SEW-Eurodrive MOVITRANS TES31A User manual

*25975072_0519*
Drive Technology \ Drive Automation \ System Integration \ Services
Operating Instructions
Contactless Energy Transfer System
MOVITRANS® TES31A Decentralized Supply Unit
System frequency A, B
Edition 05/2019 25975072/EN

SEW-EURODRIVE—Driving the world

Table of contents
Operating Instructions – MOVITRANS® TES31A Decentralized Supply Unit 3
Table of contents
1 General information.................................................................................................................. 6
1.1 About this documentation ...............................................................................................6
1.2 Other applicable documentation .....................................................................................6
1.3 Structure of the safety notes ...........................................................................................6
1.3.1 Meaning of signal words ................................................................................ 6
1.3.2 Structure of section-related safety notes........................................................ 6
1.3.3 Structure of embedded safety notes .............................................................. 7
1.4 Decimal separator in numerical values ...........................................................................7
1.5 Rights to claim under limited warranty ............................................................................7
1.6 Product names and trademarks......................................................................................8
1.7 Copyright notice ..............................................................................................................8
2 Safety notes .............................................................................................................................. 9
2.1 Preliminary information ...................................................................................................9
2.2 Duties of the user............................................................................................................9
2.3 Electromagnetic fields.....................................................................................................9
2.4 Target group .................................................................................................................10
2.5 Designated use .............................................................................................................10
2.6 Functional safety technology ........................................................................................10
2.7 Transport.......................................................................................................................11
2.8 Installation/assembly.....................................................................................................11
2.8.1 Restrictions of use........................................................................................ 11
2.9 Electrical installation .....................................................................................................12
2.9.1 Required preventive measure ...................................................................... 12
2.10 Protective separation ....................................................................................................12
2.11 Startup/operation ..........................................................................................................12
3 Device structure ..................................................................................................................... 14
3.1 Type designation...........................................................................................................14
3.2 Short designation ..........................................................................................................15
3.3 Scope of delivery ..........................................................................................................15
3.4 Device overview............................................................................................................16
3.5 Nameplate.....................................................................................................................18
3.6 Accessories...................................................................................................................19
3.6.1 Accessory components ................................................................................ 19
3.7 Operating principle........................................................................................................20
4 Mechanical installation .......................................................................................................... 21
4.1 Requirements................................................................................................................21
4.2 Mounting position..........................................................................................................22
4.3 Minimum clearance.......................................................................................................22
4.4 Waste heat....................................................................................................................23
4.5 Installation.....................................................................................................................23
5 Electrical installation.............................................................................................................. 25
5.1 Installation notes ...........................................................................................................25
5.2 Low-voltage supply systems .........................................................................................25
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Table of contents
Operating Instructions – MOVITRANS® TES31A Decentralized Supply Unit
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5.3 Cable routing.................................................................................................................25
5.4 Protective measures against electrical hazards............................................................26
5.4.1 Overview ...................................................................................................... 26
5.4.2 Installing ground connection or equipotential bonding ................................. 26
5.4.3 Required cable cross section ....................................................................... 27
5.5 Line components...........................................................................................................29
5.5.1 Residual current device................................................................................ 29
5.5.2 Line fuse types ............................................................................................. 29
5.5.3 Contactors.................................................................................................... 29
5.6 Installation of several devices .......................................................................................30
5.7 Connection block ..........................................................................................................31
5.7.1 Devices with 12A, 30A, 42.5A................................................................... 31
5.7.2 Devices with a load current of 60A, 85A .................................................... 32
5.8 Electrical connections ...................................................................................................33
5.8.1 Representation of connections..................................................................... 33
5.8.2 Connection cables........................................................................................ 33
5.8.3 Cable structure............................................................................................. 34
5.8.4 X1201: AC400V input................................................................................. 35
5.8.5 X2337: Load connection TLS....................................................................... 37
5.8.6 X4101: CAN bus – system bus .................................................................... 39
5.8.7 X4108: CAN bus – system bus .................................................................... 42
5.8.8 X5102_1: Digital inputs – power section ...................................................... 45
5.8.9 X5102_2: Digital outputs – power section.................................................... 46
