Manual. Contactless Energy Transfer MOVITRANS Project Planning. Edition 06/ / EN

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1 Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services Contactless Energy Transfer MOVITRANS Project Planning Edition 06/ / EN Manual

2 SEW-EURODRIVE Driving the world

3 Content Content 1 Important Notes Safety and warning instructions Rights to claim under limited warranty Exclusion of liability Safety Notes Target group Designated use Operational environment Installation and startup Operation and service Waste disposal System Description What is MOVITRANS? System benefits Areas of application Theory of operation Regulations, certifications and standards Application examples Project Planning General information Documentation MOVITRANS implementation and project planning - yes or no? Drive and project planning information Project planning procedure Project planning for the vehicles Project planning for the track Project planning for the power supply System power and system-related power reduction Project Planning Example for Flat THM10E Pick-Ups General information Technical data Project planning for the vehicles Project planning for the track Project planning for the power supply System power and system-related power reduction Component selection Alternative project planning example with reduced acceleration Project Planning Example for U-shaped THM10C Pick-Ups General information Technical data Project planning for the vehicles Project planning for the track Project planning for the power supply Manual MOVITRANS Project Planning 3

4 Content 6.6 System power and system-related power reduction Component selection Preventive Measures against Electrical Hazards Overview General information Unit connection points for grounding or equipotential bonding Stationary components Mobile components Installation Notes Connecting the MOVITRANS TPM12B mobile converter Connection via hybrid cable Connecting MOVIMOT Connecting MOVIFIT Connecting MOVIDRIVE MDX60B/61B Connecting MOVITRAC 07A Connecting brakes / brake rectifiers Connecting the MOVITRANS TPM12B mobile converter in parallel External DC 24 V supply Project Planning Information Overview and functions of the MOVITRANS components with part numbers V Dimension sheets for the MOVITRANS components System-related power reduction of the MOVITRANS components Selection tables for MOVITRANS TCS compensation boxes Service Maintenance Electronics Service Questionnaire - Project Planning for MOVITRANS Administrative information Project planning for the mobile energy supply - vehicle Project planning for the stationary energy supply - power supply and track Address List Index Manual MOVITRANS Project Planning

5 Important Notes Safety and warning instructions 1 1 Important Notes 1.1 Safety and warning instructions Always observe the safety and warning information in this documentation. Electrical hazard Possible consequences: Severe or fatal injuries. Hazard Possible consequences: Severe or fatal injuries. Hazardous situation Possible consequences: Slight or minor injuries. Harmful situation Possible consequences: Damage to the unit and the environment. Tips and useful information. 1.2 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 operating instructions. Consequently, read the operating instructions before you start working with MOVITRANS units! Make sure that the operating instructions are available to persons responsible for the plant and its operation, as well as to person who work independently on the units. You must also ensure that the documentation is legible. 1.3 Exclusion of liability You must comply with the information contained in these operating instructions to ensure safe operation of the MOVITRANS units and to achieve the specified product characteristics and performance requirements. SEW-EURODRIVE assumes no liability for injury to persons or damage to equipment or property resulting from non-observance of the operating instructions. In such cases, any liability for defects is excluded. Manual MOVITRANS Project Planning 5

6 2 Safety Notes Target group 2 Safety Notes 2.1 Target group This documentation has been drawn up to support the work of the sales teams byanswering general questions on the technology and project planning phase of MOVITRANS systems. 2.2 Designated use MOVITRANS components are intended for use in industrial and commercial installations for the operation of contactless power transmission systems. Only connect stipulated and suitable components. For detailed information on the units and their fields of applications, refer to the specific operating instructions for the MOVITRANS components. Do not start up the MOVITRANS components (take them into operation in the designated fashion) until you have established that the machinery complies with the EMC Directive 89/336/EEC and that the conformity of the end products has been determined in accordance with the Machinery Directive 89/392/EEC (with reference to EN 60204). Observe all information on the technical data and the permitted conditions where the unit is operated. The Professional Association (Berufsgenossenschaft, BG) BG regulation B11 "Electromagnetic fields" must be observed during installation, startup and operation of systems with contactless energy transmission by induction for use in industrial workplaces. Always comply with the safety instructions in the operating instructions for all the MOVITRANS components installed in your system. 2.3 Operational environment The following uses are prohibited unless the units are expressly designed for the purpose: Use in potentially explosive areas. Use in areas exposed to harmful oils, acids, gases, vapors, dust, radiation, etc. Use in non-stationary applications that are subject to mechanical vibration and shock loads in excess of the requirement in EN Manual MOVITRANS Project Planning

7 Safety Notes Installation and startup Installation and startup Never install damaged products or take them into operation. Submit a complaint to the shipping company immediately in the event of damage. Only specialists with the appropriate accident prevention training are allowed to perform installation, startup and service work on the unit. These specialists must also comply with the regulations in force (e.g. EN 60204, VBG 4, DIN-VDE 0100/0113/ 0160) when performing this work. Follow the specific instructions during installation and startup of the other components! Preventive measures and protection devices must correspond to the regulations in force (e.g. EN or EN 50178). Required preventive measures: Ground the unit Take suitable steps to ensure that the preventive measures and protection devices described in the operating instructions for the individual MOVITRANS components have been implemented correctly. Take appropriate measures (for example, connect binary input DI00 "/CONTROLLER INHIBIT" to DGND on the TPS10A stationary converter) to ensure that the system does not start up unintentionally when power is switched on. Please wear appropriate protective clothing during assembly, especially when soldering 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. 2.5 Operation and service Disconnect the TPS10A stationary converter and the TAS10A transformer module from the supply system before removing the protective cover. Dangerous voltages may still be present for up to 10 minutes after disconnection from the power supply source. With the protective cover removed, the MOVITRANS units have enclosure IP00. This also applies to the TCS compensation box and the TVS connection distributor. Dangerous voltages are present at all components. All units must be closed during operation. When the unit switch is in the ON position, dangerous voltages are present at the output terminals as well as any connected cables and terminals. This is also the case when the TPS10A stationary converter is inhibited. The fact that the V1 operation LED and other display elements are no longer illuminated on the TPS10A stationary converter does not indicate that the TPS10A stationary converter and the TAS10A transformer module 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 the system re-starting on its own. If this action is not permissible due to reasons of safety, disconnect the TPS10A stationary converter and the TAS10A transformer module from the power supply before correcting the fault. Manual MOVITRANS Project Planning 7

8 2 Safety Notes Waste disposal 2.6 Waste disposal Please follow the current national regulations. Dispose of materials separately in accordance with the regulations in force, for example: Electronics scrap (circuit boards) Plastic (housing) Sheet metal Copper Aluminum 8 Manual MOVITRANS Project Planning

9 System Description What is MOVITRANS? 3 3 System Description 3.1 What is MOVITRANS? MOVITRANS is a system consisting of stationary and mobile components that contactlessly supplies energy to mobile electrical consumers. The required energy is transferred inductively (without contact) from an insulated stationary conductor to the mobile consumers (vehicles) via an air gap. 3.2 System benefits Major advantages of the MOVITRANS contactless technology compared to the traditional method of energy transfer: Wear-free energy transfer Components are not subject to wear and do not require maintenance Isolated cables Cables are not impaired by contamination, moisture or temperature. High mechanical tolerances More flexible design with curves and points. High speeds due to contactless energy supply. Simple track segmentation 3.3 Areas of application Requirements Contactless supply systems are preferably used instead of the traditional methods of energy transfer when the mobile equipment has to cover long distances, when a variable, extendable track layout is required when energy has to be transmitted at high speeds when the energy transfer has to be maintenance-free when the operation takes place in wet and humid areas when additional environmental contaminants are not permitted in sensitive areas Manual MOVITRANS Project Planning 9

10 3 System Description Areas of application Areas of application today The MOVITRANS system is preferably used in materials handling technology in following sectors: Automotive industry Transportation and storage logistics Sorting technology Typical applications The MOVITRANS system is preferably used in following applications: Conveyor trolleys Push-skid conveyor systems Guided floor conveyor systems Automated guided vehicle systems Storage and retrieval units Overhead trolley systems Pallet transportation systems Baggage handling systems Panel gantries Elevator technology (construction elevators, electrical supply for elevators) Rides in amusement parks Battery charging stations 10 Manual MOVITRANS Project Planning

11 System Description Theory of operation Theory of operation Energy transfer Electrical energy is transferred without contact from a fixed conductor to one or more mobile consumers. The principle of inductive energy transfer is used in the process. The electromagnetic connection is made via an air gap and is not subject to wear, making it maintenance-free System overview The MOVITRANS system is divided into stationary and mobile components: [A] [B] L1 L2 L3 Einspeisestelle Gyrator + I = const. Trafo TPS U AC TAS THM TPS TAS TPM DC-500-V U DC DC-24-V [1] [2] [3] [4] [5] [6] [A] [B] Stationary components Mobile components [1] MOVITRANS TPS stationary converter [2] MOVITRANS TAS transformer module [3] MOVITRANS TCS, TIS, TLS, TVS installation equipment (transmission line) [4] MOVITRANS THM pick-up [5] MOVITRANS TPM mobile converter [6] Mobile consumer Stationary Components [A] MOVITRANS TPS stationary converter [1] The TPS converter, which is based on the MOVIDRIVE series, converts the incoming low frequency alternating voltage (50/60 Hz) from the three-phase system into an alternating voltage with a constant frequency of 25 khz. MOVITRANS TAS transformer module [2] The TAS transformer module converts the output voltage from the TPS stationary converter into a constant sinusoidal alternating current. The output current is isolated from the AC power supply via a matching transformer. An adjustment of the transmission line takes place via compensation components. Manual MOVITRANS Project Planning 11

12 3 System Description Theory of operation MOVITRANS TLS, TIS, TCS, TVS installation equipment [3] (transmission line) The TLS supply cable is used in 60-A systems between transformer module and transmission line as well as for the interconnection of several transmission lines. The line TLS conductor conducts the impressed alternating current from the TAS transformer module. It forms a conductor loop with supply and return cable. The line cable is supported by the TIS profile system when U-shaped pick-ups are used for energy transfer. When flat THM pick-ups are used, the line cables are cast in the floor, installed on the floor with TIS installation plates, or installed in the floor with the TIS rubber profile (in preparation). The TCS compensation box is used for compensating the inductive reactance of the TLS line cable. Each TCS compensation box compensates a particular track section. The TVS connection distributor can be used to connect individual track parts and to connect the TLS supply cable to the track Mobile Components [B] MOVITRANS THM pick-up [4] The THM pick-ups transfer the energy contactlessly from the line cable to the TPM mobile converter. Different mechanical designs and electrical performance ratings are available for the different transmission concepts. The TPM mobile converters must match the THM pick-ups. The power that can be transmitted per THM pick-up depends on the size of the TLS line cable current and the electromagnetic connection between the TLS line cable and the THM pick-up. MOVITRANS TPM mobile converter [5] The TPM mobile converter converts the current impressed from the pick-up into DC voltage. The system is optimized for use of inverters from SEW-EURODRIVE such as MOVIDRIVE, MOVITRAC 07 and MOVIMOT. 12 Manual MOVITRANS Project Planning

13 System Description Regulations, certifications and standards Regulations, certifications and standards CE marking MOVITRANS components comply with the regulations of the low voltage directive 2006/95/EC. The CE mark on the nameplate indicates conformity with the Low Voltage Directive 2006/95/EC and the EMC Directive 89/ 336/EEC. We can provide a declaration of conformity on request UL approval UL and cul approval has been granted for all MOVITRANS components. cul is equivalent to CSA approval. C U L U L Electromagnetic compatibility (EMC) Introduction The MOVITRANS system allows for contactless energy transfer to mobile consumers. With respect to electromagnetic compatibility, SEW-EURODRIVE applies the EMC product standard EN for the MOVITRANS system. This standard specifies the requirements for interference immunity and interference emission for electrical drive technology units. A large number of tests ensures that the MOVITRANS components meet these requirements. During installation, make sure that the regulations and recommendations for EMC-compliant installation described in this documentation are observed in order to ensure smooth operation of the system. This section details the level of electromagnetic compatibility (EMC) for MOVITRANS systems in control cabinet installation. TPS stationary converter and TAS transformer module The MOVITRANS TPS stationary converter and TAS transformer module are power electronics components that operate with switching frequencies that are also common in the switched-mode power supply and inverter technology. The magnetic fields that occur on the TAS transformer module are sufficiently shielded by the control cabinet. Limit value class A in accordance with EN is achieved by using an upstream line filter. Manual MOVITRANS Project Planning 13

14 3 System Description Regulations, certifications and standards Electromagnetic fields (EMF) Introduction SEW-EURODRIVE had measurements taken for systems with MOVITRANS components for contactless energy transmission. The goal of the measurements was to check that the systems comply with the permitted values. Topologies with THM10E flat pick-up and THM10C U-shaped pick-up had been checked. Flat THM10E pickup Standards and guidelines Field of application International an professional association limit values The standards and directives in force are: BGV B11 06/2001 (VBG 25) DIN VDE 0848 part 1 08/2000 ICNIRP 1998 IEEE Std. C95.1, Edition 1999 Systems comprising a TPS stationary converter, a TAS transformer module, transmission lines with TLS line cables, a THM pick-up, a TPM mobile converter and mobile consumers were checked. The following transmission line designs were tested: Line cable Distance between line cables = 140 mm The line cable was operated with 85 A in order to measure and evaluate the permitted limit values (magnetic medium-frequency fields at 25 khz sinusoidal current). The measured values were compared with the values permitted according to BGV B11 (06/01). The comparison showed, that the measured values (200 mm distance to the line cable) were significantly below the permitted values. The permitted values in the ICNIRP standard are complied with a distance of 0.3 m from the line cables. For the US-American market, the measured values were significantly below the permitted distance values of the "IEEE standard C95.1 Edition 1999" in the systems tested. A risk to health is ruled out. Exposure situation The system sections examined can be assigned exposure area 1. Permanent exposure was assumed during the tests. 14 Manual MOVITRANS Project Planning

15 System Description Regulations, certifications and standards 3 Protective measures Comply with the following instructions and take any measures necessary: Special protective measures are not required for persons without medical devices. Persons with medical devices, e.g. pacemakers must keep at least 60 cm away from the line cables. This information must be documented in the operating instructions and suitable signs must be attached to the system as described in BGV A8 (VBG 125). U-shaped THM10C pick-up Standards and guidelines Field of application Professional association limit values The standards and directives in force are: BGV B11 exposure area 1 and 2 Systems comprising a TPS stationary converter, a TAS transformer module, transmission lines with TLS line cables, a THM pick-up, a TPM mobile converter and mobile consumers were checked. The following transmission line designs were tested: TLS10E line cable Line cable routing in TIS profile section system Profile section system mounted on aluminum carrier plate The line cable was operated with 60 A in order to measure and evaluate the permitted limit values (magnetic medium-frequency fields at 25 khz sinusoidal current). The measured values were compared with the values permitted according to BGV B11. The comparison showed, that the measured values (100 mm distance to the line cable) were below the permitted values. A risk to health is ruled out. Exposure situation Protective measures The system sections examined can be assigned exposure area 1. Permanent exposure was assumed during the tests. Comply with the following instructions and take any measures necessary: Special protective measures are not required for persons without medical devices. Persons with medical devices, e.g. pacemakers must keep at least 32 cm away from the line cables. This information must be documented in the operating instructions and suitable signs must be attached to the system as described in BGV A8 (VBG 125). Manual MOVITRANS Project Planning 15

16 3 System Description Application examples 3.6 Application examples Conveyor trolleys Use The following figure shows the pallet transportation and distribution with a conveyor trolley in transportation logistics and the MOVITRANS energy supply for travel and chain drives: Requirements Moving pallets transversely over longer distances Replacing cable carriers with contactless energy transfer Reducing downtimes by eliminating repairs (cable breaks) Extending travel distance without having to use complicated holders for drag-chains Benefits of Permanently high level of availability MOVITRANS Long travel distances Simple installation High mechanical tolerances Easy to extend (e.g. extending / changing the travel distance) Simple to integrate in existing systems Wear-free system (no wear from bending or torsion) High travel speeds Compact dimensions in transfer area 16 Manual MOVITRANS Project Planning

17 System Description Application examples Push-skid conveyor system Use The following figure shows a push-skid conveyor system with elevating table in the automotive industry and the MOVITRANS energy supply for the elevating table: Requirements Wear-free power supply system for the elevating table mounted on the push-skid conveyor High mechanical tolerances (air gap) between the line cable and pick-up ensure that the individual conveyor platforms can be integrated smoothly into the conveyor system Benefits of Wear-free system (slide line does not have to be opened for maintenance work) MOVITRANS Compact unit (all MOVITRANS components can be installed in the intermediate space of the push-skid conveyor platform. This means that the entire surface of the push-skid conveyor is accessible) The compact dimensions of the pick-ups make it possible to convert existing systems with conductor rails Manual MOVITRANS Project Planning 17

18 3 System Description Application examples Floor conveyor system (FCS) / automated guide vehicle system (AGV) Use The following figure shows a floor conveyor system (FCS)/automated guide vehicle system (AGV) in final assembly and the application and installation of the MOVITRANS components in FCS/AGV systems: Requirements Provide energy without a battery (short cycle times) or contact wires/trailing cables (no channels under the vehicle) Flat accessible areas (due to transverse traffic) without grooves for track guidance Flexible track layout (with points if required) Benefits of Wear-free and maintenance-free energy transfer MOVITRANS Line cables are laid in the floor (up to 15 mm effective air gap) allows other transport systems to cross (e.g. forklifts) The individual power supply of the vehicles allows for a separation of rigging station and assembly line The electromagnetic field emitted from the line cables can be used to guide the vehicle along the track Easy to change the track layout by relaying the line cable 18 Manual MOVITRANS Project Planning

19 System Description Application examples Storage and retrieval unit (SRU) Use The following figure shows a storage and retrieval unit (SRU) in a high-bay warehouse in warehouse logistics and the MOVITRANS energy supply for travel and hoist drive up to max. 12 kw (total dynamic power) and the telescopic drive: Requirements Resistant to dirt caused by leakages of the means of transport Permanent access to warehouse system Contactless energy supply of telescopic drive on the load platform (no need for drag chain) Benefits of Wear-free and maintenance-free system MOVITRANS Resistance to dirt High availability Manual MOVITRANS Project Planning 19

