SEW-Eurodrive MOVITRANS THM20C User manual

Drive Technology \ Drive Automation \ System Integration \ Services
Operating Instructions
Mobile Energy Supply
MOVITRANS
®
THM20C / THM20E Pick-Ups
Edition 01/2012 19328826 / EN

SEW-EURODRIVE—Driving the world

Operating Instructions – MOVITRANS® THM20C / THM20E Pick-Ups 3
Contents
Contents
1 General Information ............................................................................................ 4
1.1 Use of this documentation .......................................................................... 4
1.2 Structure of the safety notes ....................................................................... 4
1.3 Rights to claim under limited warranty ........................................................ 5
1.4 Exclusion of liability..................................................................................... 5
1.5 Copyright..................................................................................................... 5
2 Safety Notes ....................................................................................................... 6
2.1 Preliminary information ............................................................................... 6
2.2 General information .................................................................................... 6
2.3 Target group ............................................................................................... 6
2.4 Designated use ........................................................................................... 7
2.5 Transport..................................................................................................... 7
2.6 Storage ....................................................................................................... 8
2.7 Installation................................................................................................... 8
2.8 Functional safety technology ...................................................................... 8
2.9 Electrical connection ................................................................................... 9
2.10 Safe disconnection...................................................................................... 9
2.11 Startup/operation ...................................................................................... 10
2.12 Inspection/maintenance ............................................................................ 10
2.13 Disposal .................................................................................................... 10
3 Unit Design ........................................................................................................ 11
3.1 THM20C unit design ................................................................................. 11
3.2 THM20E unit design ................................................................................. 13
4 Mechanical Installation..................................................................................... 15
4.1 Mechanical installation of THM20C .......................................................... 15
4.2 Mechanical installation of THM20E........................................................... 18
5 Electrical Installation ........................................................................................ 20
5.1 Electrical installation of THM20C .............................................................. 20
5.2 Electrical installation of THM20E .............................................................. 23
6 Technical Data................................................................................................... 28
6.1 Technical data of THM20C ....................................................................... 28
6.2 Technical data of THM20E ....................................................................... 32
7 Address List ...................................................................................................... 47
Index................................................................................................................... 58

4Operating Instructions – MOVITRANS® THM20C / THM20E Pick-Ups
1Use of this documentation
General Information
1 General Information
1.1 Use of this documentation
The documentation is an integral part of the product and contains important information
on operation and service. The documentation is written for all employees who assemble,
install, startup, and service this product.
The documentation must be accessible and legible. Make sure that persons responsible
for the system and its operation, as well as persons who work independently on the unit,
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 Structure of the safety notes
1.2.1 Meaning of the signal words
The following table shows the grading and meaning of the signal words for safety notes,
notes on potential risks of damage to property, and other notes.
1.2.2 Structure of the section-related safety notes
Section-related safety notes do not apply to a specific action, but to several actions per-
taining to one subject. The used symbols indicate either a general or a specific hazard.
This is the formal structure of a section-related safety note:
1.2.3 Structure of the embedded safety notes
Embedded safety notes are directly integrated in the instructions just before the descrip-
tion of the dangerous action.
This is the formal structure of an embedded safety note:
•SIGNAL WORD Nature and source of hazard.
Possible consequence(s) if disregarded.
– Measure(s) to prevent the danger.
Signal word Meaning Consequences if disregarded
DANGER Imminent danger 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 drive system or its envi-
ronment
INFORMATION Useful information or tip: Simpli-
fies the handling of the drive
system.
SIGNAL WORD
Type and source of danger.
Possible consequence(s) if disregarded.
• Measure(s) to prevent the danger.

