SEW-Eurodrive MOVITRANS TPM12B User manual

*23613653_0118*
Drive Technology \ Drive Automation \ System Integration \ Services
Operating Instructions
Contactless Energy Transfer System
MOVITRANS® TPM12B Mobile Converter, System Frequency
A – 25 kHz
Edition 01/2018 23613653/EN

SEW-EURODRIVE—Driving the world

Contents
Operating Instructions – MOVITRANS® TPM12B Mobile Converter, System Frequency A – 25 kHz 3
Contents
1 General information.................................................................................................................. 5
1.1 About this documentation ...............................................................................................5
1.2 Structure of the safety notes ...........................................................................................5
1.2.1 Meaning of signal words ................................................................................ 5
1.2.2 Structure of section-related safety notes........................................................ 5
1.2.3 Structure of embedded safety notes .............................................................. 6
1.3 Rights to claim under limited warranty ............................................................................6
1.4 Product names and trademarks......................................................................................6
1.5 Copyright notice ..............................................................................................................6
2 Safety notes .............................................................................................................................. 7
2.1 Preliminary information ...................................................................................................7
2.2 User duties......................................................................................................................7
2.3 Target group ...................................................................................................................8
2.4 Designated use ...............................................................................................................8
2.5 Functional safety technology ..........................................................................................9
2.6 Transport.........................................................................................................................9
2.7 Installation/assembly.......................................................................................................9
2.8 Electrical connection .....................................................................................................10
2.8.1 Mobile application ........................................................................................ 10
2.9 Protective separation ....................................................................................................10
2.10 Startup/operation ..........................................................................................................11
3 Device structure ..................................................................................................................... 12
3.1 Device designation........................................................................................................12
3.2 Scope of delivery ..........................................................................................................12
3.3 Short designation ..........................................................................................................12
3.4 Nameplate.....................................................................................................................13
3.5 Device overview............................................................................................................14
4 Mechanical installation .......................................................................................................... 16
4.1 Mounting positions ........................................................................................................16
4.2 Minimum clearance and bore dimensions ....................................................................17
5 Electrical installation.............................................................................................................. 18
5.1 Installation notes ...........................................................................................................18
5.2 Shielding .......................................................................................................................18
5.3 Protective measures against electrical hazards............................................................19
5.3.1 Overview ...................................................................................................... 19
5.3.2 Contactless energy transfer system............................................................. 19
5.4 Connections..................................................................................................................24
5.4.1 TPM12B030 mobile converter...................................................................... 24
5.4.2 TPM12B036 mobile converter...................................................................... 25
5.4.3 Connector assignment X11.......................................................................... 27
5.5 Connection via hybrid cable..........................................................................................27
5.5.1 Prefabricated hybrid cable ........................................................................... 27
5.5.2 Cable cross section...................................................................................... 28
23613653/EN – 01/2018

Contents
Operating Instructions – MOVITRANS® TPM12B Mobile Converter, System Frequency A – 25 kHz
4
5.5.3 Assignment .................................................................................................. 28
6 Startup ..................................................................................................................................... 29
6.1 For your safety ..............................................................................................................29
6.2 Requirements................................................................................................................29
6.3 Startup procedure .........................................................................................................30
7 Operation................................................................................................................................. 31
7.1 Operating state .............................................................................................................31
7.2 Operating displays ........................................................................................................31
7.3 Fault information ...........................................................................................................31
7.3.1 Device protection ......................................................................................... 31
7.3.2 Reset............................................................................................................ 31
8 Service..................................................................................................................................... 32
8.1 Electronics Service by SEW‑EURODRIVE...................................................................32
8.2 Waste disposal..............................................................................................................32
9 Technical data......................................................................................................................... 33
9.1 Basic device..................................................................................................................33
9.2 Device data for 100% coupling with the THM pick-up ..................................................35
9.3 Dimension drawing .......................................................................................................36
10 Address list ............................................................................................................................. 37
Index ........................................................................................................................................ 48
23613653/EN – 01/2018