20 3 System Description Application examples Overhead trolley system Use The following figure shows the material feed with a Overhead trolley system (OTS) for light loads in the automotive industry and the contactless MOVITRANS energy transfer to mobile OTS vehicles: Requirements Reduce downtimes caused by maintenance or malfunctions such as a short circuit due to contamination or moisture Flexible system due to simple modification or extension Lower operating noise of the OTS 20 Manual MOVITRANS Project Planning

21 System Description Application examples 3 Benefits of Trolleys are integrated smoothly into the conveyor system MOVITRANS High mechanical tolerances due to large airgap High availability (particularly important when used in assembly lines) Flexible system due to modular system Wear-free system No rail sections required. Line cables are laid continuously System is completely insulated Manual MOVITRANS Project Planning 21

22 4 Project Planning General information 4 Project Planning 4.1 General information Project planning for a MOVITRANS system requires specified knowledge specified in this documentation. The following information is based on the general guidelines that apply to project planning. This documentation is drawn up for users that are familiar with and have basic knowledge of drive project planning. 4.2 Documentation Required documentation For technical details and additional information on the MOVITRANS system and the current system components, refer to the following documentation: System Description "MOVITRANS " Operating Instructions "MOVITRANS TPS10A Stationary Converter" Operating Instructions "MOVITRANS TAS10A Transformer Module" Operating Instructions "MOVITRANS THM10C/THM10E Pick-Ups" Operating Instructions "MOVITRANS TPM12B Mobile Converter" Operating Instructions "MOVITRANS TCS / TLS / TVS Installation Equipment" Manual "MOVITRANS Installation Transmission Lines for THM10E Pick-Ups" Manual "MotionStudio Engineering Software Module MOVITRANS Parameter Tree" Additional documentation In addition to the documents listed above and the information in this documentation, SEW-EURODRIVE GmbH & Co. KG provides comprehensive information on the entire topic of electrical drive technology. The lists below include other documents that are of interest for application project planning: Drive configuration Drive Engineering - Practical Implementation "Drive Planning". Drive Engineering - Practical Implementation "Controlled AC Drives" Drive Engineering - Practical Implementation "Servo Drives" Drive Engineering - Practical Implementation "EMC in Drive Engineering" 22 Manual MOVITRANS Project Planning

23 Project Planning Documentation 4 Decentralized drive control System Description "MOVIPRO PHC" (in preparation) Applications System Description "Application System Solution EMS - Electrified Monorail System" Manual "EMS Advanced" (in preparation) Manual "EMS Customized" (in preparation) System Description "Floor Conveyor System" (In preparation) System Description "Conveyor Trolley" (in preparation) System Description "Push-skid/Pallet Conveyor" (in preparation) Electronics Operating Instructions "MOVIDRIVE Compact MCF/MCV/MCS4_A" System Manual "MOVIDRIVE Compact" System Manual "MOVIDRIVE MD_60 A" System Manual "MOVIDRIVE MDX60/61B" Operating Instructions "MOVIDRIVE MDX60/61B" System Manual "MOVITRAC 07" Operating Instructions "MOVITRAC 07" System Description "MOVITRAC 07" System Manual "MOVITRAC B" Operating Instructions "MOVITRAC B Basic Unit" Operating Instructions "MOVIMOT " System Manual "Drive System for Decentralized Installation" (MOVIMOT, MOVISWITCH, Communication and Supply Interfaces) Motors and Brakes Operating Instructions "DR/DT/DV AC Motors" Manual "Brakes and Accessories" Operating Instructions "BST Safety-oriented Brake Module" (In preparation) Ordering documentation A wide selection of our documentation is available in many languages for download on our Internet site at If required, you can also order printed and bound copies of the documentation from SEW-EURODRIVE. Manual MOVITRANS Project Planning 23

24 4 Project Planning MOVITRANS implementation and project planning - yes or no? 4.3 MOVITRANS implementation and project planning - yes or no? Introduction Mobile materials handling technology with contactless energy transmission offers a number of advantages compared to traditional drive and materials handling technologies. The type and complexity of an application are the factors used to decide whether the drive task can be solved using MOVITRANS components. can be configured without the support of the SEW head office in Bruchsal. must be configured with the support of the SEW head office in Bruchsal Prerequisites Before you start project planning, you must check whether the required drive task can be solved with MOVITRANS components and contactless energy and information transmission. Use the following list to determine the basic conditions on-site: Description of the entire system Power demand Functional characteristics Start-ups Special features Ambient conditions Temperature, dampness, dust Enclosure Mechanical load Swarf Communication External: Data light barrier, radio SEW WLAN Line cable routing Distance to magnetic material (min cm) Control cabinet power supply cable Options to install compensation boxes Installation equipment Mechanical tolerances Vertical tolerance pick-up line cable Horizontal tolerance pick-up line cable (clearance at the sides) Torsion angle in curves There is a detailed questionnaire for the project planning of MOVITRANS systems in the appendix. 24 Manual MOVITRANS Project Planning

25 Project Planning Drive and project planning information Drive and project planning information Drive data It is first necessary to determine the basic general conditions and drive data (machine data, mass, speed, setting range, etc.) to configure the drive correctly. This data helps determine the required power, torque and speed. Refer to the publication "Drive Engineering Practical Implementation - Project Planning of Drives" and the "SEW Workbench" project planning software. To be able to perform project planning for MOVITRANS, you must have already performed project planning for the drive Application data The type of application plays an important role in the project planning for a MOVIT- RANS system. Therefore, the relevant application data must be determined in addition to the basic general conditions and drive data. Use the following list to determine the required information: Mobile area Number of drives Demand factor of the drives Power profile P max in the mobile section DC 24 V supply Other consumers Pick-up type Stationary area Track layout: track length, curve radii, switches, segmentation, emergency stop areas (disconnection of parts of the track) Mechanical installation of the line cables Number of mobile stations Demand factor (if necessary, with reference to the track layout) There is a detailed questionnaire for the project planning of MOVITRANS systems in the appendix. Manual MOVITRANS Project Planning 25

26 4 Project Planning Project planning procedure 4.5 Project planning procedure Prerequisites Before you start, you must gather information on all the basic conditions relevant to the design of the new application. To be able to perform project planning for MOVITRANS, you must have already performed project planning for the drive! Procedure Project planning for contactless energy transmission with MOVITRANS components is performed in several steps. The following illustration gives you an overview of the procedure: Mobile energy supply Project planning for the vehicle (drive, mobile components) Project planning for the track Stationary energy supply Dimensioning the supply not OK Control calculation OK List of components Project planning steps Several project planning steps are contained in an entire project planning process: Project planning for vehicles (mobile) Project planning for the track (stationary) and the compensation Project planning for power supply (stationary) 26 Manual MOVITRANS Project Planning

27 Project Planning Project planning for the vehicles Project planning for the vehicles The first step is to determine the drive power and sensors required for the mobile consumers in the planned system Procedure Proceed as follows to perform project planning for the vehicles: 1. First determine the power required to move the vehicle. 2. Next choose a suitable motor. The field weakening range of motors wound for 230/400 V and 50 Hz starts at ~ 45 Hz in star connection ~ 77 Hz in delta connection 3. Determine whether auxiliary drives are required. If so, select the correct motors for the auxiliary drives. 4. Optimize the cycles of motion to minimize the peak power. Observe the efficiency of gears and motors, and the power losses of the frequency inverters, when determining the electrical power. 5. From the peak power, deduce the following values that are required on the vehicle: Power at the DC 500 V level Number of pick-ups Pick-up type Number of TPM12B mobile converters 6. Take the influence of the following components into account for the configuration of the DC 24 V level: Configured control Power determined for the sensors DC 24 V demand of the frequency inverters If necessary, determine a suitable external synchronous encoder system If the power supplied by the TPM12B mobile converter is not sufficient at the DC 24 V level, a DC 500 V DC 24 V power supply can be installed. In this case, the power of the power supply must be taken into account in the configuration of the DC 500 V level. Manual MOVITRANS Project Planning 27

28 4 Project Planning Project planning for the vehicles Structure Version with THM10E pick-up For the remaining project planning process it is helpful to display the technical structure of the vehicles as a diagram. The following illustration is an example of the technical structure of a vehicle with flat THM10E pick-ups: [3] [4] [5] [2] TPM M [6] [1] MM M [7] [1] MOVITRANS THM10E pick-ups [5] Frequency inverter [2] MOVITRANS TPM mobile converter [6] Drive [3] Sensor technology [7] Auxiliary drives, e.g. MOVIMOT (optional) [4] Vehicle control Version with THM10C pick-up The following illustration is an example of the technical structure of a vehicle with U- shaped THM10C pick-ups: [2] [3] MM M [7] [1] TPM M [6] [5] [4] [1] MOVITRANS THM10C pick-ups [5] Drive control [2] MOVITRANS TPM mobile converter [6] Drive [3] Sensors (optional) [7] Auxiliary drives, e.g. MOVIMOT (optional) [4] Communication If optional auxiliary drives and sensors are used, they must be taken into account during project planning. 28 Manual MOVITRANS Project Planning

29 Project Planning Project planning for the track Project planning for the track In a second step, the design and segmentation of the track are determined for the planned drive Overview installation types The following installation types are possible depending on pick-up type: Pick-up type Installation type Description II I Grouting suitable for floors that are sealed, e.g. industrial floor surface I III II III flat THM10E pick-up Installation plate suitable for fast and easy installation on the floor II I Rubber profile (In preparation) suitable for easy installation in the floor II I Universal retaining plate with aluminum plate suitable for aluminum structures or nonmagnetizable mounting surfaces e.g. plastic U-shaped THM10C pickup Universal retaining plate with shielding plate suitable for steel structures Aluminum profile rail suitable for overhead trolley systems Manual MOVITRANS Project Planning 29

30 NF NF 4 Project Planning Project planning for the track Procedure Proceed as follows to perform project planning for the track: 1. Determine the installation type according to pick-up type. The further proceeding for planning a track does not depend on on the pick-up/installation type. 2. Determine the required emergency stop areas. 3. Determine the subsequent track segmentation. 4. Plan the compensation Structure The following figure shows the schematic structure of a track with maintenance and track loop: TPS TAS [1] [2] [3] 3 ~ [4] [5] [6] TPS TAS 3 ~ [1] Emergency stop circuit 1 - segment 1 track [4] Joint loop [2] Emergency stop circuit 1 - segment 2 [5] Switch [3] Emergency stop circuit 2 - maintenance loop [6] Supply cable Since the electromagnetic coupling between TLS line cable and THM pick-up is suboptimal at joints, switches and supply connections, the THM pick-ups cannot provide the rated power at these points. Should the rated power of the THM pick-up be required at these points, an additional THM pick-up has to be installed. 30 Manual MOVITRANS Project Planning

31 Project Planning Project planning for the track Compensation The number of TCS compensation boxes in the supply areas can be determined with the tables in the section "Project Planning Information/Selection tables for TCS compensation boxes" (page 104). In order to determine the position of the TCS compensation boxes on the track, the length of the TLS line cables in a track segment is determined first. ltls tot [m] = 2 l [m] l TLS tot l Total line cable length Length of the transmission lines With the total length of the line cables and the number of TCS compensation boxes, you can determine the line cable length after which a TCS compensation box has to be installed: l TCS l [m] = n TLS tot TCS [m] l TCS l TLS tot n TCS Line cable length after which a TCS compensation box has to be installed Total line cable length Number of TCS compensation boxes If the determined location for the TCS compensation box is in an unfavorable area (e.g. in the way of floor conveyor vehicles like forklifts), the TCS compensation box can be installed ± 2 m before or after the determined location. SEW-EURODRIVE recommends to compile an overview of the arrangement of the TCS compensation boxes in case of a larger project. Please find an according example in the section"project planning example for flat THM10E pick-ups/project planning for the track/project planning of the compensation" (page 47) Manual MOVITRANS Project Planning 31

32 4 Project Planning Project planning for the track Supply cable For 60 A systems, the TLS10E cable type is used as supply cable for the transmission line. For 85 A systems, the TLS line cables are also used as supply cable. In a 60 A system, the power supply is carried out via the supply cable and the TVS connection distributor at any point of the track. For an 85 A supply, the TLS line cable is fed directly to the TAS transformer module. It is important that the maximum power is not required at the point where the power is supplied. The illustration shows the power supply on the track: 60-A system 85-A system [1] [3] [4] [1] [2] [2] TVS [1] Transmission line [3] MOVITRANS TVS connection distributor [2] MOVITRANS TLS line cable [4] MOVITRANS TLS supply cable Cable routing for floor routing Outside the transmission line, the TLS line cables are routed next to or on top of each other without a gap. If the flat THM10E pick-ups are used, the distance between the line cables in the transmission line should be 140 mm. You will find further information on the cable routing for floor routing in the manual "Installation Transmission Lines for THM10E Pick-Ups". 32 Manual MOVITRANS Project Planning

33 Project Planning Project planning for the track Cable routing in profile section system On the track, the TLS line cables are routed in the profile section system. Cable bushing frames and cable bushing grommets can be used at the supply points and compensation boxes, or the TLS line cables are inserted directly into the profile section system. The following figure shows the supply with the cables being inserted via cable bushing frames and cable bushing grommets: [1] [2] [3] [4] [5] [6] [1] MOVITRANS TVS connection distributor [4] MOVITRANS TIS cable bushing frame [2] Aluminum profile rail [5] MOVITRANS TIS profile sections with TLS line cable (supply line) [3] MOVITRANS TIS cable bushing grommets [6] MOVITRANS TIS profile sections with TLS line cable (return line) The following figure shows the supply with the cables being inserted directly into the profile section system: [4] [3] [2] [1] [1] MOVITRANS TVS connection distributor [3] MOVITRANS TIS profile sections with TLS line cable (return line) [2] MOVITRANS TIS holding fixture [4] MOVITRANS TIS profile sections with TLS line cable (supply line) Manual MOVITRANS Project Planning 33

34 4 Project Planning Project planning for the track Wiring in the connection distributor for 60 A systems On delivery, the TVS connection distributors are jumpered as follows: [1] [2] [1] MOVITRANS TVS connection distributor [2] Jumpered connection Wire the TVS connection distributor at the supply point as follows: HL [2] HL [2] [1] RL [3] [2] [1] RL [3] [2] [4] [4] [1] MOVITRANS TLS10E supply cable HL Supply line [2] MOVITRANS TLS10E line cable RL Return line [3] MOVITRANS TVS connection distributor [4] Jumpered connection 34 Manual MOVITRANS Project Planning

35 Project Planning Project planning for the track Determining the components for floor routing The length of the TLS line cable required for floor routing can be determined with the track length and the total of all supply cables (double for supply and return lines) l [m] = ( a [m] + a [m] + l[m] ) TLS tot l TLS tot a 1 a 2 l Total line cable length Distance between the power supply and the track Distance between the compensation boxes and the track Length of the transmission lines Floor routing with TIS installation plates is only suitable for straight tracks. The required number of TIS installation plates can be determined as follows: n TIS..-V.. l Number of TIS installation plates Length of the transmission lines n TIS..... l [m] V = 05. m Only the line cable with 25 mm² cable cross section can be used in conjunction with the TIS installation plates. Observe the manual "MOVITRANS Installation Transmission Lines for THM10E Pick- Ups" when planning the track Determining the components for cable routing in profile section system Two TLS line cables (8 mm² cable cross section) are used parallel as supply and return line in the profile section system. The 6-core supply cable is used as TLS supply cable between power supply and track. ltls tot [m] = 4 l[m] + min. 2m per TVS or TCS l TLS tot l Total line cable length Length of the transmission lines ltls10e006 [m] = a1 [m] l TLS10E006 a 1 Total supply cable length Distance between the power supply and the track Manual MOVITRANS Project Planning 35

36 4 Project Planning Project planning for the track The TIS10A008 installation material is used for the profile section system. The TIS10A008 comprises: the TIS...-P.. rigid profile section the TIS...-F.. flexible profile section the TIS...-H.. holding fixture. Generally, the TIS...-P.. rigid profile sections are used on straight tracks and the TIS...- F.. flexible profile sections are used in curves. On the straight tracks and in the curves, the return line always requires twice as many profile sections than the supply line. The determined numbers of profile sections is rounded up to whole numbers. n TIS... P.., HL n TIS... F.., HL n n = l [m] G 3m l [m] = K 22. m = 2 n = 2 n TIS... P.., RL TIS... P.., HL TIS... F.., RL TIS... F.., HL n TIS...-P.., HL n TIS...-F.., HL n TIS...-P.., RL n TIS...-F.., RL l G l K Number of rigid profile sections for supply line Number of flexible profile sections for supply line Number of rigid profile sections for return line Number of flexible profile sections for return line Total length of all track sections Total length of all curves In order to fix the TIS profile sections on the transmission line, TIS...-H.. holding fixtures are installed in certain intervals. The distance between two TIS...-H holding fixtures on straight track sections should be about 50 cm and about 36 cm in curves. Depending on the structure of the transmission line, TIS..-X.. retaining plates and TIS...- A.. cable bushing frames/grommets are required for the holding fixtures. SEW-EURO- DRIVE recommends to increase the order quantity by 5-10% to take the off-cut during installation into account. Observe the system description "Application System Solution EMS - Electrified Monorail System" for applications with electrified monorail systems. 36 Manual MOVITRANS Project Planning

37 Project Planning Project planning for the power supply Project planning for the power supply The third step is to perform project planning for the power supply. The power supply is achieved with the TPS stationary converter and the TAS transformer module. Before the power supply components can be determined, the transmission line must already be planned and divided into emergency stop circuits and track segments Procedure Proceed as follows to perform project planning for the power supply: 1. Calculate the maximum power demand per track element. Note the following points during calculation: Power of the individual vehicles in the track segment Number and coincidence factor of the vehicles in the track segment Losses due to TLS line cables, reactive power and, if need be, stray field induction 2. The results of this calculation can be used to determine the power supply components. If the S1 total power (incl. reactive power) of one track segment is higher than 16 kw, either the track segment must be divided or the segmentation of the entire transmission line must be revised! Depending on the THM pick-up structure and the power that has to be transferred per vehicle, a line cable current of 60 A or 85 A has been determined. The 60 A or 85 A TAS transformer module must be selected accordingly Emergency stop function In an emergency stop situation, the disconnection can be carried out on the line side (3 x V) via contactors in the supply cable of the stationary converter. Several TPS stationary converters can be connected to and be switched off by the same contactors. Alternatively, depending on emergency stop area, each MOVITRANS power supply can be connected to a contactor and can be switched off separately Structure The following illustration shows the power supply for the same power in different emergency stop circuits and track sections: [2] [1] [3] NF NF TPS TPS NF TPS [4] 3 ~ TAS TAS TAS [5] [6] [1] Mains [4] MOVITRANS TPS stationary converter [2] Power contactors [5] MOVITRANS TAS transformer module [3] Line filter [6] Transfer of emergency stop circuits and track segments 1 to 3 Manual MOVITRANS Project Planning 37

