SEW-Eurodrive MOVITRANS Administrator guide

Drive Technology \ Drive Automation \ System Integration \ Services
Compact Operating Instructions
Mobile Energy Supply
MOVITRANS
®
Stationary Components
Edition 10/2010 16732014 / EN

SEW-EURODRIVE—Driving the world

Compact Operating Instructions – MOVITRANS® Stationary Components 3
Contents
Contents
1 General Information ............................................................................................ 4
1.1 Scope of this documentation....................................................................... 4
1.2 Validity of this documentation ..................................................................... 4
2 Safety Notes ........................................................................................................ 5
2.1 Preliminary information ............................................................................... 5
2.2 General information .................................................................................... 5
2.3 Target group ............................................................................................... 5
2.4 Designated use ........................................................................................... 6
2.5 Transport..................................................................................................... 7
2.6 Storage ....................................................................................................... 7
2.7 Installation................................................................................................... 7
2.8 Functional safety technology ...................................................................... 7
2.9 Electrical connection ................................................................................... 8
2.10 Safe disconnection...................................................................................... 8
2.11 Startup/operation ........................................................................................ 9
2.12 Inspection/maintenance ............................................................................ 10
2.13 Disposal .................................................................................................... 10
3 Mechanical Installation..................................................................................... 11
3.1 TPS stationary converter and TAS transformer module ........................... 11
3.2 Installation Material TCS, TVS, TLS, TIS (Transmission Line) ................. 13
4 Electrical Installation ........................................................................................ 14
4.1 TPS stationary converter and TAS transformer module ........................... 14

4Compact Operating Instructions – MOVITRANS® Stationary Components
1Scope of this documentation
General Information
1 General Information
1.1 Scope of this documentation
This documentation comprises the general safety notes and a selected information re-
garding the device.
• Please note that this documentation does not replace the detailed operating instruc-
tions.
• Read the detailed operating instructions before you start working with the device.
• Observe the information, instructions and notes in the detailed operating instructions.
This is essential for fault-free operation of the unit and fulfillment of any rights to claim
under guarantee.
• The enclosed CD or DVD contains PDF files of the additional operating instructions
as well as further documentation regarding the device.
• All SEW-EURODRIVE’s technical documentation is available for download in PDF
format from the SEW-EURODRIVE website: www.sew-eurodrive.de
1.2 Validity of this documentation
This documentation applies to the following stationary MOVITRANS®units:
• TPS stationary converter
• TAS transformer module
• Installation Material TCS, TVS, TLS, TIS

Compact Operating Instructions – MOVITRANS® Stationary Components 5
2
Preliminary 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.

6Compact Operating Instructions – MOVITRANS® Stationary Components
2Designated 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.
•TPS stationary converter and TAS transformer modules
TPS stationary converters and TAS transformer modules are designed to be installed
in control cabinets. Only connect MOVITRANS®devices that are designed and suit-
able for connection to TPS stationary converters and the TAS transformer modules,
such as TLS line cables, TVS connection distributors and TCS compensation boxes.
•TLS line cable
The TLS lines cables are laid along the transmission line. The TLS line cables are
suitable for the connection to the TAS transformer module on the output side.
•TCS compensation boxes
In longer transmission lines, the TCS compensation boxes are connected in series
to the TLS line cables.
•TVS connection distributor
The TVS connection distributors are used as connection points for the TLS line cable
in the field.
•TIS installation material
The installation components TIS...025... may only be used with flat pick-ups THM..E.
The installation components TIS...008... may only be used with U-shaped pick-ups
THM..C.
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 98/37/EC (with reference to
EN 60204).
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.

Compact Operating Instructions – MOVITRANS® Stationary Components 7
2
Transport
Safety Notes
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.
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.
• In case of long-term storage, connect the TPS stationary converter to the power sup-
ply for at least 5 minutes every 2 years.
• 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.
The following applications are prohibited unless the unit is explicitly designed for such
use:
• 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 EN61800-5-1.
2.8 Functional safety technology
MOVITRANS®units may not execute any safety functions without master safety
systems.