1
General information
About this documentation
Operating Instructions – MOVITRANS® TPM12B Mobile Converter, System Frequency A – 25 kHz 5
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 written for
all employees who assemble, install, start up, and service this product.
Make sure this documentation is accessible and legible. Ensure that persons respons-
ible for the machinery and its 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 require further in-
formation, contact SEW‑EURODRIVE.
1.2 Structure of the safety notes
1.2.1 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 envir-
onment
INFORMATION Useful information or tip: Simplifies
handling of the product.
1.2.2 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.
Meaning of the hazard symbols
The hazard symbols in the safety notes have the following meaning:
Hazard symbol Meaning
General hazard
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1General information
Rights to claim under limited warranty
Operating Instructions – MOVITRANS® TPM12B Mobile Converter, System Frequency A – 25 kHz
6
Hazard symbol Meaning
Warning of dangerous electrical voltage
Warning of hot surfaces
Warning of risk of crushing
Warning of suspended load
Warning of automatic restart
1.2.3 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 disreg-
arded. Measure(s) to prevent the hazard.
1.3 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.
1.4 Product names and trademarks
The brands and product names in this documentation are trademarks or registered
trademarks of their respective titleholders.
1.5 Copyright notice
©2018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.
23613653/EN – 01/2018

2
Safety notes
Preliminary information
Operating Instructions – MOVITRANS® TPM12B Mobile Converter, System Frequency A – 25 kHz 7
2 Safety notes
2.1 Preliminary information
The following general safety notes have the purpose to avoid injury 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 User duties
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 le-
gislation governing technical work equipment and accident prevention regulations.
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2Safety notes
Target group
Operating Instructions – MOVITRANS® TPM12B Mobile Converter, System Frequency A – 25 kHz
8
2.3 Target group
Specialist for
mechanical 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,
mechanical 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 com-
pany to operate, program, parameterize, label, and ground units, 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.
2.4 Designated use
The product is intended for installation in electrical plants or machines.
The product is intended for mobile use in industrial and commercial systems with con-
tactless 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 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.
Only operate the pick-up with direct connection with the designated und suitable con-
sumers, and in combination with the relevant cooling components designated for the
system or machine.
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2
Safety notes
Functional safety technology
Operating Instructions – MOVITRANS® TPM12B Mobile Converter, System Frequency A – 25 kHz 9
2.5 Functional safety technology
The product must not perform any safety functions without a higher-level safety sys-
tem, unless explicitly allowed by the documentation.
2.6 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.
• Before transportation, cover the connections with the supplied protection caps.
• Only place the product on the cooling fins or on the side without connectors during
transportation.
• Always use lifting eyes if available.
If necessary, use suitable, sufficiently dimensioned handling equipment.
Observe the information on climatic conditions in chapter "Technical data" of the docu-
mentation.
2.7 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 16) in the documenta-
tion.
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2Safety notes
Electrical connection
Operating Instructions – MOVITRANS® TPM12B Mobile Converter, System Frequency A – 25 kHz
10
2.8 Electrical connection
Make yourself familiar with the applicable national accident prevention guidelines be-
fore you work on the product.
Perform electrical installation according to the pertinent regulations (e.g. cable cross
sections, fusing, protective conductor connection). The documentation at hand con-
tains additional information.
Make sure that all required covers are installed correctly after electrical installation.
Make sure that preventive measures and protection devices comply with the applic-
able regulations (e.g. EN60204-1 or EN61800-5-1).
2.8.1 Mobile application
Necessary protective measures for the product are:
Type of energy transfer Preventive measure
Direct power supply • Ground connection
MOVITRANS® contactless energy trans-
fer system
• Protective separation
DINVDE0100-410/IEC60364-4-41
• ESD protection
2.9 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.
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2
Safety notes
Startup/operation
Operating Instructions – MOVITRANS® TPM12B Mobile Converter, System Frequency A – 25 kHz 11
2.10 Startup/operation
Observe the safety notes in the chapters "Startup" (→ 2 29) and "Opera-
tion"(→231) in the 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.
An electric arc may occur when plug-in connections are disconnected or connected
while voltage is applied (e.g. connection between drive and control). Observe the fol-
lowing to avoid risk of injury, risk of electric shock and damage to property:
• Ensure that the product is de-energized before disconnecting and connecting the
plug-in connections.
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.
Mechanical blocking or internal safety functions of the product can cause the power to
interrupt. Removing the cause of the problem or performing a reset can result in an
automatic restart of the plant. If, for safety reasons, this is not permitted for the drive-
controlled machine, 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.
23613653/EN – 01/2018

