REPAIR INSTRUCTIONS - PFISTERER · HVC8 pin contact strip C-type AVE130. 2 ... PFISTERER accepts no...

040 257 012

REPAIR INSTRUCTIONSfor the repair of a defective pin contact strip of type 382 005 102 with repair set 382 015 010 HVC8 pin contact strip C-typeAVE130

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Drawings not to scale – for information purposes only Repair of HVC8 pin contact strip / No. 040 257 012 (2020-01-15) Index 02

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Contents

General information

Safety

Transportation / storage

Page 4

Page 6

Page 9

Page 10

Page 12

Page 14

Page 22

Components

RepairPart A: Replacing the pin contact strip, including contact studs Page 15Part B: Repairing the contact stud cap Page 21

Tools and assembly aids

Criteria & repair recommendation

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1 General information

General information

1.1 Information on these instructions

These repair instructions describe the safe and proper use of the described product. The safety information and instructions must be observed in ad-dition to the locally applicable accident prevention regulations relating to the area of use of the product and general safety rules.Carefully read through the repair instructions, especially the section on safety and the relevant safety information, before starting any work on the product. The reader must understand the information contained here.

1.2 Contents of the instructions

Every person who is commissioned to perform work on or with the product must have read and understood the repair instructions before working on/with the product. This requirement applies even if the per-son has already worked with such a product or a similar product or has been trained by the manufacturer. Knowledge of the contents of the re-pair instructions is one of the requirements for protecting personnel from hazards as well as for preventing errors, thus ensuring the product is used in a safe and trouble-free manner. The operator is advised to have the staff confirm that they have familiarized themselves with the contents of these repair instructions.

Repair instructions for the repair of a defective pin contact strip of type 382005102. These instructions list the necessary components and tools and describe the relevant parts and the general process. They also contain a description of the method for crimping the contact stud.

These instructions describe the basic, recommended procedure for re-pairing / replacing components of the pin contact strip 382005102. In a specific case, it may be necessary to deviate from the suggested proce-dure. The criteria for determining whether components of the pin contact strip need to be replaced are only described verbally. An evaluation must always be conducted by an electrical expert.

The repair recommendation is intended to assist customers and provide guidance for effectively using and getting the best performance from the product. It is not guaranteed to be correct or applicable in all cases and shall not be considered an extension, modification or expansion of the warranty. There is no warranty extension for connecting elements and individual parts. A partial exchange of connection or socket components such as plastic parts, contact studs or screws does not alter the guarantee period of the originally delivered part. PFISTERER accepts no responsibili-ty for consequential damages of any kind.

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General information

1.4 Liability and warranty

All information and data contained in these repair instructions were com-piled under consideration of the applicable regulations, the technological state of the art and our long-standing expertise and experience.The instructions are to be kept accessible at all times to all persons who work on or with the product.The repair instructions are to be read carefully before starting work on and with the product. The manufacturer shall accept no liability for any damage or malfunctions resulting from failure to observe the repair in-structions.The text and images contained in the assembly instructions do not nec-essarily correspond to the scope of delivery. The illustrations are not to scale. Due to fact that special versions or additional options may have been ordered or innovative technical modifications may have been made, the actual scope of delivery can differ from the explanations and illus-trations described in these instructions. Please direct any queries to the manufacturer.We reserve the right to make technical modifications to the product with-in the framework of improving performance characteristics and further development.

1.5 Spare parts

Only use genuine spare parts of the manufacturer.The use of unapproved spare parts voids all claims concerning service, compensation for damages and liability against the manufacturer or its agents, dealers or representatives.

1.3 Copyright protection

The repair instructions are confidential. They are intended solely for per-sons who work on and with the product.All contents, text, drawings, images and other representations are pro-tected under copyright law and are subject to other intellectual property rights. Any misuse is punishable by law.Disclosure to third parties, including making copies of any type or form - even of extracts - as well as the use and/or communication of the contents without written permission from the manufacturer is prohibited. Any in-fringements shall be subject to claims for compensation. We reserve the right to assert further claims.We reserve the right to exercise any of our intellectual property rights.

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Safety

Any use other than the intended use of the product is pro-hibited and is deemed as not for its intended purpose.Any claims against the manufacturer and/or his authorized representatives for damage resulting from use of the prod-uct not for its intended purpose shall not be accepted.The operator shall be solely liable for any damage resulting from use of the product other than its intended purpose.