5.8.10 X5121: MOVITRANS® synchronization signal.............................................. 47
5.8.11 X5122: MOVITRANS® synchronization signal.............................................. 49
5.8.12 X5161: Device interface for dual-channel disconnection – input ................. 50
6 Parameters .............................................................................................................................. 51
6.1 Notes.............................................................................................................................51
6.2 Parameter overview by parameter tree.........................................................................52
6.3 Parameter description...................................................................................................59
6.3.1 Display values .............................................................................................. 59
6.3.2 Setpoints/modulation.................................................................................... 63
6.3.3 Device functions........................................................................................... 68
6.3.4 Manual operation ......................................................................................... 76
7 Startup ..................................................................................................................................... 77
7.1 For your safety ..............................................................................................................77
7.2 Requirements................................................................................................................78
7.3 Control via terminals .....................................................................................................78
7.4 Operation with the MOVITOOLS® MotionStudio engineering software .......................79
7.4.1 About MOVITOOLS® MotionStudio.............................................................. 79
7.4.2 First steps..................................................................................................... 80
7.4.3 Communication SBus (CAN) via interface adapter ..................................... 85
7.4.4 Executing functions with the devices ........................................................... 89
7.5 Communication via system bus ....................................................................................91
7.5.1 MOVILINK® protocol..................................................................................... 91
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Table of contents
Operating Instructions – MOVITRANS® TES31A Decentralized Supply Unit 5
7.5.2 Reading a parameter ................................................................................... 97
7.6 Control via SBus ...........................................................................................................98
7.6.1 Control via process data telegrams.............................................................. 98
7.6.2 Control via parameter telegrams.................................................................. 98
7.7 Compensation.............................................................................................................100
7.7.1 Track compensation................................................................................... 100
7.7.2 Prerequisites .............................................................................................. 100
7.7.3 Procedure................................................................................................... 100
8 Operation............................................................................................................................... 103
8.1 For your safety ............................................................................................................103
8.2 Status and fault messages..........................................................................................104
8.2.1 Status of LED V1........................................................................................ 104
8.2.2 Status of LED V2........................................................................................ 105
8.2.3 Fault list...................................................................................................... 106
8.3 Fault reset ...................................................................................................................108
9 Service................................................................................................................................... 109
9.1 Status and fault messages..........................................................................................109
9.2 Inspection/maintenance..............................................................................................109
9.3 Electronics Service by SEW‑EURODRIVE.................................................................109
9.4 Shutdown....................................................................................................................110
9.5 Storage .......................................................................................................................110
9.6 Extended storage........................................................................................................110
9.7 Cleaning......................................................................................................................111
9.8 Waste disposal............................................................................................................112
10 Technical data....................................................................................................................... 113
10.1 Design with operating voltage AC400/500V .............................................................113
10.1.1 3.2kW devices........................................................................................... 113
10.1.2 8kW devices.............................................................................................. 114
10.1.3 14kW devices............................................................................................ 115
10.1.4 General electronics data ............................................................................ 116
10.2 Dimension drawings....................................................................................................116
10.2.1 3.2kW ........................................................................................................ 116
10.2.2 8kW, 14kW............................................................................................... 117
11 Appendix ............................................................................................................................... 118
11.1 Parameters ordered by indexes..................................................................................118
12 Address list ........................................................................................................................... 127
Index ...................................................................................................................................... 138
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1General information
About this documentation
Operating Instructions – MOVITRANS® TES31A Decentralized Supply Unit
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1 General information
1.1 About this documentation
The current version of the documentation is the original.
This documentation is an integral part of the product. The documentation is intended
for all employees who perform work on the product.
Make sure this documentation is accessible and legible. Ensure that persons respon-
sible for the systems and their operation as well as persons who work on the product
independently have read through the documentation carefully and understood it. If you
are unclear about any of the information in this documentation, or if you require further
information, contact SEW‑EURODRIVE.
1.2 Other applicable documentation
Observe the corresponding documentation for all further components.
1.3 Structure of the safety notes
1.3.1 Meaning of signal words
The following table shows the grading and meaning of the signal words for safety
notes.
Signal word Meaning Consequences if disregarded
DANGER Imminent hazard Severe or fatal injuries
WARNING Possible dangerous situation Severe or fatal injuries
CAUTION Possible dangerous situation Minor injuries
NOTICE Possible damage to property Damage to the product or its envi-
ronment
INFORMATION Useful information or tip: Simplifies
handling of the product.
