SEW-Eurodrive MOVITRANS TCS Operating Instructions Manual
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SEW-Eurodrive MOVITRANS TCS Operating Instructions Manual

SEW-Eurodrive MOVITRANS TCS Operating Instructions Manual

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*31984428_225*
Drive Technology \ Drive Automation \ System Integration \ Services
Operating Instructions
®
MOVITRANS
Installation Material TCS, TVS, TLS
Edition 2/2025
31984428/EN

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Summary of Contents for SEW-Eurodrive MOVITRANS TCS

  • Page 1 *31984428_225* Drive Technology \ Drive Automation \ System Integration \ Services Operating Instructions ® MOVITRANS Installation Material TCS, TVS, TLS Edition 2/2025 31984428/EN...
  • Page 2 SEW-EURODRIVE—Driving the world...

  • Page 3: Table Of Contents

    Connecting the TCS compensation box/TVS connection distributor ...... 35 Establishing inductive compensation ................ 49 Service .............................  51 Waste disposal...................... 51 Technical data .........................  52 General ......................... 52 TLS line cable and supply cable ................... 53 Dimension drawings...................... 57 Contacting SEW-EURODRIVE....................  61 Stichwortverzeichnis ......................  62 ® Operating Instructions – MOVITRANS Installation Material TCS, TVS, TLS...

  • Page 4: General Information

    General information About this documentation General information About this documentation The documentation at hand is the original. This documentation is an integral part of the product. The documentation is intended for all employees who perform work on the product. Make sure this documentation is accessible and legible. Ensure that persons respon- sible for the systems and their operation as well as persons who work on the product independently have read through the documentation carefully and understood it.

  • Page 5: Decimal Separator In Numerical Values

    General information Decimal separator in numerical values This is the formal structure of an embedded safety note:   SIGNAL WORD! Type and source of danger. Possible consequence(s) if disre- garded. Measure(s) to prevent danger. Decimal separator in numerical values In this document, a period is used to indicate the decimal separator. Example: 30.5 kg Rights to claim under limited warranty Read the information in this documentation.

  • Page 6: Safety Notes

    Safety notes Preliminary information Safety notes Preliminary information The following general safety notes serve the purpose of preventing injury to persons and damage to property. They primarily apply to the use of products described in this documentation. If you use additional components, also observe the relevant warning and safety notes.

  • Page 7: Designated Use

    2.4.1 Restrictions under the European WEEE Directive 2012/19/EU Options and accessories from SEW-EURODRIVE may only be used in combination with products from SEW-EURODRIVE. Functional safety technology If the documentation does not expressly permit it, the product must not perform any drive safety functions without higher-level safety systems.

  • Page 8: Transport

    Safety notes Transport Transport Inspect the shipment for damage as soon as you receive the delivery. Inform the ship- ping company immediately about any damage. If the product or the packaging is dam- aged, do not assemble, install, connect, or start up the product. If the packaging is damaged, the product itself may also be damaged.

  • Page 9: Electrical Connection

    Safety notes Electrical connection In order to avoid exceeding the permitted contact voltages in SELV or PELV power cir- cuits in the event of a fault, continuous equipotential bonding is required in the vicinity of these power circuits. If this is not possible, other protective measures must be taken.

  • Page 10: Startup/Operation

    Safety notes Startup/operation 2.11 Startup/operation ® Observe the following notes during startup and operation of the MOVITRANS units: • Only electrical specialists with the appropriate accident prevention training are al- lowed to perform installation, startup, and service work on the units. These special- ists must also comply with the regulations in force (e.g.