Operational reliability/safety can only be ensured if the product is used as intended.

2.1 Intended use

At the time of its development and manufacture, the product was constructed according to currently applicable, accepted codes of engi-neering practice and is safe to operate. Nevertheless, the product can pose dangers if it is not used by professionally trained personnel or is used improperly or in a manner deemed not for its intended purpose.

2 Safety

2.2 High voltage

The voltages occurring during operation can be as high as 1000 V. Work on the connector system may only be performed by qualified technical personnel. It must be ensured that no components are energized during the work. The system must be securely prevented from reactivation until the work is complete.

2.3 Warming during operation

The plug system may warm up during operation when transmitting large amounts of electrical current. When working on the plug system immedi-ately after operation, ensure that all components have cooled to prevent personal injuries.

To avoid hazards and to ensure optimum performance, no changes, ad-ditions or modifications may be made to the product that have not been expressly approved by the manufacturer.

2.4 Changes and modifications to the product

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Safety

The product may only be used in a technically perfect and operationally reliable condition. The information given in the repair instructions must be followed in its entirety and without restrictions!In addition to the safety precautions and instructions specified in these repair instructions, the locally applicable accident prevention regulations relating to the product’s area of application and the general safety regula-tions as well as the applicable environmental protection regulations must be observed and followed.The operator and personnel authorized by the operator shall be responsi-ble for fault-free operation of the product and for clear definitions of the responsibilities for operation and repair of the product.

2.5 Responsibility of the operating company

2.6 Work safety

Personal injury and material damage while working with and on the prod-uct can be avoided by following the safety precautions and instructions specified in these repair instructions.Failure to comply with these instructions can result in personal injury and damage to or destruction of the product.Any liability and compensation claims against the manufacturer or his authorized representative resulting from non-compliance with the safe-ty precautions and instructions specified in these repair instructions as well as the accident prevention regulations applicable to the area of ap-plication of the product and the general safety regulations shall not be accepted.

Sicherheit

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When working on and with the product, it is fundamentally recommend-ed that the following be worn:

Safety footwear to provide protection from heavy, falling objects and slipping on slippery floors.

For work in particularly hazardous areas (depending on local conditions):

Safety helmet to provide protection from falling and flung objects and materials.

Protective clothing, close-fitting working clothes (low tear resistance, close-fitting sleeves, no rings or other jewellery etc.).

Safety gloves to prevent the skin coming in contact with harmful substances.

During cleaning and greasing work, the following are to be worn:

2.8 Personal protective equipment (PPE)

Safety

Technical personnel are persons who, on the basis of their technical train-ing, knowledge and experience as well as knowledge of the applicable regulations, can assess the tasks assigned to them and recognize poten-tial hazards.Only persons who can be entrusted to work reliably are permitted to work on and with the product. All working methods that impair the safety of persons, the environment or of the product are prohibited.Persons under the influence of drugs, alcohol or medication that impedes their reactions must not work on or with the product.The personnel must immediately report to the operator any changes to the product that impair safety.

2.7 Requirements for the personnel

Only qualified personnel who have been authorised and trained by the manufacturer may work on and with the product. The personnel receive a certificate from the manufacturer attesting to the training. The certifi-cate is valid for 3 years and can be extended by 3 additional years after consultation with Pfisterer as long as practical experience can be verified.

Safety goggles to protect the eyes from liquids

Transport/Lagerung

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Transportation / Storage

Grease and other additives are subject to special waste treatment and may only be disposed of by specialist waste disposal companies!

3.3 Disposal

If no return or disposal agreement has been made, consign disassembled components after proper disassembly for recycling as follows:

■ Scrap the metallic materials.

■ Recycle plastic elements and seals.

■ Sort and dispose of remaining components according to material type.

3.1 Storage time

The storage time is generally not limited. However, all parts should be stored in a cool place (T ≤ 30°C).

3.2 Batch tracking

To identify the plug installed in the customer’s product in the event of damage, the customer must be able to establish a clear association be-tween our delivery batch and the customer product.