38 4 Project Planning System power and system-related power reduction 4.9 System power and system-related power reduction Determining the mobile power available at the TPM mobile converter plays an important role when performing project planning for MOVITRANS systems. If the available mobile power is reduced by system-related power losses to such an extent that the mobile consumers are no longer supplied with sufficient power, this causes the system to come to a standstill or to breakdown. Successful project planning must not only determine the general conditions and data, but also the exact system-related power losses and the effective mobile power available in the system. Inaccurate project planning at the power limit can cause the mobile unit to start incorrectly System-related power reduction The following section describes the various system-related power losses for the mobile and stationary components and their influence on the effective mobile power available. When selecting the drive technology, you must be aware that the output power of the TPM mobile converter is to be taken into account as electrical power and not as mechanical output power ( observe the efficiency of the motors). TLS line cable Mobile components You have to take the following power reductions into account when calculating the power available at the TLS line cables: Losses caused by incorrect compensation Power loss from the TAS transformer module Ohmic losses in the TLS line cables Losses caused by stray field induction along the TLS line cable You have to take the following power reductions into account when calculating the power available for the mobile components: Power loss of the THM pick-ups Power loss of the TPM mobile converter For continuous operation, the maximum power available for the individual mobile components is the rated output power of the TPS stationary converter. 38 Manual MOVITRANS Project Planning

39 Project Planning System power and system-related power reduction Calculations The following formulas and selection tables are used to calculate the maximum incorrect compensation that can occur at the TPM mobile converter under the least favorable conditions.: For tables displaying the different system-related power losses, refer to section "Project Planning Information". Incorrect compensation The power of the TPS stationary converter (P TPS ) is 4 kw or 16 kw. Losses caused by incorrect compensation are reactive power losses. Determine the effective power of the system using the following formula. Effective power after deducting the reactive power: P [ W] = P [ W] Q[var] eff TPS P eff P TPS Q Effective power of the system Power of the MOVITRANS TPS stationary converter Track-dependent reactive power Track-dependent reactive power The track-depending reactive power can be determined for each case using the formulas below. The reactive power is calculated on the basis of the least favorable compensation conditions. Determine the reactive power of the system depending on the line cable current and the type of cable routing using the following formula: Reactive power of the system: var Q [ var]= Qfix [ var ]+ Q vari l m [ m] Q Q fix Q variable l Track-dependent reactive power Track-independent reactive power Affected by the quantification of the capacitor capacities Track-dependent reactive power Affected by the track-related component tolerances length of the transmission line Reactive power for floor routing with 85 A line cable current: Q = 795var + 55 var m l [m] Manual MOVITRANS Project Planning 39

40 4 Project Planning System power and system-related power reduction Reactive power for floor routing with 60 A line cable current: var Q = 400 var + 30 l[m] m Reactive power for routing in profile section with 60 A line cable current: var Q = 400 var + 20 l[m] m Example Basic data Procedure Calculation The following section explains the calculation of the power losses and the remaining mobile power using a practical example. The following technical data is given: Power supply TPM: 4 kw Length of the transmission line: 25 m Cable cross-section: 25 mm 2 Distance power supply - track: 5 m Required mobile power: 1.8 kw (with S1 operation) Distance reinforcing iron in the floor to TLS line cable: ca. 10 cm The calculation takes place in several steps. Proceed as follows: Determine the individual power losses. From this data, deduce the mobile power available in the system. The following values result using the technical data above: 1. Track-dependent reactive power: var Q = 795 var m = 2170 var m Manual MOVITRANS Project Planning

41 Project Planning System power and system-related power reduction 4 2. Effective power of the system: var kW P eff = ( kw) ( k ) = Ohmic losses in the TLS line cables: W W W PVTLS[ W] = I[m] ( PV [ ] + PVInd [ ]) + a1 [m] PV [ ] m m m = 25 m ( 25 W +12 W m m )+5m 25W =1050 W m P V TLS P V P V Ind Line cable power loss Power loss per track meter See section "Ohmic losses" (page 103). Cable power loss per track meter due to induction See section "Losses due to eddy currents" (page 103). 4. Available power in the TLS line cable: P [ W] = P [ W] P [ W] P [ W] TLS eff VTLS VTAS = 3360 W 1050 W 50 W = 2260 W Available power in the TPM mobile converter: P [ W] = P [ W] P [ W] P [ W] P [ W] TPM TLS VTHM VTHM VTPM = 2260 W 60 W 60 W 120 W = 2020 W Result The mobile power available in the TPM mobile converter is 2.02 kw. The required value for the mobile power of 1.8 kw is achieved. Manual MOVITRANS Project Planning 41

42 5 Project Planning Example for Flat THM10E Pick-Ups General information 5 Project Planning Example for Flat THM10E Pick-Ups 5.1 General information This section considers the project planning for a rail-mounted conveyor trolley based on MOVITRANS components with flat THM10E pick-up using a model system. 5.2 Technical data Project planning is to be performed for a rail-mounted conveyor trolley application comprising a straight track and 2 vehicles with a roller conveyor Structure The following figure shows the design of the model system: [1] [2] [1] 60 m [2] [3] [1] Conveyor trolley [2] Roller Conveyor [3] Track (line) Data The following data is known for project planning: Number of vehicles: 2 Vehicle movement: independent of each other Travel and roller conveyor drive: never in operation simultaneously on the same vehicle Track length: 60 m Distance track - control cabinet: 10 m Frequency inverter: MOVIMOT ( 93% efficiency) Gear unit efficiency: 94% Communication: PROFIBUS radio module (DC 24 V/800 ma) Distance reinforcing iron in the floor - TLS line cable: ca. 10 cm 42 Manual MOVITRANS Project Planning

43 Project Planning Example for Flat THM10E Pick-Ups Project planning for the vehicles Project planning for the vehicles To be able to select the mobile MOVITRANS components correctly, the maximum electrical power required on the vehicle must be determined as accurately as possible. If an accurate calculation is not possible, we strongly recommend that you provide for power reserves Configuration travel drive The following technical data is given: Max. vehicle mass: 2,5 t Resistance to motion: 120 N/t Velocity: 0.75 m/s Acceleration: 0,5 m/s 2 The following formulas can be used to configure the travel drive and to determine the motor power. N Fveh = 2. 5 t 120 = 300 N t Pveh stat = Fveh [ ] V[ m m, N ] = 300 N = 225 W s s Pveh, dyn m[ kg] a[ m ] V [ m m m = ] = 250 kg W s 2 s s 2. = s Pveh, stat [ W] + Pveh, dyn [ W] 225 W W Pmotor = = = 124. kw ηgear 094. P = Pveh,stat [ W] 225 W mo tor,stat η = gear 0.94 = 240 W The following motor can be selected for the calculated power: DT90S efficiency: approx. 77 % This results in the following power on the vehicle: P P on, veh on, stat P = η = motor motor P motor stat η motor [ W] 124. kw = =. kw η FU, [ W] 240 W = = 034. kw η FU Manual MOVITRANS Project Planning 43

44 5 Project Planning Example for Flat THM10E Pick-Ups Project planning for the vehicles Configuration roller conveyor drive The following technical data is given: Max. pallet mass: 1,6 t Rolling resistance: 250 N/t Velocity: 0.5 m/s Acceleration: 0,5 m/s 2 The following formulas can be used to configure the roller conveyor drive and to determine the motor power. Fveh N = 1. 6 t 250 = 400 N t Pveh, stat = Fveh [ ] V[ m N ] = 400 N 0. 5 = 200 W s s Pveh, dyn m[ kg] a[ ] V [ m m m = ] = 1600 kg = 400 W s 2 s 2 s s Pmotor Pveh, stat [ W] + Pveh, dyn [ W] 200 W W = = = 638 W ηgear 094. P motor,stat Pveh,stat [ W] 200 W = = = 213 W ηgear The following motor can be selected for the calculated power: DT80K4 efficiency: approx. 69 % This results in the following power on the vehicle: P P on, veh on, stat P = η Pm = η motor motor otor stat motor [ W] 638 W = =. kw η FU, [ W] 213 W = = 034. kw η FU Manual MOVITRANS Project Planning

45 Project Planning Example for Flat THM10E Pick-Ups Project planning for the vehicles Selecting frequency inverters MOVIMOT MOVIMOT gearmotors are selected for both drives: Travel drive: MM11C Roller conveyor drive: MM05C AC 230 V brakes are installed for the drives, which are controlled directly by the MOVIMOT units. The brake coils have a capacity of 36 W or 40 W Current demand DC 24 V level The current demand at the DC 24 V level is calculated as follows: 2 x MOVIMOT : 0.4 A Initiators/sensors: 1.7 A Communication (2 x MFx + radio module): 1.1 A Warning lamp: 0.3 A Other/reserve: 0.5 A Total current demand: 4.0 A The current of 4 A at the DC 24 V level cannot be provided solely by the TPM12B mobile converter (I 24 V,max = 2 A). Consequently, an external power supply must be installed. In this case it will be a 5 A supply Resulting vehicle power The maximum power capable of being transmitted is required in the travel drive. Since the travel drive and the roller conveyor drive do not run at the same time, the resulting power is based on the larger drive. The power demand for the vehicle is calculated as follows: Travel drive power: 1.79 kw Power at the DC 24 V level: 0.10 kw Brake power: 0.04 kw Total power demand: 1.87 kw Manual MOVITRANS Project Planning 45

46 5 Project Planning Example for Flat THM10E Pick-Ups Project planning for the track Vehicle Structure The following illustration is an example of the technical structure of the vehicles: [3] [4] [5] [2] TPM M [6] [1] MM M [7] [1] MOVITRANS THM10E pick-ups [5] Frequency inverter [2] MOVITRANS TPM mobile converter [6] Travel drive [3] Sensor technology [7] Roller conveyor drive [4] Vehicle control/communication 5.4 Project planning for the track The length of the track means that the track installation has to be considered more closely because a track length of 60 m cannot be operated without intermediate compensation Track structure The following figure shows the track design: 60 m [1] [2] [3] [1] Transmission line [2] MOVITRANS TLS supply cable [3] MOVITRANS Power supply in control cabinet 46 Manual MOVITRANS Project Planning

47 Project Planning Example for Flat THM10E Pick-Ups Project planning for the track 5 The total length of the line cable can be calculated as follows: Total length line cable = distance of the control cabinet from the track + distance between the compensation boxes and the track + length of the transmission line x supply and return cable ( x 2 ) The total length of the model system can be calculated as follows: Total length line cable = (10 m + 4 m + 60 m) x 2 = 148 m 148 m of the TLS10E line cable are required for this application. The line cable is routed on the floor SEW-EURODRIVE offers installation plates for this installation type. The installation plates have a length of 50 cm, hence 120 installation plates are required for this example. The line cable installation with installation plates is described in the manual "MOVITRANS Installation Transmission Lines for THM10E Pick-Ups" Project planning for compensation Two compensation boxes are required in the system to compensate the track (see the tables in the section "Project Planning Information"). They must be installed so that the entire track can be divided into three sections that are roughly the same size. Position The following figure shows the position of the compensation boxes on the track: 60 m ca. 20 m ca. 40 m TCS TCS 140 mm ± 2.5 mm [4] [1] [2] [3] [1] Transmission line [2] MOVITRANS TLS supply cable [3] MOVITRANS Power supply in control cabinet [4] MOVITRANS TCS compensation boxes Manual MOVITRANS Project Planning 47

48 5 Project Planning Example for Flat THM10E Pick-Ups Project planning for the track Layout When two TCS compensation boxes are connected to the TLS line cable at the same level, the points where the TLS line cables exit the track must be moved away from each other in order to ensure the transmission power of the THM pick-ups. The following figure shows the arrangement of the compensation boxes on the track: TCS [1] [2] [3] 140 mm ± 2.5 mm ca. 500 mm [3] [2] TCS [1] [1] MOVITRANS TCS compensation boxes [2] Connection between MOVITRANS TLS line cable and MOVITRANS TCS compensation box [3] MOVITRANS TLS line cable For more complex travel distances, it is a good idea to draw up an overview of the arrangement and wiring of the track components. 48 Manual MOVITRANS Project Planning

49 Project Planning Example for Flat THM10E Pick-Ups Project planning for the power supply Project planning for the power supply Due to the small dimensions of the track, only one emergency stop circuit is configured for the entire track Function The supply voltage is provided to the TPS stationary converter via a line filter. The stationary converter processes the energy and passes it onto the TAS transformer module. The output of the transformer module acts as a power supply from where the energy is fed into the first track section Operating conditions As the vehicles move independently of each other, the least favorable case for operation is the simultaneous acceleration of both conveyor trolleys Dimensioning This is why the dimensions of the power supply must be designed so that a min. power of 3.8 kw can be transmitted for acceleration. This results in the following values: Supply power: 16 kw TPS10A stationary converter: Size 4 TAS10A transformer module: Size 4 Line cable current: 85 A The maximum vehicle power for the project planning example is P FZ max = 1.87 kw. The flat THM10E pick-up provides 0.9 kw for a 60 A line cable current, and 1.5 kw for a 85 A line cable current. With 2 pick-ups and a 60 A line cable current, the MOVITRANS system provides 1.8 kw. This value is smaller than 1.87 kw, which is P FZ max. This is why a 85 A line cable current must definitely be provided. With this current, a track length of 60 m and a 4 kw power supply, the transmission power is reduced significantly. Manual MOVITRANS Project Planning 49

50 5 Project Planning Example for Flat THM10E Pick-Ups System power and system-related power reduction 5.6 System power and system-related power reduction Control calculation A control calculation can be carried out using the technical data. The calculation determines the power that is available at different points under the most unfavorable conditions. var Q = 795var m = 4095 var m 2 2 = ( 16kW) ( 4. 1kvar) = kW P eff If you add all the possible causes for incorrect track compensation, a total reactive power of approximately 4.1 kva results. As you can gather from the control calculation, the system will provide the required acceleration power despite the incorrect compensation: W P 0m m + 12 W m )+14m 25W m =2.57kW VTLS = 6 ( 25 PTLS = kW 2. 57kW 0. 2kW = kW Pmobile = ( 4 60 W) ( W) = kW > kw = 2 P FZ max is a higher value than 2 x P FZ max and is thus sufficient for the required power. Operation with extreme incorrect compensation is not recommended because of the excessive heat that the stationary converter would be subject to and also due to the fact that it is uneconomical as it uses energy unnecessarily. An excessively incorrect compensation can usually be ruled out or corrected by checking the compensation annually using the MOVITRANS parameter tree in the Motion- Studio software. 50 Manual MOVITRANS Project Planning

51 Project Planning Example for Flat THM10E Pick-Ups Component selection Component selection Mobile components With a maximum power of 1.87 kw per conveyor trolley, the following mobile MOVITRANS components are required for one conveyor trolley: Component Description Unit designation 2 THM10E pick-up 1 TPM12B mobile converter 1 Connection cable TPM12B mobile converter flat pick-up with 1.5 kw mobile converter for flat pick-ups hybrid cable with Phoenix T1 plug connector open at one end with wire end sleeves THM10E TPM12B 030-ENE-5A Stationary components The following stationary MOVITRANS components are required for the conveyor trolleys to design the power supply and the track: Number Number Component Description Unit designation 1 NF053 line filter 1 TPS10A stationary converter 1 TAS10A transformer module 1 set TCS Compensation capacitors for TAS10A 148 m TLS10E line cable 2 TCS compensation boxes 120 TIS installation plate built-in unit, IP20, 35 A, used for TPS10A160 built-in unit, IP20, 16 kw connection AC V +/-10 % built-in unit, IP20, 16 kw incl. gyrator, transformer, without compensation capacitors 60 A or 85 A complete set of compensation capacitors for installation in TAS10A floor routing, cable cross section 25 mm 2 60 A or 85 A capacitive reactance at 25 khz = 5.3 ohm straight cable bridge with cover, for cable cross section 25 mm 2 NF TPS10A160-NF TAS10A160-N08-4x1-1 TCS10A-008-xxx-0 TLS10E TCS10A -E TIS10A025-V Alternative project planning example with reduced acceleration Provided that the ramp time of the travel drive can be prolonged a little - i.e. the acceleration is reduced - the maximum peak power of the conveyor trolley drops below 1.8 kw. If the acceleration for the project planning example is assumed with a = 0,45 m/s 2 instead of 0,5 m/s 2, the MOVITRANS system offers a significant economization. The maximum peak power per vehicle a = 0,45 m/s 2 is P FZ max = 1,73 kw. With two flat THM10E pick-ups P FZ max is 1,73 kw, thus below the 1,8 kw transmission power with a 60 A line cable current. The reduction of the line cable current to 60 A results in improved values for the systemrelated power reduction and the line cable losses. Further, only one TCS compensation box is required as opposed to the 85 A system that requires 2 TCS compensation boxes. Manual MOVITRANS Project Planning 51

52 5 Project Planning Example for Flat THM10E Pick-Ups Alternative project planning example with reduced acceleration In the 60 A MOVITRANS system, the system-related power reduction is: var Q = 400 var m = 2. 2kvar m The following continuos and peak power values result from a 4 kw power supply (calculated with a 1.5-fold overload): P P eff 2 2 = ( ) ( ) = 4kW 2. 2kvar 3. 3kW ( ) ( ) = 2 2 eff max = 15. 4kW 22. kvar 558. kw The line cable losses for a 60 A line cable current are also lower than in a 85 A system: W W P VTLS = 60m ( = 1 27 m m ) m W. kw m Hence, the following continuos and peak power can be transmitted: PTLS = 334. kw 127. kw 005. kw = 202. kw PTLS max = 558. kw 127. kw 005. kw = 426. kw The following power is provided to both vehicles at the output of the mobile MOVITRANS components in total: Pmobilemax = 426. kw 4 60W 2 60W = 39. kw > 346. kw = kW = 2 PFZ max The calculation shows that both vehicles can accelerate simultaneously. P mobile = 202. kw 4 60W 2 60W = 166. kw > 096. kw = 2 ( 0. 34kW kW kW ) = 2 P FZ stat Thus, the continuos power of both vehicles is also below the S1 Transmission power of the MOVITRANS system. 52 Manual MOVITRANS Project Planning