8Compact Operating Instructions – MOVITRANS® Stationary Components
2Electrical connection
Safety Notes
2.9 Electrical connection
Observe the following notes for the electrical connection of MOVITRANS®units:
• Do not connect or disconnect any cables, plug connectors or conductor rails 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.
• Preventive measures and protection devices must correspond to the regulations in
force (e.g. EN 60204-1 or EN 50178).
• 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 TPS stationary converter meets all requirements for safe disconnection of power
and electronics connections in accordance with EN 50178. All connected circuits must
also maintain the requirements for safe disconnection.
Required preventive measures: – Ground the units
Required protection device: – Over-current protection devices for the sup-
ply system lead

Compact Operating Instructions – MOVITRANS® Stationary Components 9
2
Startup/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 appropriate measures (for example, connect binary input DI00 "/CONTROL-
LER INHIBIT" to DGND on the TPS stationary converter) to ensure that the system
does not start up unintentionally when power 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 TPS stationary converter supply is disabled and
the system is at a standstill.
• The fact that the operation LED V1 and other display elements are no longer illumi-
nated on the TPS stationary converter does not indicate that the device and con-
nected MOVITRANS®units have been disconnected from the power supply and do
not carry 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.
• Before removing the protective cover, disconnect the units from the supply system.
Dangerous voltages may still be present in the units and the connected
MOVITRANS®devices for up to 10 minutes after disconnection.
• With the protective cover removed, the MOVITRANS®units have enclosure IP00.
Dangerous voltages are present at all components. All units must be closed during
operation.
• Please wear appropriate protective clothing during assembly, especially when sol-
dering the TLS line cables.
• Take appropriate security measures to prevent burns by the soldering iron or by hot
solder. Take appropriate measures to prevent hot solder from leaking.

10 Compact Operating Instructions – MOVITRANS® Stationary Components
2Inspection/maintenance
Safety Notes
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

Compact Operating Instructions – MOVITRANS® Stationary Components 11
3
TPS stationary converter and TAS transformer module
Mechanical Installation
3 Mechanical Installation
3.1 TPS stationary converter and TAS transformer module
3.1.1 Tightening torques
Only use genuine connection elements.
Observe the following tightening torques:
• TPS stationary converter, size 2
– all power terminals →1.5 Nm (13.3 lb.in)
• TPS stationary converter, size 4
– all power terminals →14 Nm (124 lb.in)
• TAS transformer module, size 2:
– Terminals X2/X3 →1.5 Nm (13.3 lb.in)
– Terminals LA/LI →8 Nm (69.33 lb.in)
• TAS transformer module, size 4:
– all power terminals →14 Nm (124 lb.in)
3.1.2 Mounting position
The TPS stationary converter and the TAS transformer module must only be installed in
upright position. You must not install them horizontally, tilted or upside down!
3.1.3 Installation
The TPS stationary converter and the TAS transformer module can be installed stacked
or next to each other. SEW-EURODRIVE recommends a stacked installation.
Stacked installa-
tion
Observe the following notes regarding the stacked installation of the TPS stationary con-
verter and the TAS transformer module:
• Install the TPS stationary converter and the TAS transformer module vertically on top
of one another.
• Use twisted cables as described in section "Wiring diagram – power terminals" to
connect the size 2 TAS transformer module to the size 2 TPS stationary converter.
Use standardized connection conductor rails as described in section "Wiring diagram
– power terminals" to connect the size 4 TAS transformer module to the size 4 TPS
stationary converter.

