1 Instruction for the LISIM 7.1 - electrical preassemly[edit | edit source]
1. Install terminals in terminal boxes, numbering ascending in film direction. In hot-jnction-boxes (HJB), use ceramic terminals.
2. Insert cable-glands into terminal boxes according to the Excel list. Close the holes which are not used with dummies. Install the bold and locking nut. You have to tighten the locking nut so that two treahds protrude.
3. Have the terminal boxes attached by the mechanics.
4. Route the engine hoses along the cooling pipes to the terminal box and insert into the terminal box. Cooling hose at the bottom, cable at the top.
- Bad example:
- File:LISIM 3.png
5. Cut the supply cable to length according to the Excel list (+1m), mark one end with yellow cable marker, and check for damage.
- Example: damaged cable:
- File:LISIM 4.png
6. Run the cable in tray from the cable arm to the terminal box. (longest distance first). Attach the supply cable and motor cable to the cooling pipe separately and without crossing. Cables have to lie as flat as possible against the cooling-pipe. Power cable at the rear, sensor cables at the front.
- Good example:
- File:LISIM 5.png
- Bad example:
- File:LISIM 6.png File:LISIM 7.png
7. Turn the shield inside out so that no braid can pierce the core insulation, then insert the cable into the EMC gland. 150mm PTFE heat shrink tubing is inserted between conductors and shielding. This is an additional protection against short circuits between the shielding and the conductor.
8. Attach metal cable markers behind the EMC gland so that the inscription can be read from below.
9. Connect cables according to the wiring diagram.
10. Shorten sensor cables on the motor side. Push back lables.
11. Sensor cables are crimped, insulated with PTFE heat shrink tubing which is compressed at the end. Then pull back cables into the clamp.
12. After connection, the rail-segment is checked with the testing equipment.
13. Instruction for running the test device is performed by a specialist.
14. The PT100 are measured with the multimeter.
15. Before measuring, the aluminum rail (as a sliding rail) is attached to the beam. Spring steel rails are mounted. for curve measurement.
16. Plugs are connected to the motor cables only for the measurement.
17. After the measurement, the power cables are brazed. A special device is supplied for this purpose.
18. Before brazing, the coals should be checked. New coals have to be sawn to size.
1.1 Instructions for brazing the inverter and motor cable to the contact chassis of terminal block.[edit | edit source]
1.1.1 Preparation[edit | edit source]
19. Dilute flux with water.
20. Stripping of the converter and motor cable by approx. 12mm with wire stripper. (Pay attention to the correct adjustment of the pliers so as not to damage any strands)
21. Removal of the coating with Schnydrig 3700 on the stripped motor cable.
- File:L1.png
- Left: FU power cable (stripped)
- Right: Motor cable (stripped and coating removed)
22. Take out the contact chassis from the terminal block and remove the adhesive strip on the side surface and any adhesive residue from the surface.
23. First, insert the conductor of the temperature-resistant motor cable into the terminal over the entire length (not beyond the edge) and clamp it tightly.
Clamping the motor cable into the contact chassis of the terminal block.
1.1.2 Brazing[edit | edit source]
24. Configuration of the pliers: the device must be set to the level 10A/2200W25.
25. Allpy flux to the tip (a few centimeters) of the soldering rod.
26. Securely clamp the soldering pliers on the contact chassis close to the inserted cable (do not touch any wires, etc.); then heat the contact chassis with controlled, short bursts; at a sufficient temperature (condition: briefly glowing) apply solder from above to the lead area and tinn completely.
- File:L3.png
Brazing the clamped motor cable in the contact chassis.
File:LISIM 26.png File:LISIM 27.png
- Left: Clamped Soldering Pliers with solder at the contact Figure
- Right: Brazed motor cable in the contact body
Template:Notice bms
27. The procedure is now repeated for the FI power cable.
28. Insert the power cable and tighten (see 4)
29. Braize and repeat steps 6 and 7. Again, tin through completely.
Template:Notice bms30. When cooled down, insert contact chassis into the terminal housing and mount on the rail)
31. After completion, clean the terminal box.
32. PE of the supply line is connected to the ground screws.
33. Connect the terminal box cover with grounding strap. The cover is fastened with self-locking screws.34. Terminal boxes on return side are not brazed. However, these are checked too.
35. A functional earth must be connected for all motors. This is done at the HJB's with a ground strap (connection outside to copper bolt - motor side to ground bolt) and at the CJB's with 2x16mm² yellow/green stranded wires (connection inside to spring terminals - motor side to ground bolt). To ensure that all motors are connected to the corresponding DC supply, the HJB's and the CJB's must also be interconnected. This is also done with grounding straps and 2x16mm² yellow/green stranded wires. The corresponding connections are shown in the electric diagram.
36. For transport, fix the wooden panel on top the rail and tie the cables to it.
37. Ready for transportation.
