and the external moment of inertia from the characteristic curve diagram
of the stepper motor.
왘 Calculate the moment of inertia of the system reduced to the axis.
왘 Use the characteristic diagram of the motor and the motor torque to
calculate the values for the

• maximum start-stop frequency

• the slope of the frequency ramp

Start-stop frequency The unloaded motor accelerates without stepping errors from standstill
with the start-stop frequency. If the motor is subject to external inertial
forces, a lower frequency than the start-stop frequency must be
selected.
The same applies for the cut-off frequency for braking the motor to
speed 0.

Fig. 5.6 Characteristics of the linear ramp with and without external moments
of inertia

The pulse frequency must be limited to the start-stop

frequency before reversion of the direction of rotation so the change of
direction can be executed without increment loss.
Frequency ramp In the acceleration and braking range above the start-stop
frequency the control frequency must be continuously changed
corresponding to the frequency ramp. The slope of the frequency ramp
depends on the external moment of inertia and the motor type.
왘 Program the frequency data into the NC or positioning controller
and start a test run under actual load conditions.
9844 1113 102, d107, 09.02

5-8 Twin Line Drive 01x

 TLD01x Operating functions

6 Operating functions

6.1 Positioning mode

The power electronic system moves a stepper motor in accordance with

a setpoint. The setpoint signal is generated by a positioning or NC
controller and fed to the PULSE-C interface as a pulse signal.
If speed monitoring is also installed and enabled by DIP switch, the
power electronic system records the position of the motor and reports
increment losses, which may occur as a result of blocking or overload of
the motor.

Fig. 6.1 Positioning controller of a stepper motor with speed monitoring

Setpoint value The setpoint value is sent as pulse-direction signal "P/R". If an encoder
connection is installed, the setpoint value can be preset as
pulse forward/pulse backward signal "PV/PR".
9844 1113 102, d107, 09.02

Twin Line Drive 01x 6-1

Operating functions TLD01x

6.2 Functions of the power electronic system

6.2.1 Monitoring functions

Different monitoring systems protect the motor and power amplifier from
overload and overheating and detect drive position deviations. You will
find an overview of all monitoring functions in "Safety devices" on
page 2-3.
The 7-segment display of the power electronic system shows error
messages and warnings as flashing signals.
Temperature monitoring Sensors in the power electronic system measure the temperature of the
power amplifier. If an encoder connection is installed, the operating
temperature of the motor can be recorded and monitored over the
encoder cable.
If the temperature of the motor or power amplifier exceeds the
permissible limit temperature for more than five seconds, the power
electronic system shuts off the power amplifier and reports a
temperature error.
Following error If speed monitoring is installed, the angular position of the motor is
transferred incrementally over the connection with A/B rectangular
signals. The unit detects stepper errors by comparison with the setpoint
position and reports a following error if the limit value of 6.4° is
exceeded.
Error message over the A following error can be reported to the NC controller over the
PULSE-C interface FUNCT_OUT output of the PULSE-C interface. The power amplifier is
blocked simultaneously and the ACTIVE switches to high.

9844 1113 102, d107, 09.02

6-2 Twin Line Drive 01x

 TLD01x Operating functions

6.2.2 Braking function with TL HBC

In motors fitted with a holding brake the brake prevents unintended
movement of the motor when not under power. The power electronic
system controls the holding brake directly or with the TL HBC holding
brake controller, which is available as an accessory.
Holding brake controller The TL HBC holding brake controller amplifies the ACTIVE_CON
control signal from the signal interface, and controls the brake in such a
way that it responds quickly whilst generating as little heat as possible.
The holding brake can be released with the push-button switch fitted to
the holding brake controller for commissioning and function tests.
Braking signals ACTIVE_CON switches to "high" and opens the brake as soon as the
power amplifier is enabled and the motor has holding torque.

I/O signal Function Value

ACTIVE_CON Brake will be opened or is open high
ACTIVE_CON Brake will be applied or is applied low

Voltage reduction The control voltage of the holding brake controller is variable when the
voltage drop is activated. The voltage is then 24 V for approx. 100 ms
and afterwards falls back to its holding voltage of 12 V.