1.3.2 Structure of section-related safety notes
Section-related safety notes do not apply to a specific action but to several actions
pertaining to one subject. The hazard symbols used either indicate a general hazard
or a specific hazard.
This is the formal structure of a safety note for a specific section:
SIGNAL WORD
Type and source of hazard.
Possible consequence(s) if disregarded.
• Measure(s) to prevent the hazard.
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1
General information
Decimal separator in numerical values
Operating Instructions – MOVITRANS® TES31A Decentralized Supply Unit 7
Meaning of the hazard symbols
The hazard symbols in the safety notes have the following meaning:
Hazard symbol Meaning
General hazard
Warning of dangerous electrical voltage
Warning of hot surfaces
Warning about suspended load
Warning of automatic restart
1.3.3 Structure of embedded safety notes
Embedded safety notes are directly integrated into the instructions just before the de-
scription of the dangerous action.
This is the formal structure of an embedded safety note:
SIGNAL WORD Type and source of hazard. Possible consequence(s) if disregar-
ded. Measure(s) to prevent the hazard.
1.4 Decimal separator in numerical values
In this document, a period is used to indicate the decimal separator.
Example: 30.5kg
1.5 Rights to claim under limited warranty
Read the information in this documentation. This is essential for fault-free operation
and fulfillment of any rights to claim under limited warranty. Read the documentation
before you start working with the product.
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1General information
Product names and trademarks
Operating Instructions – MOVITRANS® TES31A Decentralized Supply Unit
8
1.6 Product names and trademarks
The brands and product names in this documentation are trademarks or registered
trademarks of their respective titleholders.
1.7 Copyright notice
©2019SEW‑EURODRIVE. All rights reserved. Unauthorized reproduction, modifica-
tion, distribution or any other use of the whole or any part of this documentation is
strictly prohibited.
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2
Safety notes
Preliminary information
Operating Instructions – MOVITRANS® TES31A Decentralized Supply Unit 9
2 Safety notes
2.1 Preliminary information
The following general safety notes serve the purpose of preventing injury to persons
and damage to property. They primarily apply to the use of products described in this
documentation. If you use additional components, also observe the relevant warning
and safety notes.
2.2 Duties of the user
As the user, you must ensure that the basic safety notes are observed and complied
with. Make sure that persons responsible for the machinery and its operation as well
as persons who work on the device independently have read through the documenta-
tion carefully and understood it.
As the user, you must ensure that all of the work listed in the following is carried out
only by qualified specialists:
• Setup and installation
• Installation and connection
• Startup
• Maintenance and repairs
• Shutdown
• Disassembly
Ensure that the persons who work on the product pay attention to the following regula-
tions, conditions, documentation, and information:
• National and regional safety and accident prevention regulations
• Warning and safety signs on the product
• All other relevant project planning documents, installation and startup instructions,
and wiring diagrams
• Do not assemble, install or operate damaged products
• All system-specific specifications and conditions
Ensure that systems in which the product is installed are equipped with additional
monitoring and protection devices. Observe the applicable safety regulations and leg-
islation governing technical work equipment and accident prevention regulations.
2.3 Electromagnetic fields
Observe DGUV (German Social Accident Insurance) regulation15–"Electromagnetic
fields" as well as DIN EN 12198‑1:2000+A1:2008 during installation, startup, and
operation of systems with contactless energy transfer by induction for use in industrial
workplaces.
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2Safety notes
Target group
Operating Instructions – MOVITRANS® TES31A Decentralized Supply Unit
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2.4 Target group
Specialist for me-
chanical work
Any mechanical work may only be performed by adequately qualified specialists. Spe-
cialists in the context of this documentation are persons familiar with the design, me-
chanical installation, troubleshooting, and maintenance of the product who possess
the following qualifications:
• Qualification in the mechanical area in accordance with the national regulations
• Familiarity with this documentation
Specialist for elec-
trotechnical work
Any electrotechnical work may only be performed by electrically skilled persons with a
suitable education. Electrically skilled persons in the context of this documentation are
persons familiar with electrical installation, startup, troubleshooting, and maintenance
of the product who possess the following qualifications:
• Qualification in the electrotechnical area in accordance with the national regula-
tions
• Familiarity with this documentation
Additional qualifi-
cation
In addition to that, these persons must be familiar with the valid safety regulations and
laws, as well as with the requirements of the standards, directives, and laws specified
in this documentation.