53 Project Planning Example for Flat THM10E Pick-Ups Alternative project planning example with reduced acceleration 5 Number The mobile MOVITRANS components in the alternative example are the same ones as in the first example. The stationary MOVITRANS components, however, change significantly: Component Description Unit designation 1 NF014 line filter built-in unit, IP20, 14 A, used for TPS10A040 NF TPS10A stationary converter 1 TAS10A transformer module 1 set TCS Compensation capacitors for TAS10A built-in unit, IP20, 4 kw connection AC V +/-10 % built-in unit, IP20, 4 kw incl. gyrator, transformer, without compensation capacitors 60 A or 85 A complete set of compensation capacitors for installation in TAS10A TPS10A040-NF TAS10A040-N06-4x1-1 TCS10A-008-XXX m TLS10E line cable floor routing, cable cross section 25 mm 2 TLS10E TCS compensation boxes 120 TIS installation plates 60 A capacitive reactance at 25 khz = 7.1 ohm straight cable bridge with cover, for cable cross section 25 mm 2 TCS10A-E TIS10A025-V00-0 Manual MOVITRANS Project Planning 53

54 6 Project Planning Example for U-shaped THM10C Pick-Ups General information 6 Project Planning Example for U-shaped THM10C Pick-Ups 6.1 General information The second project planning example shows the configuration of the MOVITRANS system with a 3-axis portal. The components with U-shaped THM10C pick ups are selected on the basis of the model system. 6.2 Technical data Project planning is to be performed for a 3-axis portal, that takes over the material handling in a production process, for example. The 3-axis portal consists of a hoist, a vehicle for lengthwise motion and a trolley for crosswise motion. The following figure shows the design of the model system: [3] [2] [4] [1] [1] Slide rail for crane bridge [3] Vehicle for moving lengthwise [2] Hoist [4] Trolley for moving crosswise The MOVITRANS energy transfer is only provided to the vehicle that contains the entire mobile electronics. Due to the short track, the motor cables for the trolley and the hoist are designed as trailing cable. 54 Manual MOVITRANS Project Planning

55 Project Planning Example for U-shaped THM10C Pick-Ups Project planning for the vehicles 6 The following data is known for project planning: Number of vehicles: 1 (with trolley and hoist) Movement of the axes: lengthwise and crosswise motion can be carried out simultaneously, hoist never moves simultaneously with travel drives Track length lengthwise motion: 24 m Track length crosswise motion: 3 m (trailing cable) Distance track - control cabinet: 5 m Frequency inverter: MOVIDRIVE B Gear unit efficiency: 94 % Communication: PROFUBUS data light barrier (DC24V/ 800mA) 6.3 Project planning for the vehicles In order to be able to select the components for the MOVITRANS system, it is necessary to determine the peak power of the vehicle as exactly as possible. If an accurate calculation is not possible, we strongly recommend that you provide for power reserves Configuring the hoist The hoist has the following technical characteristics: Max. load: 600 kg Velocity: 0.33 m/s Acceleration: 0.2 m/s 2 The following formulas are used to determine the motor power and the electrical peak power: Fmax m[ ] ( g[ ] a[ m m = kg + ]) = 600 kg ( 9, , 2 ) = 6060 N s 2 s 2 s 2 s 2 Pmax max[ ] [ m m = F N V ] = 6060N = 2. 00kW s s Pmotor max Pmax [ kw] 200. kw = = = 213. kw ηgear Manual MOVITRANS Project Planning 55

56 6 Project Planning Example for U-shaped THM10C Pick-Ups Project planning for the vehicles The following motor and frequency inverter are determined from the calculated power: DV100M4 efficiency: ca. 82 % MDX61B0022-5A P V FU =105W Thus, the following maximum electrical power can be determined for the hoist: Pel max Pmotor max [ kw ] 231. kw = + PVFU[ kw] = kw = 271kW. ηmotor Configuring the drive for crosswise motion (trolley) The drive for crosswise motion (trolley) has the following technical characteristics: Max. weight: 1000 kg Velocity: 0.6 m/s Acceleration: 0.4 m/s 2 Resistance to motion: 150 N/t The following formulas are used to determine the motor power and the electrical peak power: N Fveh = 1 t 150 = 150 N t m Pveh, stat = Fveh [ N] V[ m ] = 150 N 0. 6 = 90 W s s Pv eh, dyn mkg [ ] a[ m ] V [ m m m = ] = 1000 kg = 240 W s 2 s s 2 s Pveh, stat [ W] + Pveh, dyn [ W] 90 W W Pmotor = = = 351 W η 094. gear The following motor and frequency inverter are determined from the calculated power: DT71D4 efficiency: ca. 66 % MDX61B0005-5A P V FU =42W Thus, the following maximum electrical power can be determined for the drive for crosswise motion: P el max Pmotor [ W] 351 W = + PVFU[ W] = + 42W = 574 W η 066. motor Manual MOVITRANS Project Planning

57 Project Planning Example for U-shaped THM10C Pick-Ups Project planning for the vehicles Configuring the drive for lengthwise motion The drive for lengthwise motion (trolley) has the following technical characteristics: Max. weight: 1500 kg Velocity: 0.6 m/s Acceleration: 0.4 m/s 2 Resistance to motion: 150 N/t The following formulas are used to determine the motor power and the electrical peak power: N Fveh = 1. 5 t 150 = 225 N t Pveh stat = Fveh [ ] V[ m m, N ] = 225 N 0. 6 = 135 W s s Pveh, dyn m[ kg] a[ m ] V [ m m m = ] = 1500 kg = 360 W s 2 s s 2 s Pveh, stat [ W] + Pveh, dyn [ W] 135 W W Pmotor = = = 527 W η 094. gear The following motor and frequency inverter are determined from the calculated power: DT80K4 efficiency: ca. 69 % MDX61B0005-5A P V_FU =42W Thus, the following maximum electrical power can be determined for the drive for lengthwise motion: P el max Pmotor [ W] 527 W = + PVFU[ W] = + 42W = 806 W η 069. motor Current demand at the DC 24 V level The drives's brakes are supplied via DC 24 V. Therefore, the following currents must be provided to the brakes on this voltage level: Hoist: DV100M4 BMG4 I 24 V brake =2.20A Drive for crosswise DT71D4 BMG05 I 24 V brake =1.38A motion: Drive for lengthwise motion: DT80K4 BMG1 I 24 V brake =1.54A Since it is possible that the two drives for lengthwise and crosswise motion are operated at the same time, a maximum braking current of 2.92 A may be required. Thus, the current of a TPM12B (2 A) is not sufficient. Variant 3 in section "Installation notes/external DC 24 V supply" (page 82) destined for the project planning of the 24 V level - an external 24 V power supply for the brakes and the 24 V output of the TMP for the signal electronics. Manual MOVITRANS Project Planning 57

58 6 Project Planning Example for U-shaped THM10C Pick-Ups Project planning for the vehicles The two cases of lengthwise/crosswise motion and hoist must be distinguished during when calculating the power on the 24 V level. Current consumption Lengthwise/crosswise motion Hoist Brake(s) 2.9 A 2.2 A Sensor technology 0.5 A 0.5 A Communication 0.8 A 0.8 A Other/reserve 0.4 A 0.4 A Total 4.6 A 3.9 A Power on DC 24 V 111 W 94 W Resulting vehicle power The peak power of the vehicle is determined by the hoist drive because the 1.5 W total power for lengthwise and crosswise motion is significantly lower than the hoist's peak power. Therefore, the maximum power to be transmitted is calculated as follows: Peak power of the hoist: 2.71 kw Power at the DC 24 V level: 0.10 kw Total power demand: 2.81 kw Vehicle structure The following illustration is an example of the schematic structure of the vehicle: [7] MDX [6] [4] [3] 24 V [8] [2] TPM [5] [7] MDX [6] [8] [7] MDX [6] [1] [1] [1] [1] [8] [1] MOVITRANS THM10C pick-up [5] Distribution list [2] MOVITRANS TPM mobile converter [6] Motor [3] external 24V power supply [7] MOVIDRIVE MDX frequency inverter [4] Communication [8] Brake control 58 Manual MOVITRANS Project Planning

59 Project Planning Example for U-shaped THM10C Pick-Ups Project planning for the track Project planning for the track The track length is unproblematic for this sample project. The track can be operated without any intermediate compensation. In order to provide the power supply, the TLS supply cable and the TVS connection distributor are connected at one end of the track. Another TVS connection distributor may be connected at the other end of the track in order to interlink supply and return line. Alternatively, the TLS line cable can be routed in loops. [5] [4] [3] [2] [1] [1] MOVITRANS TLS supply cable [4] MOVITRANS TLS line cable (return line) [2] MOVITRANS TVS connection distributor [5] Loops [3] MOVITRANS TLS line cable (supply cable) The TLS line cable (8 mm 2 cable cross section) dual-routed and connected in parallel on the transmission line. Therefore, the length of the TLS line cable to be ordered is at least 4 times the track length plus spare for connections. 4 x 24 m + 2 m = 98 m TLS10E line cable and at least 5 m TLS10E supply line are required for this application in total. Only TIS...-P.. rigid profile sections are used for straight track sections. TIS...-P74 profile sections (74 mm height) are required for the supply line. The return lines are routed separately in the profile sections, above and underneath the supply line. TIS...-P33 profile sections (33 mm height) are required for the supply line. The number of required profile sections can be determined as follows: n TIS... P.., HL n TIS... P.., RL TIS... P. l [m] G 24m = = = 8 3m 3m = 2 n.,hl = 2 8 = The TIS...-H.. holding fixtures for the TIS profile sections should be placed about every 50 cm on straight track sections. Thus, the number of TIS...-H.. holding fixtures is calculated as follows: track length/distance between holding fixtures + 1 = 24 m / 0.5 m + 1 = 49. Hence, 49 TIS...-H.. holding fixtures and TIS...-X.. universal retaining plates are required. If the profile section system is mounted on steel, you must provide for an aluminum shielding plate! The shielding plate is not included in the scope of delivery. Also see section "Shielding plate" (page 102). Manual MOVITRANS Project Planning 59

60 6 Project Planning Example for U-shaped THM10C Pick-Ups Project planning for the power supply The following figure shows the profile section system mounted on steel with a shielding plate: [1] [2] [3] [4] [5] [1] Shielding plate [4] MOVITRANS TIS profile section for return line (33 mm) [2] MOVITRANS TIS holding fixture and [5] MOVITRANS THM10C pick-up TIS universal retaining plate [3] MOVITRANS TIS profile section for supply line (74 mm) 6.5 Project planning for the power supply Due to the small dimensions of the track, only one emergency stop circuit is configured for the entire track. The MOVITRANS power supply for the system must be determined to always provide sufficient power un the TLS line cable, in order to ensure performance at any rate. The operation of the hoist represents the highest energy demand. The power supply is selected to at least transmit 2.81 kw power to the hoist. This results in the following values: Supply power: 4 kw TPS10A stationary converter: Size 2 TAS10A transformer module: Size 2 Line cable current: 60 A 60 Manual MOVITRANS Project Planning

61 Project Planning Example for U-shaped THM10C Pick-Ups System power and system-related power reduction System power and system-related power reduction A control calculation can be carried out using the technical data. The calculation determines the power that is available at different points under the most unfavorable conditions. var Q = 400 var m = 880 var = 0. 88kvar m P eff = ( kw) ( kvar) = kW The result shows that you can almost disregard the system-related power reduction curing the configuration of this system. PVTLS W W = 24m m 15 = 387 W m m PTLS = 3. 90kW 0. 39kW 0. 05kW = 3. 46kW P mobile = 3. 46kW 4 25 W 120 W = 3. 24kW In this case, however, the S1 output power is limited to 4 x 800 W = 3,2 kw by the rated transmission power of the pick-ups. The output power of the TPM mobile converter exceeds the maximum vehicle power (2.81 kw) by far, this is why the system will definitely work. For longer transmission lines, an excessively incorrect compensation can usually be ruled out or corrected by checking the compensation annually using the MO- VITOOLS software. Manual MOVITRANS Project Planning 61

62 6 Project Planning Example for U-shaped THM10C Pick-Ups Component selection 6.7 Component selection Mobile components The following MOVITRANS components are required with the maximum power of 2.81 kw on the vehicle. Component Description Unit designation 2 THM10C pick-up U-shaped pick-up with 0.8 kw THM10C TPM12B mobile converter mobile converter for 4 U-shaped pick-ups TPM12B036-ENC-5A2-2 1 Connection cable TPM12B mobile converter hybrid cable with Phoenix T1 plug connector open at one end with wire end sleeves Stationary components The following stationary MOVITRANS components are required for the 3 axes portal to design the power supply and the track: Number Number Component Description Unit designation 1 NF014 line filter built-in unit, IP20, 14 A, used for TPS10A040 NF TPS10A stationary converter 1 TAS10A transformer module 1 set TCS Compensation capacitors for TAS10A built-in unit, IP20, 4 kw connection AC V +/-10 % built-in unit, IP20, 4 kw incl. gyrator, transformer, without compensation capacitors 60 A or 85 A complete set of compensation capacitors for installation in TAS10A TPS10A040-NF TAS10A040-N06-4x1-1 TCS10A-008-xxx-0 98 m TLS10E line cable routing in the profile section system, cable cross section 8 mm 2 TLS10E m TLS10E supply cable power supply cable, track for 60 A TLS10E TVS10A connection distributor connection distributor for 60 A TVS10A-E TIS10A installation material 16 TIS10A installation material 49 TIS10A installation material 49 TIS10A installation material rigid profile section, installation dimension 74 mm, length 3 m, for a cable cross section of 8 mm 2 rigid profile section, installation dimension 33 mm, length 3 m, for a cable cross section of 8 mm 2 holding fixture for profile sections matching universal retaining plate, cable cross section 8 mm 2 universal retaining plate for TIS10A008-H02-0 holding fixture, cable cross section 8 mm 2 TIS10A008-P74-0 TIS10A008-P33-0 TIS10A008-H02-0 TIS10A008-XH Manual MOVITRANS Project Planning

63 Preventive Measures against Electrical Hazards Overview 7 7 Preventive Measures against Electrical Hazards 7.1 Overview The following figure is an overview of the preventive measures against electrical hazards: Contactless energy transfer MOVITRANS Stationary components Mobile components Protective earth Preventive separation to VDE 0100 ESD protection Warning An electric shock caused by missing or defective protection devices can lead to fatal injuries and/or death. Install the protection devices according to the regulations. The installation must only be carried out by qualified personnel. Check the protection device. 7.2 General information Observe the according information in the operation instructions of the individual units. The following units must be grounded or connected to an equipotential bonding: Stationary components: TPS10A stationary converter TAS10A transformer module NF line filter TVS10A connection distributor TCS10A compensation box Mobile components: TPM12B mobile converter THM10E pick-up Manual MOVITRANS Project Planning 63

64 7 Preventive Measures against Electrical Hazards Unit connection points for grounding or equipotential bonding Use low-impedance HF-compliant cables with a minimum diameter according to the following table and keep them as short as possible: Supply cable diameter Grounding diameter <10mm 2 10 mm 2 10 mm 2 Supply cable diameter 7.3 Unit connection points for grounding or equipotential bonding The connection points for grounding or equipotential bonding are indicated on the unit by a symbol. 7.4 Stationary components For stationary use, it is essential to ground the units. Observe the following rules: Ground the unit by the shortest possible route. Use a green and yellow grounding cable. 7.5 Mobile components The following preventive measures protect mobile systems with MOVITRANS contactless energy transfer against electrical hazards: Preventive separation to VDE 0100 ESD protection Preventive separation to VDE 0100 Compliance with "preventive separation" in line with VDE 0100 part 410 rated voltage 500 V is ensured by the following measures. All electrical equipment on the mobile component, such as a vehicle, must be linked together for equipotential bonding. Observe the following rules: Establish equipotential bonding via the vehicle frame (vehicle GND). Use a equipotential bonding cable in gray or black. This lead is for equipotential bonding and is not a PE connection. Never use a greenyellow colored cable. This is reserved for PE only. 64 Manual MOVITRANS Project Planning

65 Preventive Measures against Electrical Hazards Mobile components 7 The following figure shows a sample mobile system with contactless energy transfer with MOVITRANS : [5] [6] [5] M PH.. PH.. M [4] [3] [3] THM THM [10] [2] [1] [7] [8] [9] [8] [1] Stationary system section [6] Drive control [2] TLS line cable [7] Ground [3] Wheels [8] THM pick-ups [4] Vehicle frame [9] Vehicle GND [5] Motor [10] Temporary ground connection For certain production steps it can be mandatory to temporarily ground the vehicle frame during standstill. Note All cables must have double basic insulation. Double insulation is also required for the supply cable of the pick-up. These requirements are met as standard when using MO- VITRANS components. A conductive cable between the vehicle frame (vehicle GND) and a ground potential (ESD protection) is permitted. Possible electrical hazards are extremely unlikely in mobile systems grounded on the secondary side. In each case, at least 3 combined insulation and grounding faults must be present in the entire system to result in an electrical hazard. Additional information for operation The insulation strength of the equipment and the effectiveness of the equipotential bonding is to be confirmed by means of cyclical system inspections of the mobile components and the overall systems when operated in IT networks. Possible potential transfer to mobile components, e.g individual vehicles, due to non- SEW equipment must be ruled out when planning and operating the systems. Manual MOVITRANS Project Planning 65

66 7 Preventive Measures against Electrical Hazards Mobile components ESD protection To ensure optimum protection from electrostatic discharge (ESD), you must implement measures for dissipating charges in all places where non-conducting surfaces rub against each other. This is especially important for mobile systems such as hoists, industrial trucks, floor conveyors, etc. The charge can be dissipated in the following ways: Via conductive combs, brushes, springs or sliders Via conductive track rollers or wheels Via conductive floor or working surfaces The following figure shows the options for ESD protection: [5] [6] [5] M PH.. PH.. M [4] [3] [3] THM THM [7] [2] [8] [1] [9] [10] [9] [1] Conductive floor or working surfaces [6] Drive control [2] TLS line cable [7] Conductive combs, brushes, springs, sliders [3] Conductive track rollers or wheels [8] Ground [4] Vehicle frame [9] THM pick-ups [5] Motor [10] Vehicle GND 66 Manual MOVITRANS Project Planning