3Device structure
Device designation
Operating Instructions – MOVITRANS® TPM12B Mobile Converter, System Frequency A – 25 kHz
12
3 Device structure
3.1 Device designation
TPM12B MOVITRANS® mobile converter
... Nominal power
030 3kW
036 3.6kW
-
EN Increased degree of protection with heat sink
.Design of the pick-up
E THM10E015
C THM10C008
-
5Output voltage: DC500V
AIntegrated line filters
2DC voltage output
-
2Version
3.2 Scope of delivery
The scope of delivery includes the following components:
Device
MOVITRANS®TPM12B030-ENE-5A2-2 mobile converter
or
MOVITRANS®TPM12B036-ENC-5A2-2 mobile converter
Component Part number
Protective covers for all plug connectors –
3.3 Short designation
The following short designations are used:
Device Short designation
MOVITRANS®TPM12B030-ENE-5A2-2 mobile converter Device
MOVITRANS®TPM12B036-ENC-5A2-2 mobile converter
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3
Device structure
Nameplate
Operating Instructions – MOVITRANS® TPM12B Mobile Converter, System Frequency A – 25 kHz 13
3.4 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
=
=
=
= =
MOVITRANS
-- 73 -- -- -- --
[1]
[2]
[3]
22739379723
[1] Product name
[2] Approval identification
[3] Status line
Depending on the device design the following information are 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
23613653/EN – 01/2018

3Device structure
Device overview
Operating Instructions – MOVITRANS® TPM12B Mobile Converter, System Frequency A – 25 kHz
14
3.5 Device overview
The following illustration shows the device structure of the TPM12B030 mobile con-
verter:
[4]
[1]
[2]
[5]
[3]
21428479115
[1] Connections for THM pick-up
[2] Heat sink
[3] 4 operation LEDs to display the operating state
[4] X11, 2-pole voltage output (DC500V), control inputs and outputs
[5] Equipotential bonding
23613653/EN – 01/2018

3
Device structure
Device overview
Operating Instructions – MOVITRANS® TPM12B Mobile Converter, System Frequency A – 25 kHz 15
The following illustration shows the device structure of the TPM12B036 mobile con-
verter:
[1]
[4]
[2]
[5]
[3]
1518996107
[1] Connections for THM pick-up
[2] Heat sink
[3] 4 operation LEDs to display the operating state
[4] X11, 2-pole voltage output (DC500V), control inputs and outputs
[5] Equipotential bonding
23613653/EN – 01/2018

4Mechanical installation
Mounting positions
Operating Instructions – MOVITRANS® TPM12B Mobile Converter, System Frequency A – 25 kHz
16
4 Mechanical installation
4.1 Mounting positions
[1][2][3] [4]
(
()
)(
()
)
1572769035
[1] Recommended mounting position
[2] Non-permitted mounting positions
[3] The mounting position is only permitted if the cooling fins can be ventilated
from underneath.
[4] The mounting position is only permitted if the heated air can be dissipated up-
wards.
The disadvantage of this mounting position is that you cannot read the opera-
tion LEDs.
23613653/EN – 01/2018

4
Mechanical installation
Minimum clearance and bore dimensions
Operating Instructions – MOVITRANS® TPM12B Mobile Converter, System Frequency A – 25 kHz 17
4.2 Minimum clearance and bore dimensions
Observe the following installation instructions and illustrations when installing the
device:
• For optimum cooling results, install device so that natural convection is in direction
of cooling fins.
• Ensure unhindered flow of cool air to the device and removal of hot air from the
device via cooling fins. Observe a minimum clearance [1] of 100 mm above and
below the cooling fins.
• The clearance on the side must provide enough room to plug in and remove the
connectors.
Observe the following dimensions in mm:
Ø 8.5
308
278
8.5
[1]
100
[1]
> 120 Ã100
100
9007200826450571
[1] Clearance
23613653/EN – 01/2018