3 Transportation / Storage

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Components

4 Bill of materials, parts overview

4.1 Bill of materials article number 382 015 010

Article number Designation / description Quantity Figure

389 001 902 Contact stud sleeve HVC8-X-X-X-X-X-X-X-X

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389 002 204 Contact stud long 35_1 pre-in-stalled Repair contact stud (extended length), contact stud cap pre-in-stalled

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389 002 302 Locking sleeve pre-installed (with 2 O-rings)

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389 002 802 Shield current contact pre-installed (with O-ring)

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389 012 401 Strip HVC8-X-3-X-X-X-LF-X-X 1

389 002 002 Guide pin HVC8-X-X-X-X-X-X-X-X 1

389 012 601 Pan head screw M5x6 T25 5

100 103 692 Grease Firetemp XT2 - mini bag 3 g 3

613 199 515 Bag 120x280x0.100 mm - VCI 1

613 199 513 Bag 100x120x0.075 mm - VCI 1

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Components

4.2 Terms and definitions

Pin contact stripWhen installed, these components constitute the plug system connection on the unit itself. The elements of the pin contact strip are partially pre-in-stalled and include the contact stud HVC8 for the high-current line. The pin contact strip is either installed on an adapter board or integrated di-rectly into the customer unit. The pilot contact chamber is only equipped in specific designs.

PlugThis refers to all components of the plug system connected to the cable. A plug consists of partially pre-installed components, which are connect-ed to the high-voltage cable and installed by the assembler. The plug contains the socket contacts of the pilot contact and the socket contacts of the HVC8 high-current contact. The pilot contact chamber is only equipped in specific designs.

PanelTerm for a mechanically built housing or adapter plate in which all compo-nents of the pin contact strip are installed.

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5 Tools and assembly aids

Article number Designation / description Figure

Torque wrench with range of 5 Nm, precision ±3%

Attachment for torque wrench with Torx T25 bit

Rubber mallet 300 g

Soft face hammer 430 g, total length 330 mm, head diam. 30 mm or smaller

Brush, non-shedding

385 012 002 Cable cutter

385 012 201 Assembly tool for contact stud sleeve, index 01

385 006 001 Assembly tool for locking sleeve, index 02

385 003 101 Assembly tool for shield current con-tact, index 03

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Article number Designation / description Figure

Hydraulic battery press 60 kN with C-shell receptacle for press inserts

385001403 Press insert WM-Crimp 35 mm², press width 8 mm

Compatible with crimping pliersArt. No.: 385 005 301

External micrometer 0-25 mm with pointed measuring tip

Measurement adapter for depth measurementDesign ZF

385012101 PFISTERER assembly tool for contact stud cap(only relevant if nothing else needs to be repaired)

Consumables

ZF GSSI tubes (inner diameter = 15 mm, length = 250 mm)

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Anwendungsbestimmungen

Repair

6 Repair

6.1 General information

ForcesForces on the contact studs, introduced by the attached cables or bus bars.Significant forces can act on the contact studs, transmitted via lines such as the motor windings or the bus bars of an inverter. It must be ensured that these forces are transmitted axially and do not press the contact pins more than 0.5 mm out of their central position under any operating con-ditions or operating temperatures. If this cannot be prevented, suitable measures must be taken.

Cable clamp on the pin contact strip sideLines connected to the contact studs must be clamped in place after no more than 100 mm.

Ageing of the grease Firetemp XT2The service life of the grease is specified by the manufacturer as 4 years. After 4 years, the grease must be replaced. This also applies to enclosed housings.

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5x T25

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Repair

6.2 Repair procedure

The procedure is described under the assumption that all parts are being replaced. Because it may not be necessary to replace everything, the dam-age must be evaluated by an electrical expert based on the list of criteria and the appropriate measures determined on this basis.

Part A: Replacing the pin contact strip, including con-tact studs

Unscrewing the 5 screws

[Torx size 25]

Removing the guide pin (completely, including threaded pin)

[Combination pliers]

Removing the strip

■1

■2

■3

Removing the shield current contact

[Combination pliers or small pipe wrench]

Pull off the locking sleeves

[Combination pliers]

2 possibilities:

a) O-ring on sleeve

b) O-ring on contact stud sleeve, remove in this case

■4

■5

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Repair

Remove the motor cover.

[ZF tools]

Loosen the banding (fixation) of the (3) motor lines.

[ZF tools]

■6

■7

Remove the contact stud from the contact stud sleeve.

[Spacer ring (ZF tool), hammer]

Prevent any broken-off locking tips from entering the motor chamber. (Remove any soiling.)

■8

Pull back the stranded motor wires with contact stud and run them outside.