The persons must have the express authorization of the company to operate, pro-
gram, parameterize, label, and ground devices, systems, and circuits in accordance
with the standards of safety technology.
Instructed persons All work in the areas of transportation, storage, operation and waste disposal must be
carried out by persons who are trained appropriately. The purpose of the instruction is
that the persons are capable of performing the required tasks and work steps in a safe
and correct manner.
2.5 Designated use
The product is intended for installation in electrical plants or machines.
The product is intended for stationary use in industrial and commercial systems with
contactless energy transfer systems.
In case of installation in electrical systems or machines, startup of the product is pro-
hibited until it is determined that the machine meets the requirements stipulated in the
local laws and directives. For Europe, Machinery Directive 2006/42/EC as well as the
EMC Directive 2014/30/EU apply. Observe EN60204-1 (Safety of machinery - elec-
trical equipment of machines). The product meets the requirements stipulated in the
Low Voltage Directive 2014/35/EU.
The standards given in the declaration of conformity apply to the product.
Technical data and information on the connection conditions are provided on the
nameplate and in the chapter "Technical data" in the documentation. Always comply
with the data and conditions.
Unintended or improper use of the product may result in severe injury to persons and
damage to property.
2.6 Functional safety technology
The product must not perform any safety functions without a higher-level safety sys-
tem, unless explicitly allowed by the documentation.
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2
Safety notes
Transport
Operating Instructions – MOVITRANS® TES31A Decentralized Supply Unit 11
2.7 Transport
Inspect the shipment for damage as soon as you receive the delivery. Inform the ship-
ping company immediately about any damage. If the product is damaged, it must not
be assembled, installed or started up.
Observe the following notes when transporting the device:
• Ensure that the product is not subject to mechanical impact.
If necessary, use suitable, sufficiently dimensioned handling equipment.
Observe the information on climatic conditions in the chapter "Technical data" of the
documentation.
2.8 Installation/assembly
Ensure that the product is installed and cooled according to the regulations in the doc-
umentation.
Protect the product from strong mechanical strain. The product and its mounting parts
must never protrude into the path of persons or vehicles. Ensure that components are
not deformed and insulation spaces are not changed, particularly during transportation
and handling. Electric components must not be mechanically damaged or destroyed.
Observe the notes in chapter "Mechanical installation" (→ 221) in the documenta-
tion.
2.8.1 Restrictions of use
The following applications are prohibited unless the device is explicitly designed for
such use:
• Use in potentially explosive atmospheres
• Use in areas exposed to harmful oils, acids, gases, vapors, dust, and radiation
• Operation in applications with impermissibly high mechanical vibration and shock
loads in excess of the regulations stipulated in EN61800-5-1
• Use at an elevation of more than 2000m above sea level
The product can be used at altitudes above 1000 m above sea level up to 2000m
above sea level under the following conditions:
• Taking the reduced nominal output current into consideration, see chapter "Tech-
nical data" of the documentation.
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2Safety notes
Electrical installation
Operating Instructions – MOVITRANS® TES31A Decentralized Supply Unit
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2.9 Electrical installation
Ensure that all of the required covers are correctly attached after carrying out the elec-
trical installation.
Make sure that preventive measures and protection devices comply with the applica-
ble regulations (e.g. EN60204-1 or EN61800-5-1).
2.9.1 Required preventive measure
Make sure that the product is correctly attached to the ground connection.
2.10 Protective separation
The product meets all requirements for protective separation of power and electronics
connections in accordance with EN 61800-5-1. To ensure protective separation, all
connected circuits must also meet the requirements for protective separation.
2.11 Startup/operation
Observe the safety notes in the chapters "Startup" (→ 277) and "Opera-
tion"(→2103) in this documentation.
Make sure that any existing transport protection is removed.
Do not deactivate monitoring and protection devices of the machine or system even
for a test run.
Depending on the degree of protection, products may have live, uninsulated, and
sometimes moving or rotating parts, as well as hot surfaces during operation.