  • Page 11: Device Structure

    Device structure TCS compensation box Device structure TCS compensation box 3.1.1 Type designation The type designation of the TCS compensation box comprises the following character- istic data: ® TCS10 MOVITRANS stationary compensation box Housing protection class: Housing in protection class I Housing in protection class II Increased degree of protection IP65 Frequency:...
  • Page 12 Device structure TCS compensation box 3.1.2 Scope of delivery The following components are included in the scope of delivery of the TCS10B com- pensation box: TCS10B Compensation box Scope of delivery • 1 TCS compensation box with mounted blanking plugs TCS10B-E..-...-1 •...
  • Page 13 Device structure TCS compensation box 3.1.3 Nameplate The nameplate lists information about the product type. The following figure shows an example of a nameplate: XXXXXXXXX-XXX-XXX-X XXXXXXX IND.CONT.EQ. 37VD 30825961867 Product name Approval identification Depending on the product design, the following information is listed on the nameplate: Value Specification Type...
  • Page 14 Device structure TCS compensation box 28345252491 2 x M32 blanking plugs Flange plate Ground connection Mounting holes for fastening TCS compensation box TCS10B blanking plugs The following table provides the number and size of blanking plugs for the two flange plates of the individual TCS compensation boxes, and their protection class. TCS type compensa- Number and size of blanking plugs Protection...

  • Page 15: Tvs Connection Distributor

    Device structure TVS connection distributor TVS connection distributor 3.2.1 Type designation The type designation of the connection distributor comprises the following characteris- tic data: TVS10 ® TVS10 MOVITRANS stationary connection distributor Housing protection class: Housing in protection class I Housing in protection class II Increased degree of protection IP65 Line cable current: 60 A...
  • Page 16 Device structure TVS connection distributor TVS10B The following components are included in the scope of delivery of the TVS10B  con- nection distributor for line cable voltages of 60 A: Connection Scope of delivery distributor TVS10B-E06-000-1 • 1 connection distributor with mounted blanking plugs •...
  • Page 17 Device structure TVS connection distributor Accessories Part number Scope of delivery Accessories set 6 28313208 12 × M25 sealing insert + 12 × M25 plastic screw fit- tings (for 2 × TLS10E003-01-1) Accessories set 7 28313216 24 × M25 to M20 plastic re- duction adapters + 24 × screw fitting (for TLS10E008-01-1) For further information about the TVS-PACK-1 accessories, see the product manual...
  • Page 18 Device structure TVS connection distributor 3.2.3 Nameplate The nameplate lists information about the product type. The following figure shows an example of a nameplate: XXXXXXXXX-XXX-XXX-X XXXXXXX IND.CONT.EQ. 37VD 30825961867 Product name Approval identification Depending on the product design, the following information is listed on the nameplate: Value Specification Type...
  • Page 19 Device structure TVS connection distributor 28345252491 2 x M32 blanking plugs Flange plate PE connection Mounting holes for fastening TVS connection distributor Blanking plugs The following table provides the number and size of blanking plugs for the two flange plates of the individual TVS connection distributors, and their protection class. TVS10A TVS connection dis- Number and size of blanking plugs...

  • Page 20: Tls Line Cable And Supply Cable

    Device structure TLS line cable and supply cable TLS line cable and supply cable 3.3.1 Type designation The type designation of the line cables comprises the following characteristic data: TLS10E ® TLS10E MOVITRANS stationary high frequency line cable Cable cross section: 3 millimeters 6 millimeters 8 millimeters...
  • Page 21 Device structure TLS line cable and supply cable 3.3.2 Scope of delivery The following components are included in the scope of delivery of the TLS line cable / supply cable: TLS line cable / supply Part number Scope of delivery cable TLS10E006-06-1 13227793 TLS line cable / supply...
  • Page 22 Device structure TLS line cable and supply cable 3.3.3 Device overview The following figure shows the TLS line cable / supply cable: [1], [2], [3], [4] 50472695563 TLS10E003-01-1 line cable cross section 3 mm TLS10E008-01-1 line cable cross section 8 mm TLS10E025-01-1 line cable cross section 25 mm TLS10E041-01-1 line cable cross section 41 mm TLS10E006-06-1 supply cable cross section 6 × 6 mm TLS10K003-03-1 wedge-shaped cable cross section 3 × 3 mm...
  • Page 23 Device structure TLS line cable and supply cable 3.3.4 Functional principle INFORMATION The round line cables TLS10E003-01-1 with the cable cross section of 3  mm TLS10E008-01-1 with the cable cross section of 8  mm are only permitted for U- shaped pick-ups. The line cables TLS10E025-01-1, TLS10E041-01-1, and TLS10K003-03-1 with cable cross sections of 25 ...