67 Installation Notes Connecting the MOVITRANS TPM12B mobile converter 8 8 Installation Notes MOVITRANS has been optimized for operation with SEW inverters such as MOVIMOT, MOVIDRIVE MDX60B/61B, MOVIDRIVE MCF/MCV/MCS20A and MOVITRAC 07A/B. 8.1 Connecting the MOVITRANS TPM12B mobile converter Wiring diagram The TPM12B mobile converter has a Phoenix plug connector at the output end for the utilization voltages and for control. The following figure shows the wiring diagram for the TPM12B mobile converter (on the left hand) and the terminal arrangement on connector X11 (right hand). The terminals of the connector are displayed from outside the unit with the heat sink on bottom: power supply 1 same polarity ~ power supply 2 same polarity ~ A1 A2 B2 B4 B6 B X22 X32 X11 A1 MOVITRANS TPM12B A2 B1 B2 B3 B4 B5 B6 B7 B8 X11 B1 B3 B5 B7 0V 500 P E n.b. 500 V Shielding 500 V OK Enable Enable mode 24 V 0V Manual MOVITRANS Project Planning 67

68 8 Installation Notes Connection via hybrid cable Terminal assignment The table shows the terminal assignment for connector X11: Terminal Designation A1: +U z A2: -U z 500V 0V500 B1 B2 B3 B4 B5 B6 B7 B8 PE PE 500V OK N.C. Enable Enable mode 24V 0V24 Function DC 500 V output voltage Reference potential for the DC 500 V output voltage Equipotential bonding for shield Equipotential bonding for cable Binary output 500V OK, "1" signal, if DC 500 V output voltage is present. Not assigned Binary input enable (for DC 500 V output voltage only): "0" signal = DC 0 V output voltage "1" signal = DC -500 V output voltage Binary input enable mode (for DC 500 V output voltage only): "0" signal = delayed enable (ramp) "1" signal = instantaneous enable DC 24 V voltage output (max. 2 A) Reference potential for DC 24 V binary signals Terminals X11.C5 "Enable" and X11.B6 "Enable mode"only affect the DC 500 V output voltage. The DC 24 V voltage output X11.B7 is not affected. 8.2 Connection via hybrid cable Prefabricated hybrid cable SEW-EURODRIVE offers a prefabricated hybrid cable for connection to this plug connector. All leads are enclosed in one jacket. One cable end is fitted with a plug connector for connection to the TPM12B mobile converter. The other cable end is open and fitted with wire end sleeves. The cables are available in half-meter lengths from 1 m to 7.5 m. The following figure shows a prefabricated hybrid cable: Manual MOVITRANS Project Planning

69 Installation Notes Connection via hybrid cable Cable cross section The following illustration shows the cross-section of the open cable end: 500 V 0V V OK Enable mode OG RS+ WH 0V GN RS- BK L1 BK L2 BK L3 WH 0V RD 24V 24 V GNYE Enable 0V 24 PE Assignment of the wires The following table shows the assignment of the wires: Designation TPM mobile converter Hybrid cable 500V 0V500 PE PE 500V OK N.C. Enable Enable mode 24V 0V24 X11.A1: +U z X11.A2: -U z X11.B1 X11.B2 X11.B3 X11.B4 X11.B5 X11.B6 X11.B7 X11.B8 L1 L2 Shielding GNYE OG - GN WH RD WH Terminals X11.C5 "Enable" and X11.B6 "Enable mode"only affect the DC 500 V output voltage. The DC 24 V voltage output X11.B7 is not affected. Manual MOVITRANS Project Planning 69

70 RS Installation Notes Connecting MOVIMOT 8.3 Connecting MOVIMOT Wiring diagram The MOVIMOT frequency inverter is suitable for simple applications thanks to its uncomplicated control features and IP65 enclosure. In this inverter, the DC link circuit is not applied directly at the terminals. Nevertheless, the frequency inverter can be run at the DC 500 V output of the TPM12B mobile converter. Terminal 15 is connected directly to the U Z+ potential of the DC link. The connection to the U Z- potential is established via the diodes of the input rectifier and terminals L1, L2 and L3. The following figure shows the wiring diagram for the connection of MOVIMOT to the TPM12B mobile converter: Power supply 1 same polarity ~ Power supply 2 same polarity ~ A1 A2 B2 B4 B6 B X22 X32 X11 A1 MOVITRANS TPM12B A2 B1 B2 B3 B4 B5 B6 B7 B8 X11 B1 B3 B5 B7 0V 500 P E n.b. Enable mode 0V V Shielding 500 V OK Enable 24 V K1 L1 L2 L3 MOVIMOT M 3- phase BMG 24V R L f1/f2 K1a K1b RS- RS+ RD WH BL Manual MOVITRANS Project Planning

71 Installation Notes Connecting MOVIFIT Terminal assignment The table shows the terminal assignments on the connector X11 and the assignment of the wires in the hybrid cable and the MOVIMOT frequency inverter: Designation TPM mobile converter Hybrid cable MOVIMOT 500V 0V500 PE PE 500V OK N.C. Enable Enable mode 24V 0V24 X11.A1: X11.A2: X11.B1 X11.B2 X11.B3 X11.B4 X11.B5 X11.B6 X11.B7 X11.B8 L1 L2 Shielding GNYE OG - GN WH RD WH 15 L1 / L2 / L3 - PE Terminals X11.C5 "Enable" and X11.B6 "Enable mode"only affect the DC 500 V output voltage. The DC 24 V voltage output X11.B7 is not affected. 8.4 Connecting MOVIFIT Wiring diagram The MOVIFIT -FC field distributor for decentralized installation provides more functions than the MOVIMOT and is therefore also suitable for more complex applications. The unit can be operated directly at the DC 500 V of the TPM12B mobile converter although there are no DC link terminals. Terminal X9.7 is directly connected to the UZ+ potential of the DC link. The connection to the UZ- potential is established via the diodes of the input rectifier and the terminals X1.2, X1.3 and X1.4 (L1, L2 and L3). Manual MOVITRANS Project Planning 71

72 8 Installation Notes Connecting MOVIFIT The following figure shows the wiring diagram for the connection of MOVIFIT FC to the TPM12B mobile converter: Power supply 1 same polarity ~ Power supply 2 same polarity ~ A1 A2 B2 B4 B6 B X22 X32 X11 A1 MOVITRANS TPM12B A2 B1 B2 B3 B4 B5 B6 B7 B8 X11 B1 B3 B5 B7 0V 500 P E n.b. 500 V Shielding 500 V OK Enable Enable mode 24 V 0V X1 PE L1 L2 L3 PE L1 L2 L3 MOVIFIT - FC with SEW A Box X X9 M 3-phase blau weiß rot BW Manual MOVITRANS Project Planning

73 Installation Notes Connecting MOVIDRIVE MDX60B/61B Terminal assignment The table shows the terminal assignments on the connector X11 and the assignment of the wires in the hybrid cable and the MOVIFIT FC field distributor: Designation TPM mobile converter Hybrid cable MOVIFIT -FC 500V 0V500 PE PE 500V OK N.C. Enable Enable mode 24V 0V24 X11.A1 X11.A2 X11.B1 X11.B2 X11.B3 X11.B4 X11.B5 X11.B6 X11.B7 X11.B8 L1 L2 Shielding GNYE OG - GN WH RD WH X9.7 X1.2, X1.3, X1.4 - X Terminals X11.C5 "Enable" and X11.B6 "Enable mode"only affect the DC 500 V output voltage. The DC 24 V voltage output X11.B7 is not affected. 8.5 Connecting MOVIDRIVE MDX60B/61B Wiring diagram Only MOVIDRIVE MDX60B/61B frequency inverters with 3 x AC 400 V input voltage can be connected to TPM12B mobile converter. In contrast to MOVIMOT, MOVIDRIVE MDX60B/61B has terminals from which the DC link is applied directly. The TPM12B mobile converter can be connected directly. In this case, terminals L1, L2 and L3 are not used. Manual MOVITRANS Project Planning 73

74 8 Installation Notes Connecting MOVIDRIVE MDX60B/61B The following figure shows the wiring diagram for the connection of MOVIDRIVE MDX60B/61B to the TPM12B mobile converter: Power supply 1 same polarity ~ Power supply 2 same polarity ~ A1 A2 B2 B4 B6 B X22 X32 X11 A1 MOVITRANS TPM12B A2 B1 B2 B3 B4 B5 B6 B7 B8 X11 B1 B3 B5 B7 0V 500 P E n.b. 500 V Shielding 500 V OK Enable Enable mode 24 V 0V 24 U DC DC link connection F14/F15 X1: L1 L2 L3 X4: -UZ +UZ PE K11 (AC-3) MOVIDRIVE MDX60B/61B +U Z BRC PE X2: U V W X3: +R -R PE (only BG0) DBØØ K12 (AC-3) DGND BS BSG weiß rot blau M 3-phase BW... F16 affects K11 CT/CV/DT/DV/D: AC-side cut-off IfF16 triggers, K11 must be opened and DI00 "/controller inhibit" must receive a "0" Signal. The resistor circuit must not be interrupted! Manual MOVITRANS Project Planning

75 Installation Notes Connecting MOVITRAC 07A Terminal assignment The table shows the terminal assignments on the connector X11 and the assignment of the wires in the hybrid cable and the MOVIDRIVE MDX60B/61B frequency inverter: Designation TPM mobile converter Hybrid cable MOVIDRIVE 500V X11.A1 L1 U z+ 0V500 X11.A2 L2 U z- PE PE 500V OK N.C. Enable Enable mode 24V 0V24 X11.B1 X11.B2 X11.B3 X11.B4 X11.B5 X11.B6 X11.B7 X11.B8 Shielding GNYE OG - GN WH RD WH - PE Terminals X11.C5 "Enable" and X11.B6 "Enable mode"only affect the DC 500 V output voltage. The DC 24 V voltage output X11.B7 is not affected. 8.6 Connecting MOVITRAC 07A Wiring diagram The MOVITRAC 07A/B frequency inverter can only be operated as a 3 x AC 400 V unit on the MOVITRANS system. Operation of the AC 230 V variants is not permitted. For MOVITRAC 07A/B frequency inverters, the size of the units determines the connection technology used: Frequency inverter Size Connection MOVITRAC 07A MOVITRAC 07B 0M, 0L like MOVIMOT 2S, 2, 3, 4 like MOVIDRIVE MDX60B/61B 0XS, 0S, 0L like MOVIMOT 2S, 2, 3, 4 like MOVIDRIVE MDX60B/61B Manual MOVITRANS Project Planning 75

76 8 Installation Notes Connecting MOVITRAC 07A The following figure shows the wiring diagram for the connection of MOVITRAC 07A/ B to the TPM12B mobile converter: Power supply 1 same polarity ~ Power supply 2 same polarity ~ A1 A2 B2 B4 B6 B X22 X32 X11 A1 MOVITRANS TPM12B A2 B1 B2 B3 B4 B5 B6 B7 B8 X11 B1 B3 B5 B7 0V 500 P E n.b. 500 V Shielding 500 V OK Enable Enable mode 24 V 0V 24 U DC L1 L2 L3 PE F14/F15 MOVITRAC 07A/B K11 (AC-3) = Shield clamp U V W PE PE +R -R DBØØ K12 (AC-3) DGND BS BSG weiß rot blau M 3-phasig affects K11 F16 BW... CT/CV/DT/DV/D: AC-circuit cut-off P820 =ON! Manual MOVITRANS Project Planning

77 Installation Notes Connecting brakes / brake rectifiers Terminal assignment The following table shows the terminal assignments on the connector X11 and the assignment of the wires in the hybrid cable and the MOVITRAC 07A/B frequency inverter: Designation TPM mobile converter Hybrid cable MOVITRAC 07A/B 500V 0V500 PE PE 500V OK N.C. Enable Enable mode 24V 0V24 X11.A1 X11.A2 X11.B1 X11.B2 X11.B3 X11.B4 X11.B5 X11.B6 X11.B7 X11.B8 L1 L2 Shielding GNYE OG - GN WH RD WH +R L1 / L2 / L3 - PE Terminals X11.C5 "Enable" and X11.B6 "Enable mode"only affect the DC 500 V output voltage. The DC 24 V voltage output X11.B7 is not affected. 8.7 Connecting brakes / brake rectifiers Selecting brakes Different brakes and brake voltages are used depending on the frequency inverter selected: Frequency inverter MOVIMOT BG1 MOVIMOT BG2 MOVIFIT -FC MOVIDRIVE MDX60B/61B MOVITRAC 07A/B Brake voltage AC 230 V brake AC 110 V brake AC 400 V brake (standard) but also AC 230 V brake AC 110 V brake DC 24 V brake AC 230 V brake AC 400 V Brake DC 24 V brake AC 230 V brake AC 400 V Brake For MOVIMOT and MOVIFIT FC, brake control is taken over by the inverter itself. Manual MOVITRANS Project Planning 77

78 8 Installation Notes Connecting brakes / brake rectifiers DC 24 V brakes For MOVIDRIVE MDX60B/61B and MOVITRAC 07A/B, the brake series determines the required current. The following applies: Series BMG05 to BMG4 Connected directly to DC 24 V Use drive with BS overvoltage protection Can also be operated with BSG The brakes in this series can also be operated with BSG. However, in this case a more powerful DC 24 V power supply is required because the starting current increases by a factor of 4 when the brake is released. Series BMG8 to BM15 Connection only with BSG Series BMG05 to BMG4 The following assignments and brake currents apply to the BMG05 to BMG4 series with BS: Series BMG05 to BMG4 with BS Motor Brake BMG05 BMG1 BMG2 BMG4 Brake current [A] Series BMG8 to BM15 The following assignments and brake currents apply to the BMG8 to BM15 series with BSG: Series BMG8 to BM15 with BSG Motor S 132M-160M Brake BMG8 BM15 Inrush current 1) [A] Holding current [A] ) Duration approx. 120 ms 78 Manual MOVITRANS Project Planning

79 Installation Notes Connecting brakes / brake rectifiers AC 230 V brakes and AC 400 V brakes The AC 230 V and AC 400 V brakes can be connected via the BST brake rectifiers. The BST1.0S-230V-00 is used for AC 230 V brakes, and the power of the brake coil must not exceed 100 W. The BST0.6S-400V-00 is used for AC 400 V brakes, and the power of the brake coil must not exceed 95 W. Due to the BST power limit the BMG 4 (DV100) is the maximum. The brakes of bigger motor types (DV112 and higher) have to be planned for 24 V. Apart from the listed wiring diagrams, the BST brake rectifier also allows for a safe disconnection. Please refer to the operating instructions for more detailed information Wiring diagrams DC 24 V brake with The following figure shows the connection of a DC 24 V brake with BS brake control: BS 24 V DC - + M BS TS WH RD BU BS Manual MOVITRANS Project Planning 79

80 8 Installation Notes Connecting brakes / brake rectifiers DC 24 V brake with BSG The following figure shows the connection of a DC 24 V brake with BSG brake control: 24 V DC + - WH RD BSG M BS 4 5 TS BU AC 230 V and AC 400 V brakes with BST The following figure shows the connection of an AC 230 V and an AC 400 V brake on a BST brake rectifier: + DC 500 V - 1 NC 2 X1 BST M BS RD WH + DC 24 V - DB... GND 5 NC X2 X3 X4 TS BU Manual MOVITRANS Project Planning

81 Installation Notes Connecting the MOVITRANS TPM12B mobile converter in parallel Connecting the MOVITRANS TPM12B mobile converter in parallel Parallel connection If the power of the TPM12B is not sufficient for the application in question, the power can be increased by connecting several mobile converters in parallel Prerequisites You must take the following points into account: You can connect any number of mobile converters in parallel, but the total of the individual outputs must not exceed the supply power. Important: Very accurate project planning is required to ensure that this value is not exceeded In practice, no more than 3 or 4 TPM12B mobile converters should be connected in parallel. The consumers at the DC 24 V level must be distributed over the DC 24 V outputs of all the mobile converters. If this is not possible for technical reasons, the DC 24 V outputs can also be connected in parallel: TPM12B TPM12B TPM12B 24 V GND 24 V GND 24 V GND The DC 500 V of the TPM12B mobile converters must also be routed to two collection points. TPM12B TPM12B TPM12B 500 V 0 V 500 V 500 V 0 V 500 V 500 V 0 V 500 V Manual MOVITRANS Project Planning 81

82 8 Installation Notes External DC 24 V supply 8.9 External DC 24 V supply Project planning for the DC 24 V level When performing project planning for the DC 24 V level, try to avoid connecting the DC 24 V voltage sources in parallel. Distribute the different consumers among the available voltage sources. This simplifies startup and ensures that operation is more stable. If the external power supplies for DC 24 V supply to the TPM12B mobile converter have to be connected in parallel due to technical reasons, the voltage of the power supply must be set exactly to the voltage of the mobile converter DC 24 V supply Influencing factors The connection variant that you choose depends on the following factors: Is a DC 24 V brake installed? How high is the consumption for the control? How high is the consumption for the sensors? etc. Connection variants 4 connection variants are available. Each variant is suitable for different conditions: Variant 1 Variant 2 Variant 3 Variant 4 DC 24 V brake No No Yes Yes Power demand small large small large 82 Manual MOVITRANS Project Planning

83 Installation Notes External DC 24 V supply Wiring diagrams Variant 1 The following illustration shows connection variant 1 for DC 24 V supply: TPM12B 24 V GND Control, Sensors, Variant 2 The following illustration shows connection variant 2 for DC 24 V supply: TPM12B Power supply 24 V GND 24 V GND Control, Sensors, Manual MOVITRANS Project Planning 83

84 8 Installation Notes External DC 24 V supply Variant 3 The following illustration shows connection variant 3 for DC 24 V supply: TPM12B Power supply 24 V GND 24 V GND Control, Sensors,... Brake control BS+ BSG Variant 4 The following illustration shows connection variant 4 for DC 24 V supply: TPM12B Power supply Power supply 24 V GND 24 V GND 24 V GND Control, Sensors,... Brake control BS+ BSG DC 24 V power supplies When selecting the power supply, consider that the DC 24 V power supply must provide the maximum required current DC 500 V must be fed in at the input of the power supply. The power supplies partly have a high overload capacity and can, therefore, be better utilized. Observe the data sheets provided by the manufacturers. 84 Manual MOVITRANS Project Planning