12 Compact Operating Instructions – MOVITRANS® Stationary Components
3TPS stationary converter and TAS transformer module
Mechanical Installation
• Ensure the distance between the units for installation according to the following illus-
tration:
Installation next to
each other
Refer to the following publication for information regarding the installation next to each
other:
•"MOVITRANS
®TAS10A Transformer Module" operating instructions
3.1.4 Compensation
Refer to the following publication for information regarding the compensation capacitors:
•"MOVITRANS
®TAS10A Transformer Module" operating instructions
147038347
Size A [mm] B [mm] C [mm]
Size 2 105 300+1 348+2
(4.13 in) (11.8 + 0.04 in) (13.7 + 0.08 in)
Size 4 140 502+1 548+2
(5.51 in) (19.8 + 0.04 in) (21.6 + 0.08 in)
A
B
C
B
TPS
TAS

Compact Operating Instructions – MOVITRANS® Stationary Components 13
3
Installation Material TCS, TVS, TLS, TIS (Transmission Line)
Mechanical Installation
3.2 Installation Material TCS, TVS, TLS, TIS (Transmission Line)
Depending on the respective plant topology, refer to the following publications for infor-
mation regarding the structure of the transmission line:
•MOVITRANS
®Installation Material TVS / TCS / TLS / TIS" operating instructions
•"MOVITRANS
®Project Planning" manual
•"MOVITRANS
®Installation
of Transmission Lines with Casting Resin for THM10E Pick-Ups" manual
•"MOVITRANS
®Installation
of Transmission Lines with TIS Installation Plate for THM10E Pick-Ups" manual

14 Compact Operating Instructions – MOVITRANS® Stationary Components
4TPS stationary converter and TAS transformer module
Electrical Installation
4 Electrical Installation
4.1 TPS stationary converter and TAS transformer module
4.1.1 Cable cross sections
Note the following cable cross sections:
• TPS stationary converter:
– Supply system lead →cable cross section according to rated input current Imains
at rated load.
– Electronics cables:
• TPS stationary converter and TAS transformer module:
– Cable cross section between X2/X3 (TPS) and X2/X3 (TAS):
4.1.2 PE supply system connection (EN 50178)
Observe the following notes regarding the PE supply system connection:
• For a supply lead < 10mm2(AWG8), 2 variants of a PE mains connection are per-
mitted:
– Route a second PE conductor with the same cross section as the supply lead in
parallel to the protective earth via separate terminals, or
– route a Cu protective earth with a cross section of 10mm2(AWG8).
• If the supply system lead is ≥10 mm2(AWG8), use a Cu protective earth conductor
with the cross section of the supply system lead.
4.1.3 Line cable connection
Observe the following information regarding the line cable connection:
• Connect approved TLS line cables only. TLS line cables must be connected properly.
• Use a powerful soldering iron (at least 200 W) or a soldering bath to attach the cable
lugs to the high-frequency litz wire. Pressing on is not permitted.
• Also observe the additional information and wiring diagrams in section "Wiring dia-
gram – power terminals".
One core per terminal →0.20...2.5 mm² (AWG24...12)
2 cores per terminal →0.20...1 mm² (AWG24...17)
Size 2 (TPS10A040 and TAS10A040) →4 mm² (AWG11)
Size 4 (TPS10A160 and TAS10A160) →Connection conductor rail or
→16 mm² (AWG5)

Compact Operating Instructions – MOVITRANS® Stationary Components 15
4
TPS stationary converter and TAS transformer module
Electrical Installation
4.1.4 Line cable routing
Note the following on line cable routing:
• Route the line cables close together (cable ties, cable duct, etc.). Avoid close prox-
imity to sheet metal or other magnetic metals (heating through eddy currents). Pos-
sible installation options include
– Plastic duct or pipe on spacers
– Spacing layer of aluminum sheet metal
• If the cables are routed through walls (control cabinet, etc.), you should try to have a
common screw fitting for supply and return cable. Install a duct board made of alu-
minum or plastic if this is not possible. Install the line cables, power and signal lines
separately.
4.1.5 Shielding and grounding
Observe the following note on shielding and grounding:
• SEW EURODRIVE recommends that you shield the control cables.
• Connect the shield by the shortest possible route and make sure it is grounded over
a wide area. To avoid ground loops, you can ground one end of the shield via a sup-
pression capacitor (220 nF / 50 V). If using double-shielded cables, earth the outer
shield on the unit end and the inner shield on the other end.
• You can also route the cables (not the line cable!) in the control cabinet in grounded
sheet metal ducts or metal tubes for shielding purposes. Install the power and signal
lines separately.
• Ground the MOVITRANS®unit and all additional devices to meet the high-frequency
guidelines. To do so, provide a wide area metal-on-metal contact between the unit
housing and ground (e.g. unpainted control cabinet mounting panel).