Remove the contact stud sleeve from the motor housing.

[Offset needle-nose pliers]

Push back the GSSI tube about 50 mm and affix with a cable tie.

Clean the motor housing well. Remove any rust.

Clean flat surfaces and contours.

■9

■10

■11

■12

Testing the lines for damage

Cut off the contact stud at the end. In doing so, rest the outside of the tool blade against the end – not the blade itself – as the blade could otherwise be damaged.

[Cable cutter]

Use the specified cable cutter.Make a straight cut.

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14,5+/- 1

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Repair

Insert the stranded wire into the contact studs.

All stranded wires

Crimp the contact

[Battery press, press insert]

Insert correctly.Press until the LED turns green. (Achieve a pressing force of 65 kN).

■16

■17

Loosen the GSSI tubes and slide them forward over the contact stud again.

Push on 3 additional tubes (inner diameter = 15 mm, length = 250 mm) and mark with U, V and W.

■19

■20

Check pressed dimension.

[External micrometer]

Size X; measure with pointed measuring tip; target dimension X = 6.5 ±0.05 mm

Position the measuring tool correctly

■18

Strip the cable insulation to 14.5 ±1 mm.

Also remove the transparent film around the conductor.

The transparent film can be hard to see.Do not damage the stranded wires

■15

Front, spring-loaded stop Back,

fixed stop

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Repair

Insert the contact stud sleeve loosely into the hole from the outside.

Push the contact studs through the housing (one after the other).

Ensure the correct phase position of “U”, “V” or “W”.

Lock the contact stud sleeve into position to secure it in place.

[385 012 201]

You should hear a clicking noise.

■21

90° ±0,5

Grease the locking sleeve generously with Firetemp.

[Non-shedding brush, 100 103 692]

Observe the correct quantity and position. Pay attention to locations that must not be greased.

■24

Grease the housing around the hole with Firetemp


Do not allow any grease to coat the contact studs. If nec-essary, slide a grommet or a piece of hose over the contact stud and sleeve to protect them.

■22

Align the contact stud in the centre and pre-fasten the lines.

[Manually or with ZF tool]

The contact stud must stand vertically, with a maximum deflection of 0.5°.

■23

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Repair

Install the locking sleeve.

[385 006 001, rubber mallet]

Note the tip orientation. Seated in end position level with the top edge of the mo-tor.

■25

Repeat as of step 25, fasten 3x

Grease shield current contact receptacle generously.


■26

■27

Press the shield current contact up to the stop with tool 385003101.

[385 003 101]

Seating in end position

■28

Position the strip. Lightly screw in the guide pin and opposite M5x6 screw (for contact 2) and align the strip.

Tighten the guide pin until the tear-off head breaks off.

■29

Contact stud Contact stud sleeve Existing GSSI

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Repair

Check whether the GSSI tube has been pushed to the end position in each case.

The end of the GSSI tube must be positioned completely between the contact stud and contact stud sleeve.

■31

Slide on the additional GSSI tubes over the contact stud sleeve up to the edge.

Check whether the GSSI tube has been inserted to the end position in each case.

■32

Lightly screw in another 4 M5x6 screws. Tighten all 5 screws with 5 Nm in the specified order.

[Torque wrench, TX25]

Observe the correct torque, sequence and procedure

■30

Band the motor lines (as per ZF specifications), ensuring that the con-tact studs are positioned in the centre.

■33

Contact stud Contact stud sleeve Additional GSSI Existing GSSI

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Repair

Part B: Repairing the contact stud cap

Only relevant if no new contacts were installed.

Case A: If loosely seated: Remove contact stud cap (also remove res-idue).

Case B: If missing: Check plug, see section 7.

Install the contact stud cap with PFISTERER assembly tool 385 012 101

■1a

■1b

■2

Tests

1. Mechanical:

Measurement value 1 (checks the height of the contact stud) = 5 ±0.3 mm

Measurement value 2 (checks the height of the locking sleeve) = 13 ±0.5 mm

[ZF tool: AA02.267.150]

2. Electrical:

Testing as per ZF specifications, ZF document No. 4474.760.040

■34

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7 Criteria for evaluating a damaged pin contact strip 382 005 102 with repair recommendation

An evaluation can be performed in various ways:

a) Visually b) With a test gaugec) Electrically

7.1 Details for a) visual check

Defect Repair See section 6.2Section ...