85 Project Planning Information Overview and functions of the MOVITRANS components with part num- kva i P f n Hz 9 9 Project Planning Information 9.1 Overview and functions of the MOVITRANS components with part numbers V Stationary components The following table gives an overview of the MOVITRANS stationary components: Unit type Unit designation Power Description of functions Part number Stationary converter Transformer module Line filter TPS10A040-NF TPS10A160-NF TAS10A040-N06-4x1-1 TAS10A040-N08-4x1-1 TAS10A160-N06-4x1-1 TAS10A160-N08-4x1-1 NF NF kw 16 kw 4 kw 4 kw 16 kw 16 kw 4 kw 16 kw Built-in unit, IP20, 4 kw cdf 100%, Integrated fan, connection V AC +/-10% Built-in unit, IP20, 16 kw cdf 100%, Integrated fan, connection V AC +/-10% Built-in unit, IP20, 4 kw cdf 100%, Output 60 A/25 khz, incl. gyrator, transformer, without compensation capacitors Built-in unit, IP20, 4 kw cdf 100%, Output 85 A/25 khz, incl. gyrator, transformer, without compensation capacitors Built-in unit, IP20, 16 kw cdf 100%, Output 60 A/25 khz, incl. gyrator, transformer, without compensation capacitors Built-in unit, IP20, 16 kw cdf 100%, Output 85 A/25 khz, incl. gyrator, transformer, without compensation capacitors built-in unit, IP20, 14 A, used for TPS10A040 built-in unit, IP20, 35 A, used for TPS10A ,116 X Unit type Unit designation Line cable current Compensation capacitor, (for TAS10A transformer module) TCS10A-008-XXX-0 TCS10A TCS10A TCS10A TCS10A TCS10A A or 85 A 60 A or 85 A 60 A or 85 A 60 A or 85 A 60 A or 85 A 60 A or 85 A Description of functions Complete set of compensation capacitors for TAS10A, for adjustment of all possible track lengths up to first compensation box, Complete set consists of: 1pce TCS10A , 1pce TCS10A , 1pce TCS10A , 1pce TCS10A , 1pce TCS10A Compensation capacitor, capacity 2 µf, with setscrew for installation in TAS10A, Reactance at 25 khz = 3.2 ohm Compensation capacitor, capacity 4 µf, with setscrew for installation in TAS10A, Reactance at 25 khz = 1.6 ohm Compensation capacitor, capacity 8 µf, with setscrew for installation in TAS10A, Reactance at 25 khz = 0.8 ohm Compensation capacitor, capacity 16 µf, with setscrew for installation in TAS10A, Reactance at 25 khz = 0.4 ohm Compensation capacitor, capacity 32 µf, with setscrew for installation in TAS10A, Reactance at 25 khz = 0.2 ohm Part number Manual MOVITRANS Project Planning 85

86 9 kva i P f n Hz Project Planning Information Overview and functions of the MOVITRANS components with part num Mobile components The following table shows the mobile MOVITRANS components for the use with flat pick-ups: Unit type Unit designation Power Description of functions Part number flat pick-up Mobile converter Mobile converter connection cable THM10E THM10E TPM12B030-ENE-5A kw (at 85 A) 0.9 kw (at 60 A) 1.5 kw (at 85 A) 0.9 kw (at 60 A) to 3 kw - - Flat pick-up without UL approval (standard), IP65, 1.5 kw/cdf 100 %, T (periphery) 40 C, up to 6 m cable (Ölflex-Classic) and Han Q4/2 plug connector (please specifiy when placing your order) Flat pick-up with UL approval, IP65, 1.5 kw/cdf 100 %, T (periphery) 40 C, up to 6 m cable (Ölflex-Classic) and Han Q4/2 plug connector (please specifiy when placing your order) Connection of 1 or 2 flat THM10E pick-ups, IP65, 3 kw/ ED 100 %, Output DC 500 V + DC 24 V up to 2 A Hybrid cable with T1 plug connector, for the connection to the TPM12B mobile converter output, cable open at one end with wire end sleeves, (specify cable length in m when placing an order) The following table shows the mobile MOVITRANS components for the use with U- shaped pick-ups: Unit type Unit designation Power Description of functions Part number U-shaped pickup Mobile converter Mobile converter connection cable THM10C TPM12B018-ENC-5A2-2 TPM12B036-ENC-5A W (at 60 A) (900 W peak power) to 1.8 kw to 3.6 kw - - U-shaped pick-up with UL approval, IP65, 800 W/cdf 100%, 900 W peak power, line cable current 60 A T (periphery) 50 C, up to 6 m cable (Ölflex-Classic) and Han Q4/2 plug connector (please specifiy when placing your order) Connection of 1 or 2 U-shaped THM10C pick-ups, IP65, 1.8 kw/cdf 100 %, Output DC 500 V + DC 24 V up to 2 A Connection of 2 or 4 U-shaped THM10C pick-ups, IP65, 3.6 kw/cdf 100 %, Output DC 500 V + DC 24 V up to 2 A Hybrid cable with T1 plug connector, to connect to TPM12B output, cable open at one end with wire end sleeves, (specify cable length in m when placing an order) Manual MOVITRANS Project Planning

87 Project Planning Information Overview and functions of the MOVITRANS components with part num- kva i P f n Hz Installation equipment The following table gives an overview of the MOVITRANS installation equipment for floor routing: Unit type Unit designation Line cable current Line cable TLS10E TLS10E TLS10E TLS10E TLS10E A 85 A 85 A 85 A 85 A Supply cable TLS10E A Connection distributor TVS10A-E TVS10A-E TVS10A-E A 60 A and 85 A 60 A and 80 A Description of functions Conductor loop for flat pick-ups, MF litz wires, floor routing, Cable cross section 16 mm 2 Outer diameter 10.9 mm, reduced transmission power Conductor loop for flat pick-ups, MF litz wires, floor routing, Cable cross section 25 mm 2 Outer diameter 12.5 mm, Conductor loop for flat pick-ups, MF litz wires, floor routing, Cable cross section 25 mm 2 Outer diameter 12.5 mm, comes pre-fabricated on one end and with 1 cable lug Conductor loop for flat pick-ups, MF litz wires, Floor routing for longer track distances, Cable cross section 41 mm 2 Outer diameter 15 mm, Conductor loop for flat pick-ups, MF litz wires, Floor routing for longer track distances, Cable cross section 41 mm 2 Outer diameter 15 mm, comes pre-fabricated on one end and with 1 cable lug Power supply cable from supply cabinet to energy transmission line, fine litz wires, Routing in cable duct, Cable cross section mm 2, Outer diameter 20.5 mm, Stationary connection components (wiring box), to connect MF cables, flange plate 2 x M32 / 4 x M25 Stationary connection components (wiring box), to connect MF cables, flange plate 2 x M32 / 4 x M25 Stationary connection components (wiring box), to connect MF cables, flange plate 2 x M32 / 2 x M32 Part number Manual MOVITRANS Project Planning 87

88 9 kva i P f n Hz Project Planning Information Overview and functions of the MOVITRANS components with part num- Unit type Unit designation Line cable current Compensation box TCS10A-E TCS10A -E TCS10A -E A 60 A or 85 A 60 A or 85 A Installation plate TIS10A025-V00-0 Description of functions Stationary connection components, to connect MF cables, capacitive reactance at 25 khz = 7.1 ohm flange plate 4 x M25 / 4 x M25 Stationary connection components, to connect MF cables, capacitive reactance at 25 khz = 5.3 ohm flange plate 4 x M25 / 4 x M25 Stationary connection components, to connect MF cables, capacitive reactance at 25 khz = 5.3 ohm flange plate 2 x M32 / 2 x M32 installation plate with cover and 6 rubber studs, for flat pick-ups, cable cross section 25 mm 2 Part number In preparation The following table gives an overview of the MOVITRANS installation equipment for the installation in the profile section system: Unit type Unit designation Line cable current Line cable TLS10E A (60 A for double installation) Supply cable TLS10E A Compensation box Connection distributor TCS10A-E TVS10A-E A 60 A Description of functions Conductor loop for U-shaped pick-ups, MF litz wires, installation in TIS10A-008 profile sections, Cable cross section 8 mm 2 Outer diameter 8.6 mm, reduced transmission power Power supply cable from supply cabinet to energy transmission line, fine litz wires, Routing in cable duct, Cable cross section mm 2, Outer diameter 20.5 mm, Stationary connection components, to connect MF cables, capacitive reactance at 25 khz = 7.1 ohm flange plate 4 x M25 / 4 x M25 Stationary connection components (wiring box), to connect MF cables, flange plate 2 x M32 / 4 x M25 Part number Manual MOVITRANS Project Planning

89 Project Planning Information Overview and functions of the MOVITRANS components with part num- kva i P f n Hz 9 Unit type Unit designation Packaging unit Fixture Profile section Cable opening: Retaining plate Universal retaining plate TIS10A008-H00-0 TIS10A008-H01-0 TIS10A008-H02-0 TIS10A008-P33-0 TIS10A008-P74-0 TIS10A008-F33-0 TIS10A008-F74-0 TIS10A008-A00-0 TIS10A008-A74-0 TIS10A-008-X00-0 TIS10A008-X01-0 TIS10A008-X02-0 TIS10A008-XH2-0 1 item 1 item 1 item 1 item, 3m 1 item, 3m 1 item, 2.2 m 1 item, 2.2 m 1 item 1 item 1 item 1 item 1 item 1 item Description of functions Holding fixture with 2 rotary supports, matching AFT profile 180 for U-shaped pick-ups, MF litz wire, laid in plastic profile, cable cross section 8 mm 2 Holding fixture with 2 rotary supports, matching Cinetic profile 180 for U-shaped pick-ups, MF litz wire, laid in plastic profile, cable cross section 8 mm 2 Holding fixture with 2 rotary supports, matching Dürr profile 180 for U-shaped pick-ups, MF litz wire, laid in plastic profile, cable cross section 8 mm 2 Rigid profile section, installation dimension 33 mm, 3 m long for U-shaped pick-ups, MF litz wire, laid in plastic profile, cable cross section 8 mm 2 Rigid profile section, installation dimension 74 mm, 3 m long for U-shaped pick-ups, MF litz wire, laid in plastic profile, cable cross section 8 mm 2 Flexible profile section, installation dimension 33 mm, 2.2 m long for U-shaped pick-ups, MF litz wire, laid in plastic profile, cable cross section 8 mm 2 Flexible profile section, installation dimension 74 mm, 2.2 m long for U-shaped pick-ups, MF litz wire, laid in plastic profile, cable cross section 8 mm 2 Cable bushing grommet, for U-shaped pick-ups, MF litz wire, laid in plastic profile, Cable cross section 8 mm 2 Cable entry frame for U-shaped pick-ups, MF litz wire, laid in plastic profile, cable cross section 8 mm 2 retaining plate with 2 M6x25 socket head screws, matching AFT profile 180 for mounting the TVS connection distributor and the TCS compensation box retaining plate with 2 M6x25 socket head screws, matching Cinetic profile 180 for mounting the TVS connection distributor and the TCS compensation box retaining plate with 2 M6x25 socket head screws, matching Dürr profile 180 for mounting the TVS connection distributor and the TCS compensation box Universal retaining plate for mounting the TIS10A008- H02-0 holding fixture Part number Manual MOVITRANS Project Planning 89

90 9 kva i P f n Hz Project Planning Information Dimension sheets for the MOVITRANS components 9.2 Dimension sheets for the MOVITRANS components Stationary components TPS10A040 stationary converter size 2 The following figure shows the dimension sheet of the TPS10A040 stationary converter size 2, dimensions in mm: Manual MOVITRANS Project Planning

91 Project Planning Information Dimension sheets for the MOVITRANS components kva i P f n Hz 9 TPS10A160 stationary converter size 4 The following figure shows the dimension sheet of the TPS10A160 stationary converter size 4, dimensions in mm: TAS10A040 transformer module size 2 The following figure shows the dimension sheet of the TPS10A040 transformer module size 2, dimensions in mm: Manual MOVITRANS Project Planning 91

92 9 kva i P f n Hz Project Planning Information Dimension sheets for the MOVITRANS components TAS10A160 transformer module size 4 The following figure shows the dimension sheet of the TPS10A160 transformer module size 4, dimensions in mm: Line filter - 4 kw or 16 kw The following figure shows the dimension sheet of the line filter - 4 kw or 16 kw, dimensions in mm: L B H X Y R Type Part number L max [mm] H max [mm] B max [mm] X [mm] Y [mm] CW [mm] Current [A] NF NF Manual MOVITRANS Project Planning

93 Project Planning Information Dimension sheets for the MOVITRANS components kva i P f n Hz Mobile components THM10E pick-up flat design The following figure shows the dimension sheet of the THM10E pick-up - flat design, dimensions in mm: 425 M8 (4x) Ø Manual MOVITRANS Project Planning 93

94 9 kva i P f n Hz Project Planning Information Dimension sheets for the MOVITRANS components THM10C pick-up - U-shaped design The following figure shows the dimension sheet of THM10C pick-up, dimensions in mm: M6 (4x) 87 ± ± ± ± ± ± ± ± ± TPM12B mobile converter The following figure shows the dimension sheet of the TPM12B mobile converter, dimensions in mm: Ø ca. 175 ca. 71 ca. 106 ca ca. 75 ca. 20 ca Manual MOVITRANS Project Planning

95 Project Planning Information Dimension sheets for the MOVITRANS components kva i P f n Hz Installation equipment TCS10A compensation box The following figure shows the dimension sheet of the TCS10A compensation box, dimensions in mm: TVS10A connection distributor The following figure shows the dimension sheet of the TVS connection distributor, dimensions in mm: Manual MOVITRANS Project Planning 95

96 9 kva i P f n Hz Project Planning Information Dimension sheets for the MOVITRANS components TIS10A025-V00-0 installation plate The following figure shows the dimension sheet of the TIS10A025-V00-0 installation plate, dimensions in mm: Ø 14 Ø The following figure shows the dimension sheet of the cover of the TIS10A025-V00-0 installation plate, dimensions in mm: Manual MOVITRANS Project Planning

97 Project Planning Information Dimension sheets for the MOVITRANS components kva i P f n Hz 9 TIS10A008-X00-0 retaining plate The following figure shows the dimension sheet of the TIS10A008-X00-0 retaining plate (matching the ATF profile 180), dimensions in mm: M6 Ø TIS10A008-X01-0 retaining plate The following figure shows the dimension sheet of the TIS10A008-X01-0 retaining plate (matching the Cinetic profile 180), dimensions in mm: M Ø , Manual MOVITRANS Project Planning 97

98 9 kva i P f n Hz Project Planning Information Dimension sheets for the MOVITRANS components TIS10A008-X02-0 retaining plate The following figure shows the dimension sheet of the TIS10A008-X02-0 retaining plate (matching the Dürr profile 180), dimensions in mm: M Ø TIS10A008-XH2-0 universal retaining plate The following figure shows the dimension sheet of the TIS10A008-XH2-0 universal retaining plate (matching the TIS10A008-H02-0 holding fixture), dimensions in mm: Ø Manual MOVITRANS Project Planning

99 Project Planning Information Dimension sheets for the MOVITRANS components kva i P f n Hz 9 TIS10A008-H00-0 holding fixture The following figure shows the dimension sheet of the TIS10A008-H00-0 holding fixture (matching the ATF profile 180), dimensions in mm: TIS10A008-H01-0 holding fixture The following figure shows the dimension sheet of the TIS10A008-H01-0 holding fixture (matching the Cinetic profile 180), dimensions in mm: TIS10A008-H02-0 holding fixture The following figure shows the dimension sheet of the TIS10A008-H02-0 holding fixture (matching the Dürr profile 180 and the universal retaining plate), dimensions in mm: 153, Manual MOVITRANS Project Planning 99

100 9 kva i P f n Hz Project Planning Information Dimension sheets for the MOVITRANS components TIS10A008-P33-0 profile section The following figure shows the dimension sheet of the TIS10A008-P33-0 profile section, dimensions in mm: TIS10A008-P74-0 profile section The following figure shows the dimension sheet of the TIS10A008-P74-0 profile section, dimensions in mm: TIS10A008-F33-0 profile section The following figure shows the dimension sheet of the TIS10A008-F33-0 profile section, dimensions in mm: x Manual MOVITRANS Project Planning

101 Project Planning Information Dimension sheets for the MOVITRANS components kva i P f n Hz 9 TIS10A008-F74-0 profile section The following figure shows the dimension sheet of the TIS10A008-F74-0 profile section, dimensions in mm: x TIS10A008-A00-0 cable bushing grommet The following figure shows the dimension sheet of the TIS10A008-A00-0 cable bushing grommet, dimensions in mm: Ø Ø9.5 Ø Manual MOVITRANS Project Planning 101

102 9 kva i P f n Hz Project Planning Information Dimension sheets for the MOVITRANS components TIS10A008-A74-0 cable bushing frame The following figure shows the dimension sheet of the TIS10A008-A74-0 cable bushing frame, dimensions in mm: Ø Ø Shielding plate The shielding plate is not included in the scope of delivery. The shielding plate must be made of aluminum. The following figure shows the dimension sheet of the shielding plate dimensions in mm: Ø 10.5 Ø 5.5 R Manual MOVITRANS Project Planning

103 Project Planning Information System-related power reduction of the MOVITRANS components kva i P f n Hz System-related power reduction of the MOVITRANS components TAS transformer module The power losses of the TAS transformer module basically depend on whether there is a 4 kw or 16 kw supply: TAS10A transformer module TAS10A040- TAS10A160- N06-4X1-1 N08-4X1-1 N06-4X1-1 N08-4X1-1 Power loss P V for P N 50 W 200 W THM pick-ups The power losses of the THM pick-ups basically depend on the design and the line cable current: THM10E pick-ups THM10E THM10C Max. power loss P V 60 W 60 W 25 W UL approval No Yes Yes TLS line/supply cables The electrical and mechanical characteristics of the TLS line cables and the TLS supply cables affect the system performance. Ohmic losses Both the transmission line and the track power supply must be taken into account to determine the ohmic losses in the line cable. Determine the ohmic losses in the TLS line cable depending on the line cable current and the cable type in accordance with the following table: Cable designation cross section [mm 2 ] The specified values refer to the track lengths; that is, 1 m track = 2 m line cable Line cable current [A] Power loss [W/track meter] TLS10E (2 x 8) TLS10E TLS10E TLS10E TLS10E x 3 x losses due to eddy currents The following inductive losses occur when routing the TLS line cables close to reinforcing irons: Distance between line cable and reinforcing iron [cm] 60 A system [W/track meter] 85 A system [W/track meter] Manual MOVITRANS Project Planning 103

