Lenze MOBILE DCU, MOBILE PSU, MOBILE Advanced DCU, MOBILE Advanced PSU, MOBILE Advanced DCU PSU Hardware Manual

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Page 1

EDSMDAG

.Rtù

Ä.Rtùä

Mobile Drive

Hardware Manual

MOBILE

EMDxGxxxxxxxxxxx1x

MOBILE DCU MOBILE PSU MOBILE DCU PSU MOBILE DCU S

Page 2

0Fig. 0Tab. 0

Page 3

Contents i

1 About this documentation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Target group 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Validity information 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Document history 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Conventions used 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 Terms and abbreviations used 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 Notes used 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Safety instructions 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 General safety and application notes for Lenze MOBILE devices 10. . . . . . . . . . . . . .

2.2 Residual hazards 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Product description 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 System overview 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Device features 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Identification 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Type code 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Technical data 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 General data and operating conditions 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Rated data of the devices for HV on−board supply system 800 V 26. . . . . . . . . . . . .

4.2.1 Product finder 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.2 DC/AC inverter 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.3 DC/DC converter 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Control of MOBILE DCU, PSU, DCU PSU 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.1 Voltage supply 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.2 Digital inputs 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.3 Digital outputs 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.4 Potential−free output 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.5 CAN bus 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Control of MOBILE DCU S 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.1 Voltage supply 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.2 Digital inputs 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.3 Thermal sensor input 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.4 CAN bus 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Water cooling 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 Dimensions 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Installation 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Important notes 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Mechanical installation 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EDSMDAG EN 2.0

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Contentsi

5.3 Water cooling 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 EMC−compliant installation 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.1 Equipotential bonding 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.2 Shielding 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.3 HV on−board cable 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.4 Motor cable 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.5 Control cables 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.6 Detecting and eliminating EMC interferences 47. . . . . . . . . . . . . . . . . . . . .

5.5 Electrical installation 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.1 Basic circuit diagrams 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.2 Fuses and cable cross−sections 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.3 Wiring the CAN bus 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Connections of MOBILE DCU, PSU, DCU PSU 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6.1 PE conductor 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6.2 HV on−board supply system 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6.3 Motor 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6.4 Feedback 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6.5 LV on−board supply system 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6.6 Control system 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6.7 Addressing CAN bus nodes 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6.8 Activating the terminating resistor 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7 Connections of MOBILE DCU S 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.1 PE conductor 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.2 HV on−board supply system 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.3 Motor 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.4 Control system 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.5 Addressing CAN bus nodes 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.6 Activating the terminating resistor 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Commissioning 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Diagnostics 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 Device status 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.1 MOBILE DCU, PSU, DCU PSU 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.2 MOBILE DCU S 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Accessories (overview) 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 Prefabricated cables and plug accessories 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.1 MOBILE DCU, PSU, DCU PSU 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 Individual parts for the electrical installation 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.1 MOBILE DCU, PSU, DCU PSU 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.2 MOBILE DCU S 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 Index 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EDSMDAG EN 2.0

Page 5

1 About this documentation

This manual contains the complete information on the intended use of components of the MOBILE product platform in mobile applications in or on vehicles.

I Tip!

Information and tools concerning the Lenze products can be found in the download area at

www.lenze.com

1.1 Target group

This manual is intended for all persons who dimension, install, commission and adjust drives with the MOBILE product platform.

About this documentation

Target group

1.2 Validity information

This manual is valid for the components with the type designation:

Device type Type designation from SW

MOBILE Advanced DCU EMDAG2xxxxxxxxxx1x 06.0

MOBILE Advanced PSU EMDAG3xxxxxxxxxx1x 06.0

MOBILE Advanced DCU PSU EMDAG4xxxxxxxxxx1x 06.0

MOBILE DCU S EMDAG5xxxxxxxxxx0x 06.0

Accessories EMDAZ... ˘

The breakdown of the type designation can be found in the "Product description" chapter. (¶ 21)

EDSMDAG EN 2.0

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About this documentation

Document history

1.3 Document history

Material number Version Description

.Rtù 2.0 04/2018 TD29 Revision of the Hardware Manual to the hardware

13473426 1.1 10/2014 TD15 Corrections

13473426 1.0 10/2014 TD15 First edition

1.4 Conventions used

This documentation uses the following conventions to distinguish between different types of information:

Spelling of numbers

Decimal separator

Tex t

Program name » « PC software

Icons

Page reference ^ Reference to another page with additional

Documentation reference , Reference to another documentation with

version x1x

Point In general, the decimal point is used.