Fig. 6.2 Time diagram, brake function with voltage reduction on

When the power is switched on, the holding brake control system and
the button function are reset. No voltage is present on the control
terminals of the brake, and the control system LED is off.
9844 1113 102, d107, 09.02

Twin Line Drive 01x 6-3

Operating functions TLD01x

9844 1113 102, d107, 09.02

6-4 Twin Line Drive 01x

 TLD01x Diagnosis and troubleshooting

7 Diagnosis and troubleshooting

7.1 Operational status indicators and transitions

Status display in the unit The D2 LED on the motor plug lights when there is power in the DC link.
The 7-segment display shows the operating states of the power
electronic system in coded form.

Display Operating status

0 24 V switched on
1 Initialization of the unit electronics
2 The power amplifier is not ready to switch on
3 Switching on the power amplifier is disabled
4 The power amplifier is ready to switch on
6 The unit is working in the selected mode
7 A Quick-Stop is being executed
8, 9 An error has been detected and the error response activated
0-A Indicates an error value
flashing

Operating transitions The conditions for changing between the operating states displayed and
the response of the power electronic system to an error follow a fixed
sequence.
9844 1113 102, d107, 09.02

Fig. 7.1 Operating states and transitions of the power electronic system

Twin Line Drive 01x 7-1

Diagnosis and troubleshooting TLD01x

7.2 Error display and troubleshooting

Error display The cause of an operating malfunction is displayed

• by a flashing number in the seven-segment display
• by the error response of the power electronic system and motor

Resetting error messages When the fault is corrected, the message can be acknowledged by
return of the ENABLE signal to the signal interface. DIP switch 5 must be
set to OFF.
If DIP switch 5 is set to ON, the GATE function is enabled. In this case
an error message can only be acknowledged by briefly switching off the
24 V power supply.
Error response The power electronic system triggers an error response when a
malfunction occurs. Depending on the seriousness of the fault, the unit
responds in accordance with one of the following error classes:

Error Response Meaning

class
0 Warning Message only, no interruption to movement
operations
3 Fatal error The power amplifier and controller switch off.
The unit can only be reactivated after the error has
been corrected.
4 Uncontrolled The power amplifier and controller switch off .
operation The error response can only be reset by switching
off the unit.

Troubleshooting

Display Error Error Cause Troubleshooting

class
dark Display dark - No power supply Check power supply and fuses
Display dark - Power supply wrongly connected Connect properly
1 Undervoltage 3 DC link voltage below threshold value Check line voltage and check connections
for switching off the drive to unit
2 Following error 3 Drive blocked; start-stop frequency Reduce load or motor torque
too high; movement frequency or check settings for motor current
acceleration too high set start-stop frequency lower; reduce
movement frequency or acceleration
2 Maximum motor 3 Maximum motor speed exceeded Reduce pulse frequency
speed
3 Motor cable 3 Short circuit or ground fault in motor Check connections, replace motor cable
cable
4 Position sensor 3 Only with TLD01x with speed Check encoder cable and encoder.
monitoring: encoder or encoder cable Replace cable, replace motor
defective
9844 1113 102, d107, 09.02

5 Overvoltage 3 DC link overvoltage Use external capacitor

7 Power amplifier 3 The power amplifier is overheating Reduce load, use current drop to reduce
overtemperature power
7 Motor 3 Only with TLD01x with encoder Allow motor to cool, use a motor with a
overtemperature connection: motor overheating higher rated power, use current drop to
Temperature sensor not connected or reduce power, check or replace motor
defective encoder cable

7-2 Twin Line Drive 01x

 TLD01x Diagnosis and troubleshooting

Display Error Error Cause Troubleshooting

class
8 Watchdog 4 Internal system error Switch unit off and on, replace unit
C Timing error 4 Timing of GATE, STEP2_INV or Checking timing response of signals at
PULSE not retained PULSE-C interface.