104 9 kva i P f n Hz Project Planning Information Selection tables for MOVITRANS TCS compensation boxes Bending radius The cable cross sections and bending radii of the TLS line/supply cables must also be taken into account: Cable designation cross section [mm 2 ] Outer diameter [mm] Bending radius [mm] TLS10E TLS10E TLS10E TLS10E TLS10E x 3 x TPM mobile converter The power losses of the TPM mobile converter basically depend on the number of connected THM pick-ups and the status of Enable 500 V: TPM12B mobile converter 030-ENE-5A ENC- 5A ENC- 5A2-2 Current in line cable I 1 AC 60 A AC 85 A AC 60 A AC 60 A (at input frequency f I = 25 khz) Input frequency f E 25 khz Pick-up power rating 1) P W 1500 W 800 W 800 W Number of connected pick-ups Design of pick-up flat U-shaped Rated output power 2) Output power P 24V of the DC 24 V supply Power loss (X11:B5 has "1" signal) Power loss (X11:B5 has "0" signal) P N P V P V 1) Measured at TPM12B output 2) The power ratings of the connected pick-ups are decisive for the rated output power. 1.9 kw 0.95 kw 3.0 kw 1.5 kw 1.6 kw 0.8 kw 3.2 kw 1.6 kw 24 W 12 W 48 W 24 W 24 W 12 W 48 W 24 W 60 W 30 W 120 W 60 W 60 W 30 W 120 W 60 W 12 W 6 W 15 W 8 W 10 W 5 W 15 W 8 W 9.4 Selection tables for MOVITRANS TCS compensation boxes The table contents highlighted grey represent the track lengths that are usually connected to the corresponding supply. The contents that are not highlighted represent track lengths, that may lead to significant power losses on the mobile component in conjunction with the corresponding supply. 104 Manual MOVITRANS Project Planning

105 Project Planning Information Selection tables for MOVITRANS TCS compensation boxes kva i P f n Hz Number for floor routing (60 A) The following table is used to determine the number of TCS10A-E compensation boxes for routing the TLS line cable in the floor for 60 A: Track length l [m] Number Compensation boxes Floor routing (60 A) 4 kw power supply 16 kw power supply XL [Ω] to compensate in TAS Recommendation for start up / installation in TAS Number Compensation boxes XL [Ω] to compensate in TAS Recommendation for start up / installation in TAS x16µF x4µF x4µF; 1x8µF; 1x16µF x32µF x2µF; 1x16µF; 1x32µF x2µF; 1x4µF; 1x32µF x8µF; 1x16µF; 1x32µF x4µF; 1x8µF; 1x32µF x2µF x2µF; 1x16µF; 1x32µF x16µF x2µF; 1x4µF; 1x32µF x4µF x2µF; 1x4µF; 1x8µF; 1x16µF x4µF; 1x8µF; 1x16µF x32µF x2µF; 1x16µF; 1x32µF x8µF; 1x16µF; 1x32µF x 2 µf x2µF; 1x16µF; 1x32µF x 4 µf x2µF; 1x4µF; 1x8µF; 1x16µF x 2 µf; 1 x 16 µf; 1x32µF x8µF; 1x16µF; 1x32µF x 2 µf x2µF; 1x16µF; 1x32µF x 4 µf x2µF; 1x4µF; 1x8µF; 1x16µF x8µF; 1x16µF; 1x32µF x2µF; 1x16µF; 1x32µF x2µF; 1x4µF; 1x8µF; 1x16µF x8µF; 1x16µF; 1x32µF x2µF; 1x16µF; 1x32µF x2µF; 1x4µF; 1x8µF; 1x16µF x8µF; 1x16µF; 1x32µF x2µF; 1x16µF; 1x32µF x2µF; 1x4µF; 1x8µF; 1x16µF x8µF; 1x16µF; 1x32µF Manual MOVITRANS Project Planning 105

106 9 kva i P f n Hz Project Planning Information Selection tables for MOVITRANS TCS compensation boxes Number for floor routing (85 A) The following table is used to determine the number of TCS10A-E compensation boxes for routing the TLS line cable in the floor for 85 A: Track length l [m] Number Compensation boxes Floor routing (85 A) 4 kw power supply 16 kw power supply XL [Ω] to compensate in TAS Recommendation for start up / installation in TAS Number Compensation boxes XL [Ω] to compensate in TAS Recommendation for start up / installation in TAS x8µF x4µF; 1x16µF x8µF x2µF x4µF; 1x32µF x2µF; 1x8µF; 1x32µF x2µF; 1x4µF; 1x8µF x8µF; 1x16µF; 1x32µF x4µF; 1x8µF; 1x32µF x4µF; 1x8µF; 1x16µF; 1x32µF x2µF; 1x8µF; 1x32µF x2µF; 1x4µF; 1x16µF; 1x32µF x8µF; 1x16µF x2µF; 1x16µF x4µF; 1x8µF x2µF; 1x4µF x2µF; 1x16µF x 8 µf x2µF; 1x4µF x 2 µf x4µF; 1x32µF x2µF; 1x4µF; 1x8µF x4µF; 1x8µF; 1x32µF x2µF; 1x8µF; 1x32µF x8µF; 1x16µF; 1x32µF x2µF; 1x4µF x2µF; 1x16µF x 4 µf; 1 x 16 µf x8µF x4µF; 1x8µF; 1x16µF; 1x32µF x2µF; 1x4µF; 1x16µF; 1x32µF x4µF; 1x8µF x2µF; 1x4µF x4µF; 1x32µF x 2 µf; 1 x 8 µf; 1x32µF x 8 µf; 1 x 16 µf; 1x32µF x 2 µf; 1 x 16 µf x 8 µf x 4 µf; 1 x 8 µf; 1x16µF; 1x32µF 106 Manual MOVITRANS Project Planning

107 Project Planning Information Selection tables for MOVITRANS TCS compensation boxes kva i P f n Hz Number for routing in the profile section (60 A) The following table is used to determine the number of TCS compensation boxes for routing the TLS line cable in the profile section system for 60 A: Track length l [m] Number Compensation boxes Routing in the profile section system (60 A) 4 kw power supply 16 kw power supply XL [Ω] to compensate in TAS Recommendation for start up / installation in TAS Number Compensation boxes XL [Ω] to compensate in TAS Recommendation for start up / installation in TAS x16µF; 1x32µF x8µF; 1x16µF; 0 0-1x32µF x4µF; 1x16µF x4µF; 1x8µF; x16µF 1x16µF x2µF; 1x16µF 0 1 1x8µF; 1x32µF x2µF; 1x8µF; x4µF; 1x32µF 1x32µF x2µF; 1x4µF; x4µF; 1x8µF 1x32µF x2µF; 1x4µF; x2µF 1x8µF x2µF x2µF; 1x8µF x8µF x2µF; 1x4µF; 1x16µF x4µF; 1x16µF; x2µF; 1x16µF 1x32µF x2µF; 1x16µF; 1x32µF x8µF; 1x16µF x2µF; 1x4µF; 1x16µF x4µF; 1x8µF; 1x32µF x 2 µf; 1 x 32 µf x2µF; 1x8µF; 1x32µF x 8 µf; 1 x 32 µf x2µF; 1x4µF; 1x8µF x4µF; 1x8µF 1 7 2x2µF; 1x16µF; 1x32µF x2µF; 1x8µF x8µF; 1x16µF; 1x32µF x2µF; 1x4µF; 1x16µF x4µF; 1x8µF; 1x16µF x 2 µf; 1 x 16 µf x2µF; 1x8µF; 1x16µF x2µF; 1x4µF; 1x8µF; 1x32µF x32µF x4µF x4µF; 1x8µF; 1x16µF; 1x32µF x2µF; 1x8µF; 1x16µF; 1x32µF Manual MOVITRANS Project Planning 107

108 10 Service Maintenance 10 Service 10.1 Maintenance Introduction The MOVITRANS system for contactless energy transfer by SEW-EURODRIVE is a maintenance-free system. Nevertheless, we recommend that you perform preventive checks at regular intervals. The following components are subject to certain change and should be checked regularly - for example, once a year: Compensation The MOVITRANS TLS line cables in the system are compensated using capacitors. The capacity of these capacitors changes slightly depending on the length of service life. Hence, after a while, the track compensation is no longer optimal, which may, among other things, result in an increased energy consumption. Therefore, you should check the compensation at regular intervals. The SHELL TPS startup software can be used to check and optimize the current settings Line cable connections A constant current (60 A or 85 A) flows through the MOVITRANS TLS line cable. If screw connections at the connection points become loose over time, this can cause increased contact resistances. These resistances in turn cause power losses and excessive heating. Therefore, you should check the screw connections at the connection points at regular intervals. These checks can also be performed during operation using IR temperature measurements. A value of T < 80 C is correct Equipotential bonding Equipotential bonding between the electrical components on the vehicles in the system can be removed by vibrations. Vibrations can be caused by movement of the vehicles, for example. Therefore, you should check the equipotential bonding at regular intervals. Checking the equipotential bonding maintains the protective measures for the vehicles ESD protection Protection against electromagnetic discharge can be performed in a number of different ways. The variants (copper band, brushes, etc.) are subject to different levels of mechanical wear depending on the design. To ensure protection against electrostatic build-up in the long-term, you must check the status of the ESD protection regularly. If mechanical wear is detected, the ESD protection must be changed immediately. 108 Manual MOVITRANS Project Planning

109 Service Electronics Service Electronics Service Repair Please contact the SEW-EURODRIVE Electronics Service in Bruchsal if a malfunction cannot be rectified. When contacting the Electronics Service, please always quote the digits of the service code ( service label). Please provide the following information when sending the unit in for repair: Serial number ( nameplate) Unit designation Service code ( service label) Brief description of the application Connected load (gyrator impedance) Nature of the error Accompanying circumstances Your own presumptions as to what has happened Any unusual events preceding the problem, etc. Manual MOVITRANS Project Planning 109

110 11 Questionnaire - Project Planning for MOVITRANS Administrative information 11 Questionnaire - Project Planning for MOVITRANS In order to be properly prepared for the project planning for the MOVITRANS system components, please fill out the following questionnaire and, if in doubt, send it to the responsible contact person at the SEW in Bruchsal Administrative information Contact Enter the most important project planning information and contact persons: Project name:... Place, date:... Customer (OEM):... Contact person (OEM):... Phone/fax: Street:... Zip code/city:... Country:... End customer (system operator):... Contact person (system operator):... Phone/fax: Street:... Zip code/city:... Country: Manual MOVITRANS Project Planning

111 Questionnaire - Project Planning for MOVITRANS Project planning for the mobile energy supply - vehicle Application Describe the planned application in a separate short description. Sketch the planned track layout with length dimensions in a drawing Project planning for the mobile energy supply - vehicle General information Prepare information on the project planning for vehicles and consumers: Number of drives:... Drive power:... kw Determine the time required for the individual movements. On the basis of this data, create the movement profile: Max. power consumption:... kw Consumers Determine the consumers at the DC 500 V level: Motor: With SEW inverter With non-sew inverter DC/DC converter: Yes, power: 500 V /... V /... VA No Other - brief description:... with... VA Manual MOVITRANS Project Planning 111

112 11 Questionnaire - Project Planning for MOVITRANS Project planning for the stationary energy supply - power supply and track Determine the design of the DC 24 V level: Sensors:... A Control:... A Motor brake:... A Other - brief description:... with... VA 11.3 Project planning for the stationary energy supply - power supply and track General information Enter information on the project planning for the power supply and track: Track length:... m Number of track sections (e.g. emergency stop areas):... Number of mobile consumers per track section:... Demand factor of the vehicles: Ambient conditions Describe the ambient conditions and the location: Mechanical tolerances (line cable pick-up):... mm Ferromagnetic materials near the line cable (< 8 cm): Yes No Distance:... mm Ambient temperature: ranging from... C to... C Explosion-proof area: Yes No 112 Manual MOVITRANS Project Planning

113 Questionnaire - Project Planning for MOVITRANS Project planning for the stationary energy supply - power supply and track 11 Chemical influence: Yes No Brief description:... Location: Interior system Exterior system Line cable Enter information on the line cable routing: Line cable routing: In the floor In a guide profile Other - brief description:... Manual MOVITRANS Project Planning 113

114 12 Address List Project planning for the stationary energy supply - power supply and track 12 Address List Germany Headquarters Production Sales Service Competence Center Bruchsal Central North East South West SEW-EURODRIVE GmbH & Co KG Ernst-Blickle-Straße 42 D Bruchsal P.O. Box Postfach 3023 D Bruchsal SEW-EURODRIVE GmbH & Co KG Ernst-Blickle-Straße 1 D Graben-Neudorf SEW-EURODRIVE GmbH & Co KG Alte Ricklinger Straße D Garbsen (near Hannover) SEW-EURODRIVE GmbH & Co KG Dänkritzer Weg 1 D Meerane (near Zwickau) SEW-EURODRIVE GmbH & Co KG Domagkstraße 5 D Kirchheim (near München) SEW-EURODRIVE GmbH & Co KG Siemensstraße 1 D Langenfeld (near Düsseldorf) Electronics SEW-EURODRIVE GmbH & Co KG Ernst-Blickle-Straße 42 D Bruchsal Drive Service Hotline / 24 Hour Service Additional addresses for service in Germany provided on request! Tel Fax sew@sew-eurodrive.de Tel Fax sc-mitte@sew-eurodrive.de Tel Fax sc-nord@sew-eurodrive.de Tel Fax sc-ost@sew-eurodrive.de Tel Fax sc-sued@sew-eurodrive.de Tel Fax sc-west@sew-eurodrive.de Tel Fax sc-elektronik@sew-eurodrive.de SEWHELP France Production Sales Service Haguenau SEW-USOCOME 48-54, route de Soufflenheim B. P F Haguenau Cedex Production Forbach SEW-EUROCOME Zone Industrielle Technopôle Forbach Sud B. P F Forbach Cedex Assembly Sales Service Bordeaux Lyon Paris SEW-USOCOME Parc d'activités de Magellan 62, avenue de Magellan - B. P. 182 F Pessac Cedex SEW-USOCOME Parc d'affaires Roosevelt Rue Jacques Tati F Vaulx en Velin SEW-USOCOME Zone industrielle 2, rue Denis Papin F Verneuil I'Etang Additional addresses for service in France provided on request! Tel Fax sew@usocome.com Tel Tel Fax Tel Fax Tel Fax Manual MOVITRANS Project Planning

115 Address List Project planning for the stationary energy supply - power supply and track 12 Algeria Sales Alger Réducom 16, rue des Frères Zaghnoun Bellevue El-Harrach Alger Tel Fax reducom_sew@yahoo.fr Argentina Assembly Sales Service Buenos Aires SEW EURODRIVE ARGENTINA S.A. Centro Industrial Garin, Lote 35 Ruta Panamericana Km 37, Garin Tel Fax sewar@sew-eurodrive.com.ar Australia Assembly Sales Service Melbourne SEW-EURODRIVE PTY. LTD. 27 Beverage Drive Tullamarine, Victoria 3043 Tel Fax enquires@sew-eurodrive.com.au Sydney SEW-EURODRIVE PTY. LTD. 9, Sleigh Place, Wetherill Park New South Wales, 2164 Tel Fax enquires@sew-eurodrive.com.au Townsville SEW-EURODRIVE PTY. LTD. 12 Leyland Street Garbutt, QLD 4814 Tel Fax enquires@sew-eurodrive.com.au Austria Assembly Sales Service Wien SEW-EURODRIVE Ges.m.b.H. Richard-Strauss-Strasse 24 A-1230 Wien Tel Fax sew@sew-eurodrive.at Belarus Sales Minsk SEW-EURODRIVE BY RybalkoStr. 26 BY Minsk Tel.+375 (17) Fax +375 (17) sales@sew.by Belgium Assembly Sales Service Brüssel SEW Caron-Vector S.A. Avenue Eiffel 5 B-1300 Wavre Tel Fax info@caron-vector.be Brazil Production Sales Service Sao Paulo SEW-EURODRIVE Brasil Ltda. Avenida Amâncio Gaiolli, 50 Caixa Postal: Guarulhos/SP - Cep.: Additional addresses for service in Brazil provided on request! Tel Fax sew@sew.com.br Bulgaria Sales Sofia BEVER-DRIVE GmbH Bogdanovetz Str.1 BG-1606 Sofia Cameroon Sales Douala Electro-Services Rue Drouot Akwa B.P Douala Tel Fax bever@fastbg.net Tel Fax Manual MOVITRANS Project Planning 115

116 12 Address List Project planning for the stationary energy supply - power supply and track Canada Assembly Sales Service Toronto Vancouver SEW-EURODRIVE CO. OF CANADA LTD. 210 Walker Drive Bramalea, Ontario L6T3W1 SEW-EURODRIVE CO. OF CANADA LTD Honeyman Street Delta. B.C. V4G 1 E2 Montreal SEW-EURODRIVE CO. OF CANADA LTD Rue Leger LaSalle, Quebec H8N 2V9 Additional addresses for service in Canada provided on request! Tel Fax marketing@sew-eurodrive.ca Tel Fax marketing@sew-eurodrive.ca Tel Fax marketing@sew-eurodrive.ca Chile Assembly Sales Service Santiago de Chile SEW-EURODRIVE CHILE LTDA. Las Encinas 1295 Parque Industrial Valle Grande LAMPA RCH-Santiago de Chile P.O. Box Casilla 23 Correo Quilicura - Santiago - Chile Tel Fax ventas@sew-eurodrive.cl China Production Assembly Sales Service Assembly Sales Service Tianjin Suzhou Guangzhou Shenyang SEW-EURODRIVE (Tianjin) Co., Ltd. No. 46, 7th Avenue, TEDA Tianjin SEW-EURODRIVE (Suzhou) Co., Ltd. 333, Suhong Middle Road Suzhou Industrial Park Jiangsu Province, P. R. China SEW-EURODRIVE (Guangzhou) Co., Ltd. No. 9, JunDa Road East Section of GETDD Guangzhou P. R. China SEW-EURODRIVE (Shenyang) Co., Ltd. 10A-2, 6th Road Shenyang Economic Technological Development Area Shenyang, P. R. China Additional addresses for service in China provided on request! Tel Fax info@sew-eurodrive.cn Tel Fax suzhou@sew-eurodrive.cn Tel Fax guangzhou@sew-eurodrive.cn Tel Fax shenyang@sew-eurodrive.cn Colombia Assembly Sales Service Bogotá SEW-EURODRIVE COLOMBIA LTDA. Calle 22 No Bodega 6, Manzana B Santafé de Bogotá Tel Fax sewcol@sew-eurodrive.com.co Croatia Sales Service Zagreb KOMPEKS d. o. o. PIT Erdödy 4 II HR Zagreb Tel Fax kompeks@net.hr 116 Manual MOVITRANS Project Planning