For instance: 1234.56

For example: »Engineer«, »Global Drive Control« (GDC)

information For instance: ^ 16 = see page 16

additional information For example: , EDKxxx = see documentation EDKxxx

EDSMDAG EN 2.0

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1.5 Terms and abbreviations used

Term Description

AppC Application Controller

CAN Controller Area Network or electric circuit for CAN with its own current

DC Direct current

DCU DC/AC inverter

DCU PSU Combined device

Double inverter Inverter for two motors or two drives

Single inverter Inverter for one motor or one drive

HCU Host Control Unit (also Vehicle Control Unit or Machine Control Unit)

HV on−board supply system High−voltage (on−board) system ISO 6469−3, voltage class B

IT Isolé Terre system (star point not earthed)

TRM15 Terminal 15: Terminal 15 is the original contact "Ignition on" at the

TRM30 Positive voltage of the voltage supply (12 V or 24 V)

TRM31 Negative voltage of the voltage supply (0 V). This signal is potentially

Performance electronics Rectification, DC bus and DC−AC converter

LV on−board supply system Low−voltage (on−board) system ISO 6469−3, voltage class A

About this documentation

Terms and abbreviations used

supply

Drive Control Unit

steering lock which switches on the MOBILE PSU/DCU by a switch−on pulse (LOW−HIGH edge).

connected to the vehicle chassis.

MC Motor Controller

MOBILE Product platform for automotive drive solutions

»MOBILE Engineer« Engineering tool, software solution for easy engineering in all phases

Module Electronic unit or device

Motor A First motor controlled by MC

Motor B Second motor controlled by MC (optional)

n. c. Not connected

PE Chassis

Protective earth

Private CAN Real time CAN Bus which is used for controlling drives.

PSU DC/DC converter

Power Supply Unit

Public CAN CAN bus on the vehicle side which is used for integrating the MOBILE

Control electronics Open−loop control, closed−loop control, setpoint generation, monitoring

SM Synchronous motor

Tn Terre Neutre system (star point is earthed)

DC bus DC bus

SLVCI Sensorless vector control for asynchronous motors

SLVCS Sensorless vector control for synchronous motors

SLVFCI Sensorless V/f characteristic control for asynchronous motors

Ctrl Control

VCI Vector control for asynchronous motors

VCS Vector control for synchronous motors

PSU/DCU into vehicles.

EDSMDAG EN 2.0

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About this documentation

Terms and abbreviations used

DescriptionTerm

DC−bus level Energy storage between rectification and DCAC conversion, for one or

DC−bus connection, DC−bus operation

more controllers

Interconnection of several inverters on the DC−bus level

EDSMDAG EN 2.0

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1.6 Notes used

The following pictographs and signal words are used in this documentation to indicate dangers and important information:

Safety instructions

Structure of safety instructions:

} Danger!

(characterises the type and severity of danger)

Note

(describes the danger and gives information about how to prevent dangerous situations)

Pictograph and signal word Meaning

{ Danger!

} Danger!

( Stop!

About this documentation

Notes used

Danger of personal injury through dangerous electrical voltage.

Reference to an imminent danger that may result in death or serious personal injury if the corresponding measures are not taken.

Danger of personal injury through a general source of danger.

Reference to an imminent danger that may result in death or serious personal injury if the corresponding measures are not taken.

Danger of property damage.

Reference to a possible danger that may result in property damage if the corresponding measures are not taken.

Application notes

Pictograph and signal word Meaning

) Note! I Tip! ,

Important note to ensure troublefree operation

Useful tip for simple handling

Reference to another documentation

EDSMDAG EN 2.0

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Safety instructions

General safety and application notes for Lenze MOBILE devices

2 Safety instructions

2.1 General safety and application notes for Lenze MOBILE devices

Observe the following basic safety instructions when using the MOBILE inverters (devices). A non−compliance may cause severe injury to persons and/or damage to material assets.

General

ƒ For devices with ECE R10 approval, the ECE regulation no. 100 has to be observed.

For your personal safety

ƒ Only use the devices as directed.

ƒ Never commission the devices in the event of visible damage.

ƒ Never commission the devices before they have been completely mounted.

ƒ Only separate or plug connectors if the high−voltage mains is switched off and

discharged: – Power connector (marked with a warning sign on the cover) – Signal connector

ƒ Do not open the housings of the devices.

ƒ Do not carry out any technical changes on the devices.

ƒ Only use the accessories approved for the devices.

ƒ Only use original spare parts from Lenze.

ƒ Observe all regulations for the prevention of accidents, directives and laws

applicable on the site of installation.