5Electrical installation
Installation notes
Operating Instructions – MOVITRANS® TPM12B Mobile Converter, System Frequency A – 25 kHz
18
5 Electrical installation
5.1 Installation notes
NOTICE
Faulty installation.
Irreparable damage to the device, the pick-ups and the connected load
• Only connect the THM10C or THM10E pick-ups approved by
SEW‑EURODRIVE.
• Only connect loads approved by SEW‑EURODRIVE. For this purpose, use the
prefabricated hybrid cable from SEW‑EURODRIVE.
• Ensure correct polarity when connecting the load.
Observe the following points for electrical installation:
• The general safety notes.
• Comply with all instructions referring to the technical data and the permissible con-
ditions where the device is operated.
• Avoid using long cables running parallel to one another.
Device input/
device output
• Incorrect connection of the THM pick-ups reduces the power output of the device
due to incorrect compensation.
• If a low-resistance short circuit occurs when an output voltage is present, this res-
ults in very high discharge currents that could cause irreparable damage to the
device. If the device is connected to an existing short circuit, the current is limited
to a value of <15A.
Digital input/digital
output
• The digital inputs are electrically isolated by optocouplers.
• The digital outputs are short-circuit-proof but not external-voltage-proof. Do not ap-
ply external voltages to the digital outputs.
5.2 Shielding
Observe the following installation instructions:
• Use shielded control cables.
• Connect the shield of the hybrid cable by the shortest possible route and make
sure it is grounded over a wide area.
23613653/EN – 01/2018

5
Electrical installation
Protective measures against electrical hazards
Operating Instructions – MOVITRANS® TPM12B Mobile Converter, System Frequency A – 25 kHz 19
5.3 Protective measures against electrical hazards
5.3.1 Overview
The following figure shows an overview of preventive measures against electrical haz-
ards:
Stationary use
Protective measures in accordance with IEC 60364-4-41
Mobile use
Contactless energy transfer system
Ground connection Protective
separation ESD protection
Contactless energy transfer system
9007216786656779
5.3.2 Contactless energy transfer system
The following preventive measures protect mobile systems with contactless energy
transfer against electrical hazards:
• Protective separation
• ESD protection
Protective separation
Comply with "preventive separation" in line with VDE0100 part410 nominal voltage
<500V by using the following measures:
• All electrical equipment on the mobile part, such as on a vehicle, must be equipo-
tentially bonded to each other.
• Establish high-frequency equipotential bonding via the vehicle support frame
(vehicle GND).
• All cables must have double basic insulation. This requirement is always met when
using MOVITRANS® components.
23613653/EN – 01/2018

5Electrical installation
Protective measures against electrical hazards
Operating Instructions – MOVITRANS® TPM12B Mobile Converter, System Frequency A – 25 kHz
20
Equipotential bonding on the mobile part
Equipotential bonding on mobile systems ensures that in case of a fault, no contact
voltages occur.
You can implement equipotential bonding as follows:
• Establish high-frequency equipotential bonding via the vehicle support frame
(vehicle GND).
• Provide metal-to-metal contact over a large surface area.
• Use high-frequency equipotential bonding cables with a minimum cross section of
10mm2.
• Use only gray or black cables for equipotential bonding.
The following figure shows a sample mobile system with contactless energy transfer
system:
[1]
[2]
[3]
[4]
[6]
[5]
[7]
[9]
[10]
[11]
[8]
9007199752652939
[1] Conductive floor coverings or work
areas
[7] Mobile converter
[2] Line cable [8] Equipotential bonding
[3] Conductive track rollers or wheels [9] Vehicle GND
[4] Vehicle frame [10] Pick-up
[5] Drive and application controller [11] Ground
[6] Motor
Observe the following installation instructions:
• Confirm the insulating strength of the equipment and the effectiveness of the equi-
potential bonding within the context of cyclical system checks.
• A possible potential transfer to mobile components via third-party equipment must
be ruled out during planning and operation.
23613653/EN – 01/2018