  • Page 24: Coil Body

    Device structure Coil body Coil body 3.4.1 Scope of delivery The following components are included in the scope of delivery of the coil body: Component Part number Scope of delivery Coil body 27712788 1 × coil body 3.4.2 Unit overview The following figure shows the coil body (without line cable): 40404655371 3.4.3 Functional principle...

  • Page 25: Electrical Installation

    Electrical installation Tools Electrical installation Tools The tools that are required for assembling the TLS line cables are shown below: [10] 9007240623927179 Diagonal cutting pliers Safety knife Heat shrink tubing Soldering pot Hatchet-type soldering iron, alternatively gas torch Vise and 2 wooden boards for clamping the cable lugs Gas torch, alternatively hatchet-type soldering iron Hot air gun Work gloves...

  • Page 26: Assembly Of The Line Cable

    Electrical installation Assembly of the line cable Assembly of the line cable 4.2.1 Cable type The line cables are designed as medium-frequency cables. 4.2.2 Procedure INFORMATION When using cable lugs, observe the size of the respective connection bolts. Use the appropriate M8 ...
  • Page 27 Electrical installation Assembly of the line cable Preparing the cable for soldering To assemble the line cable, proceed as follows: 1. Slide the heat shrink tubing over the end of the cable. 2. Mark the length that you want to strip. 9007199424826379 3.
  • Page 28 Electrical installation Assembly of the line cable Method 1: Cable assembly with soldering pot  CAUTION! Danger of burns due to hot solder. Injury. Wear heat-resistant gloves when working with a with soldering pot, gas torch, or hatchet-type soldering iron. 2. Hold the stripped cable end in the soldering pot until the insulation of the individual wires melts and floats to the top of the soldering cup.
  • Page 29 Electrical installation Assembly of the line cable 5. Heat the cable lug again with the hatchet-type soldering iron, gas torch or hot air dryer. Add more solder, if necessary. 9007204870558219 6. Cut the heat shrink tubing in such a way that it completely covers the insulation of the TLS line cable inside the housing up to the cable gland.
  • Page 30 Electrical installation Assembly of the line cable Method 2: Cable assembly without soldering pot  CAUTION! Danger of burns due to hot solder. Injury. Wear heat-resistant gloves when working with a with soldering pot, gas torch, or hatchet-type soldering iron. 2. Fill the cable lug with a little solder: 9007204870554635 3.

  • Page 31: Assembly Of The Supply Cable

    Electrical installation Assembly of the supply cable Assembly of the supply cable 4.3.1 Cable outlet The TLS10E006-06-1 supply cable is a six-core cable. There are 3 blue cores and 3 black ones. In the supply cable, the conductor wires are not insulated against one an- other.

  • Page 32: Protective Measures Against Electrical Hazards

    Electrical installation Protective measures against electrical hazards Protective measures against electrical hazards 4.4.1 Overview The following figure provides an overview of the protective measures against electrical hazards according to DIN EN 61140 (IEC 61140:2016): MOVITRANS® contactless energy transfer system Protective measures against electrical hazards according to IEC 61140 Stationary components Protective bonding or reinforced/double insulation...
  • Page 33 Electrical installation Protective measures against electrical hazards 4.4.3 Earth connection of the TVS connection distributor Guidelines The TVS10A connection distributor is equipment of protection class I. Observe the following guidelines for the earth connection of the TVS10A connection distributor: • Ground the unit using the shortest possible route. •...
  • Page 34 Electrical installation Protective measures against electrical hazards 4.4.4 Earth connection of the compensation box / connection distributor Guidelines The TCS10B compensation box and the TVS10B connection distributor are qualified as equipment of protection class II. If there is a risk of external voltage effects, e.g. from a 50/60 Hz line voltage, you may connect the ground connection (chassis) to the local PE conductor.