16 Compact Operating Instructions – MOVITRANS® Stationary Components
4TPS stationary converter and TAS transformer module
Electrical Installation
4.1.6 Wiring diagram – power terminal
Size 2 Connect the power section of the size 2 TPS stationary converter and the size 2 TAS
transformer module according to the following figure:
146871179
[1] Twisted cables [A] Connection variant A: for starting up
[2] Short-circuit hoop the TPS stationary converter without
[3] TLS line cable connected TLS line cable
[B] Connection variant B: for startup
and operation with connected
TLS line cable
[2]
[1]
[1]
[3]
L1
L2
L3
PE
L1 L2 L3
L1' L2' L3'
F11/F12/F13
K11
NF...
(AC-3)
L1 L2 L3 -UZ+UZPE
X2 X3
X1
X4
G1 G2 N.C. -I +I PE
TPS
45 69
123 78
X2 X3
G1 G2 N.C. -I +I PE
IGIL
45 69
TAS
LA LI
TASTAS
[B]
LA LI
[A]

Compact Operating Instructions – MOVITRANS® Stationary Components 17
4
TPS stationary converter and TAS transformer module
Electrical Installation
Size 4 Connect the power section of the size 4 TPS stationary converter and the size 4 TAS
transformer module according to the following figure:
[3] [4] [4] [4]
[3]
[2]
[5]
[1]
[5] [5]
L1
L2
L3
PE
L1 L2 L3
L1' L2' L3'
F11/F12/F13
K11
NF...
(AC-3)
L1 L2 L3 -UZ+UZPE
X2 X3
X1
X4
G1 G2N.C. -I +I PE
TPS
45 69
123 78
X2 X3
G1 G2N.C.
N.C.
N.C.-I +I PE
IGIL
45 69
TAS
N.C. N.C.LI1LA1 LA2 PELI2
TASTAS TAS
[B]
N.C. N.C.LI1LA1 LA2 PELI2
[C]
N.C. N.C.LI1LA1 LA2 PELI2
[A]
1331776523
[1] Shielded cables [A] Connection variant A: for startup
[2] Connection conductor rail the TPS stationary converter without
[3] Short-circuit hoop connected TLS line cable
[4] optional PE connection to [B] Connection variant B: for startup
ensure the high-frequency-compliant and operation with a conductor loop
grounding [C] Connection variant C: for startup
[5] TLS line cable and operation with 2 conductor loops

18 Compact Operating Instructions – MOVITRANS® Stationary Components
4TPS stationary converter and TAS transformer module
Electrical Installation
4.1.7 Wiring diagram – control terminals
Sizes 2 and 4 Connect the control unit of the size 2 and 4 TPS stationary converter according to the
following figure:
-10 V
+10 V
+
-
IL1
X10:
S 12
S 11
R11
I
X10:AI11/AI12
Shield terminal
ON OFF
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
REF1
AI11
REF2
AI12
SC11
SC12
SS11
SS12
AGND
DI00
DI01
DI02
DI03
DI04
DI05
DCOM
VO24
DGND
DO02
DO00
DGND
VI24
U
TPS stationary converter
Reference potential analog signals
Voltage/current control
Setpoint mode A
Setpoint mode B
Reference X10:DI00...DI05
+24 V output
+24 V input
System bus terminating resistor
I signal / U signal switchover
Default setting: U signal
Reference potential binary signals
Reference potential binary signals
/Malfunction
Ready for operation
/Output stage inhibit
/Ext. error
Auto reset
AGND (reference potential 10 V analog signals)
DGND (reference potential 24 V binary signals)
Protective earth (shield)
-10…+10 V -40…+40 mA
Binary inputs
Binary outputs
Reference
Binary outputs
Higher-level
controller
DGND
Systembus High
Systembus Low
Sync signal Low
Sync signal High
++--
146888587