117 Address List Project planning for the stationary energy supply - power supply and track 12 Czech Republic Sales Praha SEW-EURODRIVE CZ S.R.O. Business Centrum Praha Lužná 591 CZ Praha 6 - Vokovice Tel Fax sew@sew-eurodrive.cz Denmark Assembly Sales Service Kopenhagen SEW-EURODRIVEA/S Geminivej DK-2670 Greve Tel Fax sew@sew-eurodrive.dk Egypt Sales Service Cairo Copam Egypt for Engineering & Agencies 33 EI Hegaz ST, Heliopolis, Cairo Tel Fax copam@datum.com.eg Estonia Sales Tallin ALAS-KUUL AS Reti tee 4 EE Peetri küla, Rae vald, Harjumaa Tel Fax veiko.soots@alas-kuul.ee Finland Assembly Sales Service Lahti SEW-EURODRIVE OY Vesimäentie 4 FIN Hollola 2 Tel Fax sew@sew.fi Gabon Sales Libreville Electro-Services B.P Libreville Tel Fax Great Britain Assembly Sales Service Normanton SEW-EURODRIVE Ltd. Beckbridge Industrial Estate P.O. Box No.1 GB-Normanton, West- Yorkshire WF6 1QR Tel Fax info@sew-eurodrive.co.uk Greece Sales Service Athen Christ. Boznos & Son S.A. 12, Mavromichali Street P.O. Box 80136, GR Piraeus Tel Fax info@boznos.gr Hong Kong Assembly Sales Service Hong Kong SEW-EURODRIVE LTD. Unit No , 8th Floor Hong Leong Industrial Complex No. 4, Wang Kwong Road Kowloon, Hong Kong Tel Fax contact@sew-eurodrive.hk Hungary Sales Service Budapest SEW-EURODRIVE Kft. H-1037 Budapest Kunigunda u. 18 Tel Fax office@sew-eurodrive.hu Manual MOVITRANS Project Planning 117

118 12 Address List Project planning for the stationary energy supply - power supply and track India Assembly Sales Service Baroda SEW-EURODRIVE India Pvt. Ltd. Plot No. 4, Gidc Por Ramangamdi Baroda Gujarat Tel Fax mdoffice@seweurodriveindia.com Ireland Sales Service Dublin Alperton Engineering Ltd. 48 Moyle Road Dublin Industrial Estate Glasnevin, Dublin 11 Tel Fax info@alperton.ie Israel Sales Tel-Aviv Liraz Handasa Ltd. Ahofer Str 34B / Holon Tel Fax office@liraz-handasa.co.il Italy Assembly Sales Service Milano SEW-EURODRIVE di R. Blickle & Co.s.a.s. Via Bernini,14 I Solaro (Milano) Tel Fax sewit@sew-eurodrive.it Ivory Coast Sales Abidjan SICA Ste industrielle et commerciale pour l'afrique 165, Bld de Marseille B.P. 2323, Abidjan 08 Tel Fax Japan Assembly Sales Service Iwata SEW-EURODRIVE JAPAN CO., LTD 250-1, Shimoman-no, Iwata Shizuoka Tel Fax sewjapan@sew-eurodrive.co.jp Korea Assembly Sales Service Ansan-City SEW-EURODRIVE KOREA CO., LTD. B 601-4, Banweol Industrial Estate , Shingil-Dong Ansan Tel Fax master@sew-korea.co.kr Busan SEW-EURODRIVE KOREA Co., Ltd. No , Songjeong - dong Gangseo-ku Busan Tel Fax master@sew-korea.co.kr Latvia Sales Riga SIA Alas-Kuul Katlakalna 11C LV-1073 Riga Lebanon Sales Beirut Gabriel Acar & Fils sarl B. P Bourj Hammoud, Beirut Tel Fax info@alas-kuul.com Tel Fax gacar@beirut.com 118 Manual MOVITRANS Project Planning

119 Address List Project planning for the stationary energy supply - power supply and track 12 Lithuania Sales Alytus UAB Irseva Naujoji 19 LT Alytus Tel Fax info@irseva.lt Luxembourg Assembly Sales Service Brüssel CARON-VECTOR S.A. Avenue Eiffel 5 B-1300 Wavre Tel Fax info@caron-vector.be Malaysia Assembly Sales Service Johore SEW-EURODRIVE SDN BHD No. 95, Jalan Seroja 39, Taman Johor Jaya Johor Bahru, Johor West Malaysia Tel Fax sales@sew-eurodrive.com.my Mexico Assembly Sales Service Queretaro SEW-EURODRIVE MEXIKO SA DE CV SEM M93 Tequisquiapan No. 102 Parque Industrial Queretaro C.P Queretaro, Mexico Tel Fax scmexico@seweurodrive.com.mx Morocco Sales Casablanca Afit 5, rue Emir Abdelkader MA Casablanca Tel Fax ali.alami@premium.net.ma Netherlands Assembly Sales Service Rotterdam VECTOR Aandrijftechniek B.V. Industrieweg 175 NL-3044 AS Rotterdam Postbus NL-3004 AB Rotterdam Tel Fax info@vector.nu New Zealand Assembly Sales Service Auckland SEW-EURODRIVE NEW ZEALAND LTD. P.O. Box Greenmount drive East Tamaki Auckland Tel Fax sales@sew-eurodrive.co.nz Christchurch SEW-EURODRIVE NEW ZEALAND LTD. 10 Settlers Crescent, Ferrymead Christchurch Tel Fax sales@sew-eurodrive.co.nz Norway Assembly Sales Service Moss SEW-EURODRIVE A/S Solgaard skog 71 N-1599 Moss Tel Fax sew@sew-eurodrive.no Peru Assembly Sales Service Lima SEW DEL PERU MOTORES REDUCTORES S.A.C. Los Calderos, Urbanizacion Industrial Vulcano, ATE, Lima Tel Fax sewperu@sew-eurodrive.com.pe Manual MOVITRANS Project Planning 119

120 12 Address List Project planning for the stationary energy supply - power supply and track Poland Assembly Sales Service Lodz SEW-EURODRIVE Polska Sp.z.o.o. ul. Techniczna 5 PL Łódź Tel Fax sew@sew-eurodrive.pl Portugal Assembly Sales Service Coimbra SEW-EURODRIVE, LDA. Apartado 15 P Mealhada Tel Fax infosew@sew-eurodrive.pt Romania Sales Service Bucureşti Sialco Trading SRL str. Madrid nr Bucuresti Tel Fax sialco@sialco.ro Russia Assembly Sales Service St. Petersburg ZAO SEW-EURODRIVE P.O. Box St. Petersburg Russia Tel Fax sew@sew-eurodrive.ru Senegal Sales Dakar SENEMECA Mécanique Générale Km 8, Route de Rufisque B.P. 3251, Dakar Serbia Sales Beograd DIPAR d.o.o. Ustanicka 128a PC Košum, IV floor SCG Beograd Tel Fax senemeca@sentoo.sn Tel / Fax dipar@yubc.net Singapore Assembly Sales Service Singapore SEW-EURODRIVE PTE. LTD. No 9, Tuas Drive 2 Jurong Industrial Estate Singapore Tel Fax sewsingapore@sew-eurodrive.com Slovakia Sales Bratislava SEW-Eurodrive SK s.r.o. Rybničná 40 SK Bratislava Žilina Banská Bystrica SEW-Eurodrive SK s.r.o. ul. Vojtecha Spanyola 33 SK Žilina SEW-Eurodrive SK s.r.o. Rudlovská cesta 85 SK Banská Bystrica Tel Fax sew@sew-eurodrive.sk Tel Fax sew@sew-eurodrive.sk Tel Fax sew@sew-eurodrive.sk Slovenia Sales Service Celje Pakman - Pogonska Tehnika d.o.o. UI. XIV. divizije 14 SLO Celje Tel Fax pakman@siol.net 120 Manual MOVITRANS Project Planning

121 Address List Project planning for the stationary energy supply - power supply and track 12 South Africa Assembly Sales Service Johannesburg SEW-EURODRIVE (PROPRIETARY) LIMITED Eurodrive House Cnr. Adcock Ingram and Aerodrome Roads Aeroton Ext. 2 Johannesburg 2013 P.O.Box Bertsham 2013 Tel Fax dross@sew.co.za Capetown SEW-EURODRIVE (PROPRIETARY) LIMITED Rainbow Park Cnr. Racecourse & Omuramba Road Montague Gardens Cape Town P.O.Box Chempet 7442 Cape Town Tel Fax Telex dswanepoel@sew.co.za Durban SEW-EURODRIVE (PROPRIETARY) LIMITED 2 Monaceo Place Pinetown Durban P.O. Box 10433, Ashwood 3605 Tel Fax dtait@sew.co.za Spain Assembly Sales Service Bilbao SEW-EURODRIVE ESPAÑA, S.L. Parque Tecnológico, Edificio, 302 E Zamudio (Vizcaya) Tel Fax sew.spain@sew-eurodrive.es Sweden Assembly Sales Service Jönköping SEW-EURODRIVE AB Gnejsvägen 6-8 S Jönköping Box 3100 S Jönköping Tel Fax info@sew-eurodrive.se Switzerland Assembly Sales Service Basel Alfred lmhof A.G. Jurastrasse 10 CH-4142 Münchenstein bei Basel Tel Fax info@imhof-sew.ch Thailand Assembly Sales Service Chonburi SEW-EURODRIVE (Thailand) Ltd. 700/456, Moo.7, Donhuaroh Muang Chonburi Tel Fax sewthailand@sew-eurodrive.com Tunisia Sales Tunis T. M.S. Technic Marketing Service 5, Rue El Houdaibiah 1000 Tunis Tel Fax tms@tms.com.tn Turkey Assembly Sales Service Istanbul SEW-EURODRIVE Hareket Sistemleri San. ve Tic. Ltd. Sti. Bagdat Cad. Koruma Cikmazi No. 3 TR Maltepe ISTANBUL Tel / /15 Fax sew@sew-eurodrive.com.tr Manual MOVITRANS Project Planning 121

122 12 Address List Project planning for the stationary energy supply - power supply and track Ukraine Sales Service Dnepropetrovsk SEW-EURODRIVE Str. Rabochaja 23-B, Office Dnepropetrovsk Tel Fax sew@sew-eurodrive.ua USA Production Assembly Sales Service Assembly Sales Service Greenville San Francisco Philadelphia/PA Dayton SEW-EURODRIVE INC Old Spartanburg Highway P.O. Box 518 Lyman, S.C SEW-EURODRIVE INC San Antonio St. Hayward, California SEW-EURODRIVE INC. Pureland Ind. Complex 2107 High Hill Road, P.O. Box 481 Bridgeport, New Jersey SEW-EURODRIVE INC West Main Street Troy, Ohio Dallas SEW-EURODRIVE INC Platinum Way Dallas, Texas Additional addresses for service in the USA provided on request! Tel Fax Sales Fax Manuf Fax Ass Telex cslyman@seweurodrive.com Tel Fax cshayward@seweurodrive.com Tel Fax csbridgeport@seweurodrive.com Tel Fax cstroy@seweurodrive.com Tel Fax csdallas@seweurodrive.com Venezuela Assembly Sales Service Valencia SEW-EURODRIVE Venezuela S.A. Av. Norte Sur No. 3, Galpon Zona Industrial Municipal Norte Valencia, Estado Carabobo Tel Fax ventas@sew-eurodrive.com.ve sewfinanzas@cantv.net 122 Manual MOVITRANS Project Planning

123 Index Index B Bending radius TLS line cable TLS supply cable Brakes AC 230 V...79 AC 400 V...79 BMG BMG BMG BMG DC 24 V...78 Selection...77 Applications...23 Decentralized drive control...23 Drive configuration...22 Electronics...23 Motors and Brakes...23 E Electronics Service Energy supply Wiring...34 Equipotential bonding ESD protection Exclusion of liability...5 C CE marking...13 Compensation Layout...48 Position...47 Components mobile components...12 stationary components...11 Connection Supply...82 Connection distributor...34 D Dimension sheet Line filter...92 shielding plate TAS10A040 transformer module (size 2)...91 TAS10A160 transformer module (size 4)...92 TCS10A compensation box...95 THM10C pick-up...94 THM10E pick-up...93 TIS...-A..-0 cable bushing grommet...101, 102 TIS...-F..-0 profile section...100, 101 TIS...-H..-0 holding fixture...99 TIS...-P..-0 profile section TIS...-V..-0 installation plate...96 TIS...-X..-0 retaining plate...97, 98 TPM10E mobile converter...94 TPS10A040 stationary converter (size 2)...90 TPS10A160 stationary converter (size 4)...91 TVS10A connection distributor...95 Documentation H Hybrid cable Assignment of the wires...69 Cable cross section...69 Prefabricated...68 I Information Preventive measures...63 Installation Notes...67 L Line cable connections Maintenance Line filter Dimension sheet...92 Losses Ohmic M Maintenance Compensation Equipotential bonding ESD protection Line cable connections Mobile components Number...51, 62 Selection...51, 62 MOVIDRIVE MDX60B/61B Terminal assignment...75 Manual MOVITRANS Project Planning 123

124 Index Wiring diagram...73 MOVIFIT -FC Terminal assignment...73 Wiring diagram...71 MOVIMOT Terminal assignment...71 Wiring diagram...70 MOVITRAC 07A Terminal assignment...77 Wiring diagram...75 MOVITRANS applications...10 areas of application...10 CE marking...13 definition...9 Einsatzgebiete...9 energy transfer...11 functional characteristics...9 Funktionsprinzip...11 mobile components...12 requirements...9 stationary components...11 system benefits...9 system overview...11 UL approval...13 O Ohmic losses TLS line cable TLS supply cable P Power reduction Control calculation...50 TAS transformer module THM pick-up TLS line cable TLS supply cable TPM mobile converter Power supplies DC 24 V...84 Project Planning Aspects...24, 25 Prerequisites...24, 25 Project planning Emergency stop circuits...37 Energy supply...37 Flow diagram...26 Incorrect compensation...39 Power reduction...39 Power reduction mobile component...38 Power supply...37 Procedure...27, 30, 37 Project planning steps...26 System...38 System-related power reduction...38 Track...29 Track sections...37 Track structure...30 Track-dependent reactive power...39 Vehicle structure...28 Vehicles...27 Project planning example Configuration roller conveyor drive...44 Configuration travel drive...43 Current demand DC 24 V level...45 Dimensioning...49 Operating conditions...49 Project planning for compensation...47 Project planning for the power supply...49 Project planning for the track...46 Project planning for the vehicles...43 Resulting vehicle power...45 Selecting frequency inverters...45 Technical data...42 Track structure...46 Vehicle data...42 Vehicle structure...46 Project planning steps Power supply...37 Track...29 Vehicles...27 Projektierung Information...22 Power reduction line cable...38 Q Questionnaire R Repair Rights to claim under limited warranty...5 S Safety instructions...5 Safety notes 124 Manual MOVITRANS Project Planning

125 Index Installation and startup...7 Operation and service...7 Selection tables TCS compensation box Service Repair Shielding plate dimension sheet Stationary components Number...51, 62 Selection...51, 62 Supply Connection variants...82 Influencing factors...82 Project planning...82 System power Control calculation...50 T TAS transformer module Power reduction TAS10A040 transformer module (size 2) Dimension sheet...91 TAS10A160 transformer module (size 4) Dimension sheet...92 TCS compensation box Selection tables TCS10A compensation box Dimension sheet...95 Terminal assignment MOVIDRIVE MDX60B/61B...75 MOVIFIT -FC...73 MOVIMOT...71 MOVITRAC 07A...77 TPM12B mobile converter...68 THM10C pick-up Dimension sheet...94 Power reduction THM10E pick-up Dimension sheet...93 Power reduction TIS...-A..-0 cable bushing grommet dimension sheet...101, 102 TIS...-F..-0 profile section dimension sheet...100, 101 TIS...-H..-0 holding fixture dimension sheet...99 TIS...-P..-0 profile section dimension sheet TIS...-V..-0 installation plate Dimension sheet...96 TIS...-X..-0 retaining plate dimension sheet...97, 98 TLS line cable Bending radius Power reduction TLS line cables Ohmic losses TLS supply cable Bending radius Ohmic losses Power reduction TPM mobile converter Power reduction TPM10E mobile converter Dimension sheet...94 TPM12B mobile converter Terminal assignment...68 Wiring diagram...67 TPS10A040 stationary converter (size 2) Dimension sheet...90 TPS10A160 stationary converter (size 4) Dimension sheet...91 TVS10A connection distributor dimension sheet...95 W Warning instructions...5 Wiring...34 Wiring diagram MOVIDRIVE MDX60B/61B...73 MOVIFIT -FC...71 MOVIMOT...70 MOVITRAC 07A...75 TPM12B mobile converter...67 Manual MOVITRANS Project Planning 125

126

127 SEW-EURODRIVE Driving the world

128 Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services How we re driving the world With people who think fast and develop the future with you. With a worldwide service network that is always close at hand. With drives and controls that automatically improve your productivity. With comprehensive knowledge in virtually every branch of industry today. With uncompromising quality that reduces the cost and complexity of daily operations. SEW-EURODRIVE Driving the world With a global presence that offers responsive and reliable solutions. Anywhere. With innovative technology that solves tomorrow s problems today. With online information and software updates, via the Internet, available around the clock. SEW-EURODRIVE GmbH & Co KG P.O. Box 3023 D Bruchsal / Germany Phone Fax sew@sew-eurodrive.com

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