Additional preventive measures may be required for applications with increased haz-
ard potential. Be sure to check the effectiveness of the protection devices after every
modification.
In the event of deviations from normal operation, switch the product off. Possible devi-
ations are increased temperatures, noise, or vibration, for example. Determine the
cause. Contact SEW‑EURODRIVE if necessary.
When the device is switched on, dangerous voltages are present at all power connec-
tions as well as at any connected cables and terminals. This is also the case even if
the product is inhibited.
Do not separate the connection to the product during operation. This may result in
dangerous electric arcs damaging the product.
If you disconnect the product from the voltage supply, do not touch any live compon-
ents or power connections because capacitors might still be charged. Observe the fol-
lowing minimum switch-off time:
10 minutes.
Observe the corresponding information signs on the product.
The fact that the operation LED and other display elements are no longer illuminated
does not indicate that the product has been disconnected from the supply system and
no longer carries any voltage.
Cover unused connections with the supplied protection caps during operation.
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2
Safety notes
Startup/operation
Operating Instructions – MOVITRANS® TES31A Decentralized Supply Unit 13
Mechanical blocking or internal protective functions of the product can cause the
power to interrupt. Removing the cause of this problem or performing a reset can re-
sult in the machine or system restarting on its own. If this is not permitted for the drive-
controlled machine or system for safety reasons, first disconnect the product from the
supply system and then start troubleshooting.
Risk of burns: The surface temperature of the product can exceed 60°C during opera-
tion. Do not touch the product during operation. Let the product cool down before
touching it.
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3Device structure
Type designation
Operating Instructions – MOVITRANS® TES31A Decentralized Supply Unit
14
3 Device structure
3.1 Type designation
TES31A MOVITRANS® stationary supply unit
... Nominal power:
030 3.2kW
080 8kW
140 14kW
-
EIncreased degree of protection
FHeat sink and fan
.Load current:
1 12A (1 load connection)
3 30A (1 load connection)
4 42.5A (1 load connection)
6 60A (2 load connections)
8 85A (2 load connections)
-
5Connection voltage: AC400/500V
.Radio interference suppression level:
A C1
B C2
3Connection type: 3-phase
-
.System frequency:
A 25kHz
B 50kHz
C 140kHz
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3
Device structure
Short designation
Operating Instructions – MOVITRANS® TES31A Decentralized Supply Unit 15
3.2 Short designation
The following short designations are used in this documentation:
Device Short designation
MOVITRANS® TES31A080‑EF3‑5B3‑A decentral-
ized supply unit (25kHz, 30A, 8kW) Device
MOVITRANS® TES31A080‑EF4‑5B3‑A decentral-
ized supply unit (25kHz, 42.5A, 8kW) Device
MOVITRANS® TES31A080‑EF6‑5B3‑A decentral-
ized supply unit (25kHz, 60A, 8kW) Device
MOVITRANS® TES31A080‑EF8‑5B3‑A decentral-
ized supply unit (25kHz, 85A, 8kW) Device
MOVITRANS® TES31A030‑EF3‑5B3‑B decentral-
ized supply unit (50kHz, 30A, 3.2kW) Device
MOVITRANS® TES31A080‑EF6‑5B3‑B decentral-
ized supply unit (50kHz, 60A, 8kW) Device
MOVITRANS® TES31A080‑EF6‑5B3‑B decentral-
ized supply unit (50kHz, 60A, 14kW) Device
3.3 Scope of delivery
The scope of delivery includes the following components:
Component
MOVITRANS® TES31A080‑EF3‑5B3‑A decentralized supply unit
or
MOVITRANS® TES31A080‑EF4‑5B3‑A decentralized supply unit
or
MOVITRANS® TES31A080‑EF6‑5B3‑A decentralized supply unit
or
MOVITRANS® TES31A080‑EF8‑5B3‑A decentralized supply unit
or
MOVITRANS® TES31A030‑EF3‑5B3‑B decentralized supply unit
or
MOVITRANS® TES31A080‑EF6‑5B3‑B decentralized supply unit
or
MOVITRANS® TES31A140‑EF6-5B3‑B decentralized supply unit
Protective covers for all plug connectors
Component Part number
2× jumper plug 11747099
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3Device structure