  • Page 35: Connecting The Tcs Compensation Box/Tvs Connection Distributor

    Electrical installation Connecting the TCS compensation box/TVS connection distributor Connecting the TCS compensation box/TVS connection distributor WARNING Live parts in the system. Severe or fatal injuries. • Disconnect the system from the power supply before starting any procedure. • Secure the system against an unintended restart. •...
  • Page 36 Electrical installation Connecting the TCS compensation box/TVS connection distributor 4.5.1 Connecting the TCS compensation box INFORMATION Make sure that the gasket is properly seated and the screws are securely tightened to ensure degree of protection IP65. The following figure shows an example of the TLS line cable connected to the TCS10B compensation box: 18014400266045067 Nomex paper...
  • Page 37 Electrical installation Connecting the TCS compensation box/TVS connection distributor 5. Insert the prefabricated line cable through the cable gland into the wiring space of the compensation box. 6. Unscrew the 2 M8 combi pan head screws from the connection points on the con- nection board of the compensation box.
  • Page 38 Electrical installation Connecting the TCS compensation box/TVS connection distributor 4.5.2 Wiring the TVS connection distributor INFORMATION Make sure that the gasket is properly seated and the screws are securely tightened to ensure degree of protection IP65. TVS connection distributors are divided into connection distributors for 60 A systems and connection distributors for 85 A systems.
  • Page 39 Electrical installation Connecting the TCS compensation box/TVS connection distributor The following figure shows the TVS10A connection distributor: 31396952075 TVS10A connection distributor Housing cover Blanking plugs Terminal studs 4 hex head screws Cable glands ® Operating Instructions – MOVITRANS Installation Material TCS, TVS, TLS...
  • Page 40 Electrical installation Connecting the TCS compensation box/TVS connection distributor The following figure shows the TVS10B connection distributor: 31396949643 TVS10B connection distributor Housing cover Blanking plugs Terminal studs Insulation insert Cable glands 4 hex head screws ® Operating Instructions – MOVITRANS Installation Material TCS, TVS, TLS...
  • Page 41 Electrical installation Connecting the TCS compensation box/TVS connection distributor Preparing the TVS connection distributor For connecting the line cable and the TLS supply cables to the TVS connection distrib- utor, proceed as follows: ü The wire ends of the cables are equipped with cable lugs. For detailed information, refer to chapters "Assembly of the line cable" (→ 2 26) and "Assembly of the sup- ply cable" (→ 2 31).
  • Page 42 Electrical installation Connecting the TCS compensation box/TVS connection distributor Wiring the 60 A system in a stationary section Wiring between TVS connection distributor and supply 26571203083 Wiring in the connection distributor is performed as follows: [1.2] [3.1] [1.1] [3.2] 26571206667 The following figure shows the TLS supply cable connected to the connection distrib- utor: [1.2] [3.1]...
  • Page 43 Electrical installation Connecting the TCS compensation box/TVS connection distributor Wiring several connection distributors in series (loop) 26572253451 Wiring in the connection distributor is performed as follows: [1.1] [1.2] [3.1] [2.1] [2.2] [3.2] 26572257547 ® Operating Instructions – MOVITRANS Installation Material TCS, TVS, TLS...
  • Page 44 Electrical installation Connecting the TCS compensation box/TVS connection distributor The following figure shows an example of the TLS supply cable connected to the con- nection distributor: [1.1] [1.2] [3.1] [3.2] [2.1] [2.2] 30422291979 ® MOVITRANS supply cable TLS10E006-06-1 [1.1] Single wires black [1.2] Single wires blue ®...
  • Page 45 Electrical installation Connecting the TCS compensation box/TVS connection distributor Wiring 60  A systems in a moving section The overview shows the wiring of a TVS connection distributor in a moving section (60 A system). The lower connection distributor is the stationary connection distributor at the supply unit.
  • Page 46 Electrical installation Connecting the TCS compensation box/TVS connection distributor Wiring 85 A systems in a moving section INFORMATION Make sure that the gasket is properly seated and the screws are securely tightened to ensure degree of protection IP65. INFORMATION The current-carrying capacity of the TLS10E006-06-1 supply cable is 60 A. If you are using this type of cable in a system with 85 A, you must route 2 cables in parallel.
  • Page 47 Electrical installation Connecting the TCS compensation box/TVS connection distributor The following figure shows an example of the TLS supply cables connected to the connection distributor: [1.2] [1.1] [10] [11] 9007204735305995 ® MOVITRANS supply cable 1 hex nut TLS10E006-06-1 [1.1] Single conductors, blue 1 lock washer [1.2] Single conductors, black 1 washer...
  • Page 48 Electrical installation Connecting the TCS compensation box/TVS connection distributor Closing the TVS connection distributor 1. Tighten the M6 hex nuts with 3.0 Nm and the M8 hex nuts with 6.0 Nm. 2. Insert the insulation insert of the TVS10B connection distributor again. Make sure that the Nomex paper is fitted between insulation insert and inner wall of the hous- ing.