Operating Instructions – MOVITRANS® THM20C / THM20E Pick-Ups 5
1
Rights to claim under limited warranty
General Information
1.3 Rights to claim under limited warranty
A requirement of fault-free operation and fulfillment of any rights to claim under limited
warranty is that you adhere to the information in the documentation. Read the documen-
tation before you start working with the unit!
1.4 Exclusion of liability
You must comply with the information contained in this documentation to ensure safe
operation and to achieve the specified product characteristics and performance
features. SEW-EURODRIVE assumes no liability for injury to persons or damage to
equipment or property resulting from non-observance of these operating instructions. In
such cases, any liability for defects is excluded.
1.5 Copyright
© 2012 – SEW-EURODRIVE. All rights reserved.
Unauthorized duplication, modification, distribution or any other use of the whole or any
part of this documentation is strictly prohibited.

6Operating Instructions – MOVITRANS® THM20C / THM20E Pick-Ups
2Preliminary information
Safety Notes
2 Safety Notes
2.1 Preliminary information
The following basic safety notes must be read carefully to prevent injury to persons and
damage to property. The operator must ensure that the basic safety notes are read and
observed.
Make sure that persons responsible for the plant and its operation, as well as persons
who work independently on the units, have read through the documentation carefully
and understood it. Consult SEW-EURODRIVE if you have any questions or if you re-
quire further information.
The following safety notes are primarily concerned with the use of MOVITRANS®units.
If you use other SEW components, also refer to the safety notes for the respective com-
ponents in the corresponding documentation.
Please also observe the supplementary safety notes in the individual sections of this
documentation.
2.2 General information
Removing covers without authorization, improper use as well as incorrect installation or
operation may result in severe injuries to persons or damage to property.
2.3 Target group
Any mechanical work may only be performed by adequately qualified personnel. Quali-
fied personnel in this context are persons who are familiar with the setup, mechanical
installation, troubleshooting and maintenance for the units. Further, they are qualified as
follows:
• Training in mechanical engineering, e.g. as a mechanic or mechatronics technician
(final examinations must have been passed).
• Knowledge of this documentation
Any electronic work may only be performed by adequately qualified electricians. Quali-
fied electricians in this context are persons who are familiar with the electronic installa-
tion, startup, troubleshooting and maintenance for the units. Further, they are qualified
as follows:
• Training in electrical engineering, e.g. as an electrician or mechatronics technician
(final examinations must have been passed).
• Knowledge of this documentation
All work in further areas of transportation, storage, operation and waste disposal may be
carried out only by persons who are trained appropriately.

Operating Instructions – MOVITRANS® THM20C / THM20E Pick-Ups 7
2
Designated use
Safety Notes
2.4 Designated use
Note the designated use of the following MOVITRANS®units:
•MOVITRANS®units in general
MOVITRANS®units are intended for use in industrial and commercial installations
for the operation of contactless power transmission systems.
•THM pick-ups
In the energy transfer system MOVITRANS®, the THM20C and THM20E pick-ups on
the mobile component tap the power without contact from the stationary line cable
through magnetic coupling. The THM pick-ups may only be operated with the follow-
ing designated and suitable units:
–MOVIPRO
®drive controller
THM20C and THM20E pick-ups must not be connected to the MOVITRANS®
TPM12B mobile converter.
Observe all information on the technical data and the permitted conditions where the
units are operated.
Do not start up the unit (operate in the designated fashion) until you have established
that the machine complies with the EMC Directive 2004/108/EC and that the end prod-
uct categorically conforms to Machinery Directive 2006/42/EC. Observe standard
EN 60204-1.
The rules and regulations of the German employers' liability insurance association
["Berufsgenossenschaft" - BG], in particular BG rules B11 concerning electromagnetic
fields, must be observed during installation, startup and operation of systems with con-
tactless energy transfer by induction for use in industrial workplaces.
2.5 Transport
Observe the following instructions when you receive a shipment:
• Inspect the shipment for any damage that may have occurred in transit as soon as
you receive the delivery.
• Inform the shipping company immediately about any damage.
• Do not startup any units if they were damaged in transit.
Observe the following notes for the transportation of MOVITRANS®units:
• Make sure that the units are not subject to mechanical impact during transport.
• Use suitable, sufficiently rated handling equipment.
• Observe the notes on the climatic conditions in the "Technical Data" chapter.
• Remove transport fixtures prior to startup.