Device overview
Operating Instructions – MOVITRANS® TES31A Decentralized Supply Unit
16
3.4 Device overview
Devices with a load current of 12A, 30A, 42.5A with 1load connection
The following figure shows the device structure:
[4]
[5]
[1] [2] [3]
[7][8] [6]
18014419138037387
[1] Housing
[2] Display elements
[3] Gyrator 8kW
[4] Signal and bus connections
[5] Power supply connection
[6] Connection for ground connection (PE)
[7] Load connection
[8] Fan
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3
Device structure
Device overview
Operating Instructions – MOVITRANS® TES31A Decentralized Supply Unit 17
Devices with a load current of 60A, 85A with 2load connections
The following figure shows the device structure:
[4]
[5]
[1] [2] [3]
[7][8] [6]
23280511499
[1] Housing
[2] Display elements
[3] Gyrator 8kW
[4] Signal and bus connections
[5] Power supply connection
[6] Connection for ground connection (PE)
[7] Load connection
[8] Fan
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3Device structure
Nameplate
Operating Instructions – MOVITRANS® TES31A Decentralized Supply Unit
18
3.5 Nameplate
The nameplate lists information about the device type. The following figure shows an
example of a nameplate:
D-76646 Bruchsal
Made in Germany
Type:
SO#:
Eingang / Input
XXXXXXX
XXXXXXXXX-XXX-XXX-X
Ausgang / Output
T P IP
U
I
f
=
=
=
U
I
f
=
=
=
= =
[2]
[1]
MOVITRANS
11 10 10 10 50 -- 10 -- -- ML
9007218450919947
[1] Product name
[2] Approval identification
Depending on the device design, the following information is listed on the nameplate:
Value Specification
Type Type designation
SO# Serial number
U Voltage
I Current
f Frequency
T Ambient temperature
P Rated output power
IP Degree of protection
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3
Device structure
Accessories
Operating Instructions – MOVITRANS® TES31A Decentralized Supply Unit 19
3.6 Accessories
3.6.1 Accessory components
Part number
PC CAN interface adapter 18210597
Note that the connection cable M12 ↔ D-sub (part number18125751) as well as the
D-sub gender changer (part number19188714) must be ordered separately.
Fan subassembly with connection cable and connector
for TES31A080‑EF6‑5B3‑B (50kHz, 60A, 8kW) 28230337
Fan subassembly with connection cable and connector
for TES31A140‑EF6‑5B3‑B (50kHz, 60A, 14kW) 28263448
Fan subassembly with connection cable and connector (for all
other devices) 28241517
INFORMATION
The scope of delivery does not include accessories, such as installation and mount-
ing material or connection cables.
INFORMATION
For available connection cables, refer to the chapter "Electrical connec-
tions"(→233).
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3Device structure
Operating principle
Operating Instructions – MOVITRANS® TES31A Decentralized Supply Unit
20
Compensation box
The following components are available for the track compensation:
Other applicable documentation
MOVITRANS® compensation box
TCS31A
Operating instructions
MOVITRANS® compensation box TCS31A
MOVITRANS® compensation box
TCS10B
Operating instructions
MOVITRANS® installation material TCS, TVS,
TLS, TIS
INFORMATION
On simple tracks, one TCS31A compensation box is adequate. On longer tracks, you
may also use one or several TCS10B compensation boxes. You can find information
about determining the number of compensation boxes in the MOVITRANS® configur-
ation manual.
For further information on compensation, refer to the chapter "Compensa-
tion"(→2100).
3.7 Operating principle
The block diagram below shows the basic structure of the device:
Line filter Network
rectifier
Output stage
DC/AC
Gyrator/
transformer
Controller
X1201 X5102 X4101 X4108 X5121 X5122 X5161 X2337
IA
L
I
20628791435
X1201 AC400V input
X4101 CAN system bus – output (System bus 1)
X4108 CAN system bus – input (System bus 1)
X5102 Digital inputs/outputs of power section
X5121 Synchronization signal MOVITRANS®–output
X5122 Synchronization signal MOVITRANS®–input
X5161 Input for dual-channel disconnection of the power section (output stage inhibit) without safety
function
X2337 Load connection of the line cables 1 and 2
25975072/EN – 05/2019