  • Page 49: Establishing Inductive Compensation

    Electrical installation Establishing inductive compensation Establishing inductive compensation In the case of very short transmission paths, inductive compensation is required. In this case, you do not need a TCS10 compensation box. track TES31A TCS31A 9007243598948491 2 load cables (5 × 6 mm² including PE) Supply cable area (line cables guided narrowly) TLS10E025-01-1 or TLS10K003-03-1 line cable Inductive compensation: Coil body wrapped with line cable...
  • Page 50 Electrical installation Establishing inductive compensation 5. Begin at the holding fixture and wrap the fed-through line cable around the coil body. [1] [2] 41356375435 Winding 1 Winding 2 6. Wrap the coil body according to the figure. 7. Make sure to use the correct number of windings: You need 15  windings for the TLS10E line cable and 19 windings for the TLS10K line cable.

  • Page 51: Waste Disposal

    Service Waste disposal Service Waste disposal Dispose of the product and all parts separately in accordance with their material struc- ture and the national regulations. Put the product through a recycling process or con- tact a specialist waste disposal company. If possible, divide the product into the follow- ing categories: •...

  • Page 52: Technical Data

    Technical data General Technical data General 6.1.1 Standards and directives ® The development and verification of the MOVITRANS   TCS10B compensation box ® and the MOVITRANS  TVS10B connection distributor are based on the following stan- dards: • EN 61140 Protection against electric shock, chapter 7.3 Protection class II equipment •...

  • Page 53: Tls Line Cable And Supply Cable

    Technical data TLS line cable and supply cable TLS line cable and supply cable 6.2.1 Mechanical properties The following table shows the mechanical properties of the TLS line cable  /  supply cable: Line cable type Cable Outer Installation type Bending cross diameter radius...
  • Page 54 Technical data TLS line cable and supply cable 6.2.2 Electrical properties The following table shows the electrical properties of the TLS line cable / supply cable: Type of line Insulation/sheath Electrical power Operating voltage cable material losses [mm] [W/m] TLS10E006-06-1 Thermoplastic / poly- 15 (at 60 A, 25 kHz) 1000 urethane...
  • Page 55 Technical data TLS line cable and supply cable 6.2.3 Data for connecting the TLS line cable/supply cable with terminal stud M6 The following tables show the data for connecting the TLS line cables / supply cables to the TVS10.-E06-000-. connection distributor with M6 terminal stud. With UL approval The following table shows the data for cable lugs with UL approval: Type of line...
  • Page 56 Technical data TLS line cable and supply cable 6.2.4 Data for connecting the TLS line cable/supply cable with M8 terminal studs The following tables show the data for connecting the TLS line cable / supply cable to the following components with M8 terminal studs: •...