8Operating Instructions – MOVITRANS® THM20C / THM20E Pick-Ups
2Storage
Safety Notes
2.6 Storage
Observe the following instructions when shutting down or storing MOVITRANS®units:
• Make sure that the units are not subject to mechanical impact during storage.
• Observe the notes on storage temperature in the "Technical Data" chapter.
2.7 Installation
Observe the following notes for installing the MOVITRANS®units:
• Protect the MOVITRANS®units from excessive strain.
• Ensure that components are not deformed and/or insulation spaces are maintained,
particularly during transportation and handling.
• Electric components must not be mechanically damaged or destroyed.
• Protect the MOVITRANS®units from direct sunlight.
The following applications are prohibited unless explicitly permitted:
• Use in potentially explosive atmospheres.
• Use in areas exposed to harmful oils, acids, gases, vapors, dust, radiation, etc.
• Use in applications that are subject to mechanical vibration and shock loads in ex-
cess of the requirements in EN 61800-5-1.
2.8 Functional safety technology
MOVITRANS®units may not execute any safety functions without master safety
systems.

Operating Instructions – MOVITRANS® THM20C / THM20E Pick-Ups 9
2
Electrical connection
Safety Notes
2.9 Electrical connection
Observe the following notes for the electrical connection of MOVITRANS®units:
• Do not connect or disconnect plug connectors while they are energized.
• Observe applicable national accident prevention guidelines when working on live
parts of MOVITRANS®units.
• Perform electrical installation according to the pertinent regulations (e.g. cable cross-
sections, fusing, protective conductor connection). For any additional information,
refer to the applicable documentation.
• Protective measures and protection devices must comply with the regulations in
force (e.g. EN 60204-1 or EN 61800-5-1).
• Take suitable steps to ensure that the preventive measures and protection devices
described in the operating instructions for the individual MOVITRANS®units have
been implemented correctly.
2.10 Safe disconnection
The MOVIPRO®drive and application controller meets all requirements for reliable iso-
lation of power and electronics connections in accordance with EN 61800-5-1. All con-
nected circuits must also meet the requirements for reliable isolation.
Required preventive measures: – Protective separation according to
VDE 0100
– Equipotential bonding
– ESD protection

10 Operating Instructions – MOVITRANS® THM20C / THM20E Pick-Ups
2Startup/operation
Safety Notes
2.11 Startup/operation
Observe the following notes for starting up and operating the MOVITRANS®units:
• Only qualified electricians with the relevant accident prevention training are allowed
to perform installation, startup and service work on the unit. They must also comply
with the regulations in force (e.g. EN 60204, VBG 4, DIN-VDE 0100/0113/0160).
• Never install damaged units and put them into operation.
• Do not deactivate monitoring and protection devices even for a test run.
• Take suitable measures to ensure that the system does not start up unintentionally
when the power supply is switched on.
• During operation, the MOVITRANS®units can have live, bare and movable or rotat-
ing parts as well as hot surfaces, depending on their enclosure.
• When the unit is switched on, dangerous voltages are present at the output terminals
and at any connected cables, terminals and MOVITRANS®units. Dangerous volt-
ages can be present even when the MOVIPRO®drive and control unit is disabled
and the system is at a standstill.
• The fact that the status LED and other display elements are no longer illuminated
does not indicate that the unit has been disconnected from the power supply and no
longer carries any voltage.
• Safety functions within the unit may cause system standstill. Removing the cause of
the problem or performing a reset can result in an automatic restart of the plant. If
safety reasons prohibit this action, disconnect the TPS10A stationary converter from
the power supply before correcting the fault.
• Dangerous voltages can still be present at the unit inputs and outputs for up to
10 minutes after disconnecting the power supply.
• Do not remove the housing covers.
2.12 Inspection/maintenance
Only SEW-EURODRIVE is authorized to carry out repairs.
Never open the unit.
2.13 Disposal
Observe the latest national regulations in effect!
Dispose of materials separately in accordance with the regulations in force, for example:
• Electronics scrap
• Plastics
• Sheet metal
• Copper
•Aluminum