7.3 Malfunctions in movement mode

Faults Cause Correction

Motor does Signal input Disable current controller (PWM)
not rotate PWM: high
and has no
holding Signal input Enable power amplifier release
torque ENABLE: low (ENABLE)
Motor incorrectly Connect motor correctly
connected
Motor does Signal input Disable GATE signal with GATE
not rotate but GATE: high function to release pulses
has holding
torque Pulse frequency Check timing and signal voltage level
of pulse signals (PULSE, DIR)
Motor does Pulse frequency Check timing and signal voltage level
not rotate of pulse signals (PULSE, DIR)
uniformly
Overload Reduce load
Motor defective Replace motor
Motor The motor phases are Check motor connection, replace
rotates in the swapped
wrong
direction +DIR/-DIR incorrectly Check signals, connect correctly
connected
PV/PR signals
swapped
Motor torque Phase current wrongly Set motor phase current as required
too low set by motor type label and phase current
table at commissioning
9844 1113 102, d107, 09.02

Twin Line Drive 01x 7-3

Diagnosis and troubleshooting TLD01x

9844 1113 102, d107, 09.02

7-4 Twin Line Drive 01x

 TLD01x Service, maintenance and warranty

8 Service, maintenance and warranty

8.1 Service address

Contact your local service representative with any questions or

problems. He will refer you to a customer service representative near
you on request.

Maintenance The Twin Line unit requires no maintenance

왘 Check the filter in the switch cabinet ventilator regularly. Inspection
intervals depend on the ambient conditions on site.

Have repairs to the unit carried out only by your local

service representative to ensure that the unit continues to
operate reliably.

Warranty If the unit is opened the warranty is canceled.

9844 1113 102, d107, 09.02

Twin Line Drive 01x 8-1

Service, maintenance and warranty TLD01x

8.2 Shipping, storage and disposal

DANGER!
Electric shock from high voltage!
Switch off the power supply at the main switch before
removing the unit.

DANGER!
Electric shock from high voltage!
> 4 min Before starting work on the connections of the power unit
(or 10 min) or on the motor terminals, wait for the 4 minutes discharge
time and then measure the residual voltage on the DC-link
terminals DC+ and DC-. The residual voltage must not
exceed 48 VDC before you start work on the connections.
If additional DC-link capacitors are connected, the
discharge period is increased to 10 minutes. Wait for this
period and then measure the residual voltage.
Shipping The unit must be protected against impact while in transit. Use the
original packaging for this purpose.
Storage Store the unit only under the permissible ambient conditions for room
temperature and humidity.
Protect the unit from dust and dirt.
Disposal The power electronic system is made from various materials which can
be recycled or which must be separately disposed of.
For recycling purposes, separate the unit into the following parts
• housing, screws and terminals for ferrous metal recycling
• cables for copper recycling
• connectors, hood for plastics recycling

Circuit boards and electronic components must be disposed of

separately in accordance with the applicable environmental protection
laws. Send these parts for special waste disposal.

9844 1113 102, d107, 09.02

8-2 Twin Line Drive 01x

 TLD01x Accessories and spare parts

9 Accessories and spare parts

9.1 List of accessories

Accessories for the power electronic system are:

Qty. Designation Order no.

1 Connector set for complete assembly 6250 1519 001
1 Motor cable 1.5 mm2 6250 1317 xxx 1)
1 Pulse direction cable for PULSE-C interface
2 x socket, 15-pin 6250 1447 yyy 2)
1 x socket, 15-pin, one end open 6250 1452 yyy 2)
1 Encoder cable for speed monitoring 6250 1440 xxx 1)
1 Holding brake controller TL HBC 6250 1101 606
1 External line filter for units without internal filters
for TLD011 NF, 4 A 5905 1100 200
for TLD012 NF, 10 A 6250 1101 606
1) Cable length xxx: 003, 005, 010, 020, 3 m, 5 m, 10 m, 20 m, longer cables on
request
2) Cable length yyy: 005, 015, 030, 050: 0.5 m, 1.5 m, 3 m, 5 m;

9.2 List of spare parts

Power electronic system

Qty. Designation Order no.
1 TLD011, TLD012 Type code
1 SK14 shielding terminal 6250 1101 400
1 Documentation on the TLD01x on CD-ROM, 9844 1113 138
multilingual
9844 1113 102, d107, 09.02

Twin Line Drive 01x 9-1

Accessories and spare parts TLD01x

9844 1113 102, d107, 09.02

9-2 Twin Line Drive 01x

 TLD01x Unit label

10 Unit label

10.1 Illustration of the unit label

왘 Copy the unit label and stick it on the inside of the Twin Line unit's
hood.