Compact Operating Instructions – MOVITRANS® Stationary Components 19
4
TPS stationary converter and TAS transformer module
Electrical Installation
4.1.8 Functional description of the power and control terminals
TPS stationary
converter
The following table shows the functional description of the power and control terminals
of the size 2 and 4 TPS stationary converter:
Terminal Function
X1: 1/2/3
X2: 4/5
X3: 6/9
X4: +UZ/-UZ
L1 / L2 / L3
G1 / G2
-I/+I
+VZ/-VZ
Power supply
Gyrator connection
Current feedback
DC link connection
X10: 1
X10: 2/4
X10: 3
X10: 5/7
X10: 6
X10: 8
REF1
AI11/AI12
REF2
SC11/SC12
-
AGND
Reference voltage +10 V (max. 3 mA) for setpoint potentiometer
Setpoint input IL1 (differential input), switching between current/voltage input with
S11
Reference voltage -10 V (max. 3 mA) for setpoint potentiometer
System bus (SBus) high/low
No function
Reference potential for analog signals (REF1, REF2, AI11, AI12)
X10: 9
X10: 10
X10: 11
X10: 12
X10: 13
X10: 14
X10: 15
X10: 16
X10: 17
DI00
DI01
DI02
DI03
DI04
DI05
DCOM
VO24
DGND
Binary input 1, with fixed assignment /Output stage
inhibit
Binary input 2, with fixed assignment /Ext. Error
Binary input 3, with fixed assignment "Auto-reset"
Binary input 4, with fixed assignment "Voltage/current
control"
Binary input 5, with fixed assignment "Setpoint mode
A"
Binary input 6, with fixed assignment "Setpoint mode
B"
Reference for binary inputs DI00...DI05
Auxiliary voltage output +24 V (max. 200 mA)
Reference potential for binary signals
The binary inputs are elec-
trically isolated by optocou-
plers. DCOM must be
connected to DGND if the
binary inputs are controlled
with +24 V by VO24!
X10: 18 - No function
X10: 19
X10: 21
X10: 23
DO02
DO00
DGND
Binary output 2, malfunction configurable
Binary output 0, ready configurable
Reference potential for binary signals
Load capacity: Max. 50 mA
X10: 20/22 SS11/SS12 Synchronization signal high/low
X10: 24 VI24 Input +24 V power supply (only required for diagnostic purposes)
S11
S12
I ↔U
On ↔Off
AI11/AI12 toggle I signal (-40 ... +40 mA) ↔V signal (-10 ... +10 V), factory setting V
signal
System bus terminating resistor

20 Compact Operating Instructions – MOVITRANS® Stationary Components
4TPS stationary converter and TAS transformer module
Electrical Installation
TAS transformer
module
The following table shows the functional description of the power terminals of the size 2
TAS transformer module:
The following table shows the functional description of the power terminals of the size 4
TAS transformer module:
Terminal Function
X2: 4/5
X3: 6/9
G1 / G2
-I/+I
Gyrator connection ( →from TPS X2: G1/G2)
Current feedback ( →from TPS X3: -I/+I)
LA
LI
Line cable outer connection
Line cable inner connection
Terminal Function
X2: 4/5
X3: 6/9
G1 / G2
-I/+I
Gyrator connection ( →from TPS X2: G1/G2)
Current feedback ( →from TPS X3: -I/+I)
LA1
LI1
LA2
LI2
1. line cable outer connection
1. line cable inner connection
2. line cable outer connection
2. line cable inner connection