Operating Instructions – MOVITRANS® THM20C / THM20E Pick-Ups 11
3
THM20C unit design
Unit Design
3 Unit Design
3.1 THM20C unit design
3.1.1 Type designation
The type designation of the MOVITRANS®THM20C pick-up comprises the following
characteristic unit data:
3.1.2 Short designation
This documentation uses the following short designations:
3.1.3 Scope of delivery
The scope of delivery includes the following components:
T H M 20 C 008 - 490 - 008 - 1
Variant:
1 = Standard
Compensation capacity:
008 = 8 nF
Inductance: 490 = 4.9 mH
Nominal power: 008 = 0.8 kW
Type of pick-up: C = U shape
Series and generation
Type of installation: M = mobile
Component: H = pick-up
Type: T = MOVITRANS®
Unit Short designation
MOVITRANS®THM20C008-490-008-1 pick-up THM20C pick-up
Unit
1 THM20C pick-up
MOVITRANS®THM20C008-490-008-1 pick-up with PBT housing (polybutylene terephthalate)
With permanently installed connection cable including Han®Q 4/2 connector with angled cable
outlet (maximum length 6 m (20 ft), depending on order)
With permanently installed connection cable including Han®Q 4/2 connector with straight
cable outlet (maximum length 6 m (20 ft), depending on order)

12 Operating Instructions – MOVITRANS® THM20C / THM20E Pick-Ups
3THM20C unit design
Unit Design
3.1.4 Nameplate
The THM20C pick-up has a nameplate that provides important information. The follow-
ing figure shows the nameplate:
3.1.5 Basic unit
The following figure shows the unit design of the THM20C pick-up:
2799663115
Type Type designation f Frequency
U Voltage P Output power
I Current T Ambient temperature
D-76646 Bruchsal
Übertragerkopf
MOVITRANS
Made in Germany
Typ:
Ser.Nr.: 0053185Sach.Nr.:
Eingang / Input
THM20C008-490-008-1
13000748
Ausgang / Output
--- P
I
f
T
U
=
=
=
U
I
f
=
=
=
60 A AC
25 kHz
0 ... 45 °C
350 V AC
2,3 A AC
25 kHz
800 W
==
ͺͿ͵ʹ΀Ϳ΅Ͷ΂ͺͿ͵ʹ΀Ϳ΅Ͷ΂͵
Betriebsart S1
1530912139
[1] U-shaped THM20C pick-up
[2] Permanently installed connection cable including Han®Q 4/2 connector with angled cable outlet;
max. length 6 m (max. 20 ft), depending on order
[3] 4 threaded holes M6 for fastening of THM10C pick-up
[1]
[2]
[3]

Operating Instructions – MOVITRANS® THM20C / THM20E Pick-Ups 13
3
THM20E unit design
Unit Design
3.2 THM20E unit design
3.2.1 Type designation
The type designation of the MOVITRANS®THM20E pick-up comprises the following
characteristic unit data:
3.2.2 Short designation
This documentation uses the following short designations:
3.2.3 Scope of delivery
The scope of delivery includes the following components:
T H M 20 E 020 - 579 - 007 - 1
Variant:
1 = Standard
Compensation capacity:
007 = 7 nF
Inductance: 579 = 5.79 mH
Nominal power: 020 = 2.0 kW
Type of pick-up: E = flat
Series and generation
Type of installation: M = mobile
Component: H = pick-up
Type: T = MOVITRANS®
Unit Short designation
MOVITRANS®THM20E020-579-007-1 pick-up THM20E pick-up
Unit
1 THM20E pick-up
MOVITRANS®THM20E020-579-007-1 pick-up
With permanently installed connection cable with flat plug (max. length 6 m (20 ft), depending on
order)
With permanently installed connection cable including Han®Q 4/2 connector with angled cable
outlet (max. length 6 m (20 ft), depending on order)
With permanently installed connection cable including Han®Q 4/2 connector with straight
cable outlet (max. length 6 m (20 ft), depending on order)