Visible break, crack or angled orientation of the locking sleeves, defects or dents on the face side

Replace locking sleeve, check contact stud sleeve for damage

Part A: Steps 1 – 3 and 5, then continue from step 25

Missing or loosely seated contact stud cap

Remove cap from plug, if necessary; install new cap using the tool

■ Contact stud cap HVC8 389 002 102

■ Assembly tool for contact stud cap 385 012 101

Part B

Bare copper areas on the contact stud (worn off, partial removal of the silver coating)

Part A; complete

Scratches on the contact stud in the area of the contact lines or scratches that cross the contact lines ≥ 0.1 mm

Part A; complete

Damaged or loosely seated shield current contact in the cast part, gap size > 0.2 mm

Part A: Steps 1 – 4 and 28 – 34

Missing M5x6 screws Part A: Steps 1, 30, 31

Broken-off or bent guide pin Part A: Steps 2 and 30

Tarnished contact stud Not necessary (No sanding or polishing)

---

Contact stud soiled Clean with damp cloth using no chemicals (No sanding or polishing)

---

Damaged motor line Restore insulation Removal of contact stud as per part A. Replacement of line as per ZF specifications.

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7.2 Details on b) evaluation with test gauge

Check for defects Repair See section 6.2Section ...

Check the thread on the cast part for sticking using a thread gauge

Determination of repair by ZF, e.g. HeliCoil use.

Gap between strip and cast block, lock-ing sleeves not in end position

Replace the plug components and check the motor block for corrosion.

Part A: Steps 1, 2, 3, 5, 23, 25, 26, 30, 31, 34

Plug can generally only be inserted with forces > 100 N

Check plug and pin contact strip for deformation / damage. Check whether the contact studs are at an angle.

Part A: Steps 4, 28, 29

Test gauge for the correct seating of the entire assembly in the cast block of the motor (ZF test gauge, identical to initial factory assembly)

Part A: Step 34

7.3 Details on c) electrical check

For electrical check, see ZF document No. 4474.760.040

Check for defects(See ZF document No. 4474.760.040)

Repair See section 6.2Section ...

Insufficient insulation resistance (2.1.4 Insulation resistance check)

Troubleshooting in steps Part A: Steps 1 – 13 and 20 – 34

Insufficient voltage endurance (2.1.5 High voltage test)

Troubleshooting in steps Part A: Steps 1 – 13 and 20 – 34

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PFISTERER Kontaktsysteme GmbH Rosenstraße 44 73650 Winterbach GermanyPhone +49 7181 7005 0 Fax +49 7181 7005 565 [email protected]

Bahnhofstraße 3089547 Gerstetten-GussenstadtGermanyPhone +49 7323 83 0Fax +49 7323 83 [email protected]

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Gotthardstrasse 31 6460 Altdorf SwitzerlandPhone +41 41 8747 575 Fax +41 41 8747 576 [email protected]

PFISTERER UPRESA S.A.U.Calle Industria 90 – 9208025 BarcelonaSpainPhone +34 93 4367409Fax +34 93 [email protected]

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PFISTERER Ltd.2 – 4 Orgreave PlaceOrgreaveSheffield S13 9LU, South Yorkshire Great BritainPhone +44 114 [email protected]

PFISTERER Power Connection Systems Beijing Co. Ltd.Unit 1106, Landmark Tower 28 North Dong San Huan RoadChaoyang District100004 BeijingChinaPhone +86 10 6590 6272-0Fax +86 10 6590 [email protected]

PFISTERER North America Inc. 130 Gilbert StreetLeRoy, NY 14482USA Phone +1 240 482 4955Fax +1 240 482 [email protected]

PFISTERER Dubai BranchGate 7, 3rd Floor, Hamarain CentreP.O. Box 184090, DubaiUnited Arab EmiratesPhone +971 4 2690147Fax +971 4 [email protected]

PFISTERER Hungary BranchMontevideo u. 3/a. II.em1037 BudapestHungaryPhone +36 1 2513441Fax +36 1 [email protected]

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PFISTERER Czech Republic Representative OfficeBudova MediahallBidláky 2063900 BrnoCzech RepublicPhone +420 533 337 190Fax +420 533 337 [email protected]

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REPAIR INSTRUCTIONS - PFISTERER · HVC8 pin contact strip C-type AVE130. 2 ... PFISTERER accepts no...

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