  • Page 57: Dimension Drawings

    Technical data Dimension drawings Dimension drawings 6.3.1 TCS10 compensation box The following figure shows the dimension drawing of the TCS10A / TCS10B compen- sation box with dimensions in mm (in): 210 (8.27) 227 (8.94) 240 (9.45) 9007201014694155 Flange plate 1 Flange plate 2 TCS...-1 blanking plugs The following figure shows the dimension drawing of the TCS...-1 blanking plugs, di- mensions in mm (in): 80 (3.1)
  • Page 58 Technical data Dimension drawings TCS...-3 blanking plugs The following figure shows the dimension drawing of the TCS...-3 blanking plugs, di- mensions in mm (in): 80 (3.1) 80 (3.1) 1761275915 Flange plate 1 Flange plate 2 6.3.2 TVS10 connection distributor The following figure shows the dimension drawing of the TVS10A / TVS10B connec- tion distributor with dimensions in mm (in): 210 (8.27) 227 (8.94)
  • Page 59 Technical data Dimension drawings TVS...-1 blanking plugs The following figure shows the dimension drawing of the TVS...-1 blanking plugs, di- mensions in mm (in): (3.0) 80 (3.1) (1.4) (1.6) 9007199430420875 Flange plate 1 Flange plate 2 TVS...-2 blanking plugs The following figure shows the dimension drawing of the TVS...-2 blanking plugs, di- mensions in mm (in): 80 (3.1) 80 (3.1)
  • Page 60 Technical data Dimension drawings 6.3.3 Coil body 42767710859 ® Operating Instructions – MOVITRANS Installation Material TCS, TVS, TLS...

  • Page 61: Contacting Sew-Eurodrive

    Contacting SEW-EURODRIVE Contacting SEW-EURODRIVE You can find the worldwide contact data and locations on the SEW‑EURODRIVE website via the following link or the QR code shown below. https://www.sew-eurodrive.de/contacts-worldwide ® Operating Instructions – MOVITRANS Installation Material TCS, TVS, TLS...
  • Page 62 Index Index Numerical Connecting the TLS line cable to the TCS compen- sation box 60 A system in a moving section Connection of the TCS compensation box / the Wiring in the TVS connection distributor .. 45 TVS connection distributor...... 36 60 A system in stationary section Connection Wiring in the TVS connection distributor ..
  • Page 63 Index TLS line cable .......... 21 TLS supply cable .......... 21 Ground connection .......... 32 TVS connection distributor...... 15 TCS10B compensation box...... 34 Section-related safety notes ........ 4 TVS10B connection distributor.......  34 Separation, protective .......... 8 Grounding Signal words in safety notes ........ 4 TVS10A connection distributor.......  33 Startup Safety notes............ 10 Information...
  • Page 64 Index Scope of delivery.......... 21 TLS supply cable .......... 20 Technical data .......... 53 TVS connection distributor...... 15 Type designation .......... 20 Unit overview.......... 22 Tools Approvals............ 52 Assembly............ 25 Unit overview Trademarks ............ 5 TCS compensation box ........ 13 Transport ...............  8 TLS line cable .......... 22 TVS connection distributor TLS supply cable .......... 22 Blanking plugs ..........
  • Page 68 SEW-EURODRIVE—Driving the world SEW-EURODRIVE GmbH & Co KG Ernst-Blickle-Str. 42 76646 BRUCHSAL GERMANY Tel. +49 7251 75-0 Fax +49 7251 75-1970 sew@sew-eurodrive.com www.sew-eurodrive.com...

This manual is also suitable for:

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