14 Operating Instructions – MOVITRANS® THM20C / THM20E Pick-Ups
3THM20E unit design
Unit Design
3.2.4 Nameplate
The THM20E pick-up has a nameplate that provides important information. The follow-
ing figure shows an example of a nameplate:
3.2.5 Basic unit
The following figure shows the unit design of the THM20E pick-up:
2799665931
Type Type designation f Frequency
U Voltage P Output power
I Current T Ambient temperature
D-76646 Bruchsal
Übertragerkopf
MOVITRANS
Made in Germany
Typ:
Ser.Nr.: 0053184Sach.Nr.:
Eingang / Input
THM20E020-579-007-1
13000551
Ausgang / Output
--- P
I
f
T
U
=
=
=
U
I
f
=
=
=
60 ... 85 A AC
25 kHz
0 ... 40 °C
350 V AC
6 A AC
25 kHz
2 kW
==
ͺͿ͵ʹ΀Ϳ΅Ͷ΂ͺͿ͵ʹ΀Ϳ΅Ͷ΂͵
Betriebsart S1
2803032203
[1] Permanently installed connection cable including Han®Q 4/2 connector with angled cable outlet;
max. length 6 m (max. 20 ft), depending on order
[2] Flat THM20E pick-up
[3] Four threaded holes M6 for mounting the THM20E pick-up
[3]
[2]
[1]

Operating Instructions – MOVITRANS® THM20C / THM20E Pick-Ups 15
4
Mechanical installation of THM20C
Mechanical Installation
4 Mechanical Installation
4.1 Mechanical installation of THM20C
4.1.1 Mounting position
Make sure that the cable outputs of the THM20C pick-ups connected to the MOVIPRO®
drive and control unit are always aligned in the same way with the TLS line cable. When
choosing the mounting position, ensure that the cable outputs of the THM20C pick-ups
do not point in opposite directions (up and down). They must all either be at the top or
at the bottom. The following illustration shows correct and incorrect mounting positions:
1362544267

16 Operating Instructions – MOVITRANS® THM20C / THM20E Pick-Ups
4Mechanical installation of THM20C
Mechanical Installation
4.1.2 Installation
Observe the following installation instructions when mounting the THM20C pick-up:
• Install the THM20C pick-up centered and parallel to the installed TLS line cable.
• Avoid lateral and angular misalignment when mounting the THM20C pick-up.
• Mount the THM20C pick-up free from stress. The THM20C pick-up must not be sub-
jected to bending forces.
• SEW-EURODRIVE recommends to use holding plates made of aluminum. Only at-
tach the holding plates on the back of the THM20C pick-up. Do not attach the holding
plates on the sides.
• Make sure that there is no ferromagnetic or electrically conductive material within a
radius of 5 cm (2 in) around the TLS line cable.
INFORMATION
The tightening torque for the M6 retaining screws is 3.5 Nm (31 in-lb).
2701695243
b Distance between TLS line cable and [3] THM20C pick-up
ferromagnetic or [4] TLS line cable
electrically conductive material [5] Space free from ferromagnetic or
= 5 cm (2 in) electrically conductive material
[1] Holding plate [6] TIS profile section system
[2] M6 retaining screw with lock washer for
securing the screw
[7] Aluminum profile rail
[3]
b
b
[6] [7][5]
b
b
[4]
THM20C
[2][1]