Fig. 10.1 Unit label

9844 1113 102, d107, 09.02

Twin Line Drive 01x 10-1

Unit label TLD01x

9844 1113 102, d107, 09.02

10-2 Twin Line Drive 01x

 TLD01x Index

Index

A
Accessories
Order nos. 9-1
Ambient conditions 2-2
B
Brake controller, see Holding brake controller
Braking function 6-3
C
CE mark 1-8
Connecting ground leakage circuit-breakers 4-8
Control cabinet 4-4
Correcting operating errors 7-3
D
Danger categories 2-1
Declaration of conformity 1-8
Disposal 8-2
E
EC directives 1-8
EMC directive 1-8
Error class 7-2
Error response
Meaning 7-2
F
Fitting the unit label 4-5
H
HMI hand-held operating unit
Manual 1-3
Holding brake controller
Dimensions 3-2
Function 6-3
Technical data 3-5
Holding brake, function check 5-6
I
Installation clearances 4-4
Intended use 2-2
Interface signal
ACTIVE_CON 6-3
IT networks, Use in 2-2
L
Laying motor cables 4-9
9844 1113 102, d107, 09.02

Line connection
Connecting 24V supply 4-11
Line filter, unit designations 4-6

Twin Line Drive 01x -1

Index TLD01x

M
Maintenance 8-1
Malfunctions in movement mode 7-3
Module
PULSE-C 1-5, 4-13
Motor connection 1-5
O
Open Collector circuit 4-18
Operating states and transitions 7-1
P
Personnel
Qualification 2-3
Q
Qualification of the personnel 2-3
R
Removal 8-2
S
Safety notes 2-1
Service address 8-1
Shipping 8-2
Signal inputs
Circuit diagram 4-18
Status display 7-1
Storage 8-2
T
Timing diagram
Braking function 6-3
Pulse direction signal 4-14
Pulse forward/backward signal 4-15
TLC53x, see Twin Line unit
Twin Line unit
24 V connection wiring 4-11
Installation clearances 4-4
Overview 1-5
Power classes 1-4
Type code 1-4
Type code 1-4
Type label, line filter information 4-6
U
Unit label
Fitting 4-5
Template 10-1
9844 1113 102, d107, 09.02

V
Voltage reduction 6-3
W
Warranty 8-1

-2 Twin Line Drive 01x

 TLD 01x Supplement

Supplement

Safety note

Twin Line units are drives designed for general use. They are state of the
art and are designed to be as safe as possible. However, drives and
drive controllers that are not specifically designed for safety functions
are not approved for applications where the functioning of the drive
could endanger persons. The possibility of unexpected or unbraked
movements can never be totally excluded without additional safety
equipment. For this reason personnel must never be in the danger zone
of Twin Line drives unless additional suitable safety equipment prevents
any personal danger. This applies for operating the machine during
production and also for all service and maintenance work on drives and
the machine.
The machine design must ensure personal safety.
Suitable measures for prevention of property damage are also required.

The following constraints must be observed for applications conforming to UL508C

• Input mains overvoltage category III (UL840): The Twin Line

product range has been designed in accordance with standard
UL840. A UL Recognized Transient Voltage Surge Suppressor,
conforming to UL 1449, with a maximum clamping voltage of 4kV,
shall be provided in all phases of the line side of the drive in the end
installation. Use Square D SDSA3650 surge arrester or equivalent.

• Branch circuit fuse class CC 600V according to UL248 required

• Max. surrounding air temperature 50 °C

9844 1113 154, d107, 09.02

Twin Line Drive 01x E-1

Supplement TLD 01x

9844 1113 154, d107, 09.02

E-2 Twin Line Drive 01x