Operating Instructions – MOVITRANS® THM20C / THM20E Pick-Ups 17
4
Mechanical installation of THM20C
Mechanical Installation
• The space between the THM20C pick-up and the TLS line cable must always be free
of metallic materials.
• Observe the following bore dimensions in mm (in):
• Best coupling is achieved when the distance x between the TLS line cable and the
THM20C pick-up is 19 mm (0.75 in). If you change the distance x, the output power
decreases.
The following figure shows a THM20C pick-up installed in an aluminum structure:
2701692427
116 ±0.5
(4.57 ±0.02)
130 ±0.6 (5.12 ±0.02)
THM20C
INFORMATION
For detailed information about the output power in relation to the distance x, refer to
chapter "Technical data of THM20C".
2701748747
x Distance between TLS line cable and
THM20C pick-up
[4] TLS10E008-01-1 line cable (supply con-
ductor)
= 19 mm (0.75 in) [5] TLS10E008-01-1 line cable (return con-
ductor)
[1] Holding plate [6] TIS profile section system
[2] M6 retaining screw with lock washer for
securing the screw
[7] Aluminum profile rail
(not included in scope of delivery)
[3] THM20C pick-up
[2][1] [3] [7][6][5][4]
==
X
THM20C

18 Operating Instructions – MOVITRANS® THM20C / THM20E Pick-Ups
4Mechanical installation of THM20E
Mechanical Installation
4.2 Mechanical installation of THM20E
4.2.1 Installation
Observe the following installation instructions when mounting the THM20E pick-up:
• Install the THM20E pick-up centered and parallel to the installed TLS line cable.
• Only mount the holding rails above the THM20E pick-up. Do not attach the holding
rails on the sides.
• Make sure that there is no ferromagnetic or electrically conductive material within a
radius of 8 to 10 cm (3 to 3.9 in) around the TLS line cable.
• The space between the THM20E pick-up and the TLS line cables must always be
free of metallic materials.
• Observe the following bore dimensions in mm (in):
• It is essential that you avoid lateral and angular misalignment of the THM20E, as this
greatly decreases the transmittable power.
2701794827
b Distance between TLS line cable [1] THM20E pick-up
and ferromagnetic or [2] TLS line cable
electrically conductive material [3] Space free from ferromagnetic and
= 8 to 10 cm (3 to 3.9 in) electrically conductive material
2701792523
THM20E
[1]
[2]
[3]
b
b
b
b
b
b
M
6
(4×
)
285 (11.2)
460 (18.1 )
THM20E
INFORMATION
The tightening torque for the M6 retaining screws is 3.5 Nm (31 in-lb).

Operating Instructions – MOVITRANS® THM20C / THM20E Pick-Ups 19
4
Mechanical installation of THM20E
Mechanical Installation
• The distance x between the TLS line cable and the THM20E influences the transmit-
table power and may not exceed 20 mm (0.79 in).
The following figure shows an installed THM20E pick-up:
INFORMATION
For detailed information on the output power, refer to chapter "Technical data of
THM20E".
2701790219
x Distance between TLS line cable and [1] THM20E pick-up
THM20E pick-up [2] TLS line cable
= max. 20 mm (max. 0.79 in) [3] E.g. concrete floor
d Distance between the TLS line cables [4] Direction of movement
= 125 mm (4.92 in)
d
=
==
=
x
[1]
[2]
[3]
THM20E
THM20E
[1]
[2]
[3]
[4]

20 Operating Instructions – MOVITRANS® THM20C / THM20E Pick-Ups
5Electrical installation of THM20C
Electrical Installation
5 Electrical Installation
5.1 Electrical installation of THM20C
5.1.1 Wiring diagram
The following table provides information about this connection:
WARNING
Faulty installation.
Severe or fatal injuries.
• It is essential to comply with the safety notes in chapter 2 during installation.
Function
Connection of the MOVITRANS®THM20C pick-up
Connection type
Han®Q 4/2, male
Wiring diagram
2444131083
Assignment
No. Name Function
1 THM pole 1 MOVITRANS®pick-up pole 1
2 n.c. Not connected
3 THM pole 2 MOVITRANS®pick-up pole 2
4 n.c. Not connected
11 n.c. Not connected
12 n.c. Not connected
PE PE PE connection
1
11
12 2
3
4PE