ƒ Transport, installation, commissioning and maintenance work must only be carried

out by qualified personnel. – Observe IEC 364 and CENELEC HD 384 or DIN VDE 0100 and IEC report 664 or DIN

VDE 0110 and all national regulations for the prevention of accidents.

– According to this basic safety information, qualified, skilled personnel are persons

who are familiar with the assembly, installation, commissioning, and operation of the product and who have the qualifications necessary for their occupation.

ƒ Observe all specifications in the documentation.

– Carry out installation and operation in accordance with the documentation. – This is the condition for safe and trouble−free operation and the achievement of

the specified product features.

– The procedural notes and circuit details described in the documentation are only

proposals. It is up to the user to check whether they can be transferred to the particular applications. Lenze Schmidhauser does not accept any liability for the suitability of the procedures and circuit proposals described.

EDSMDAG EN 2.0

Page 11

Safety instructions

General safety and application notes for Lenze MOBILE devices

ƒ The devices and related components can − depending on the degree of protection −

have live, movable or rotating parts during operation. – Surfaces can be hot. – Do not remove required covers. – Do not touch exposed contacts or non−insulated cable ends. – For more information, please see the documentation.

ƒ Before touching conductive components, ensure isolation from supply by means of

measurement.

The device−specific safety and application notes given in the chapter "Residual hazards" of this documentation must be observed.

Application as directed

The devices meet the requirements of the Low−Voltage Directive 2006/95/EC. The harmonised standard EN 61800−5−1 applies to the devices.

The devices marked with E1 are components which are designed for installation in vehicles (ECE approval). They are not to be used as domestic appliances, but only for industrial purposes according to EN 61000−3−2.

The technical data and supply conditions can be obtained from the nameplate and the documentation. They must be strictly observed.

Commissioning (i.e. start of the operation as intended) of devices installed in vehicles is only permissible if the following has been verified:

ƒ The vehicle corresponds to the valid vehicle standards (e.g. ECE R100, safety

requirements with respect to the electric power train of road vehicles); EN 60204 is observed.

ƒ The EMC Directive 2004/104/EC (last supplemented by 2009/19/EC) is complied

with.

Transport, storage

Please observe the notes on transport, storage, and appropriate handling. Observe the climatic conditions according to the technical data.

Installation

You have to mount, connect and cool the devices according to the specifications of the respective documentation. The equipotential bonding has to be dimensioned sufficiently and protected against corrosion.

When plug connections are open, the degree of pollution 2 must not be exceeded according to EN 61800−5−1.

Ensure proper handling and avoid excessive mechanical stress. Do not touch any electronic components and contacts. The devices contain electrostatic

sensitive devices that can be damaged easily by improper handling. Damaged devices must not be commissioned.

EDSMDAG EN 2.0

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Safety instructions

General safety and application notes for Lenze MOBILE devices

Electrical connection

When working on live devices, observe the applicable national regulations for the prevention of accidents and technical measures for occupational safety and health.

The electrical installation must be carried out according to the appropriate regulations (e.g. cable cross−sections, fuses, PE connection). Additional information can be obtained from the documentation.

The documentation contains notes concerning wiring according to EMC regulations (shielding, earthing, filters and cable routing). The compliance with limit values required by the EMC legislation is the responsibility of the manufacturer of vehicles or systems or machines.

Operation

If necessary, systems including these devices must be equipped with additional monitoring and protection devices according to the valid safety regulations (e.g. law on technical equipment, regulations for the prevention of accidents). The devices can be adapted to your application by parameter settings. Please observe the corresponding information given in the documentation.

After the devices have been disconnected from the supply voltage, all live components and connectors must not be touched immediately because capacitors can still be charged. Please observe the corresponding stickers on the devices.

Ensure that all protection covers are closed and screwed during operation.

Maintenance and servicing

The devices do not require any maintenance if the prescribed operating conditions are observed.

The external cleaning of the devices has to be made in the course of the general care of the vehicles, machines, or systems. Depending on the mounting place and the possible pollution, the cover sensor has to be cleaned regularly.

Disposal

For a professional disposal and utilisation of the devices, please comply with the valid regulations, e.g. 2000/53/EC (last amended by 2011/37/EC).

EDSMDAG EN 2.0

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Safety instructions

Residual hazards

2.2 Residual hazards

Protection of persons

ƒ Switch off the high voltage on−board voltage completely before working on the

devices.

ƒ Before working on the device, check whether all power terminals are deenergised

because – after disconnection, the power terminals U, V and W remain live for at least 5

minutes depending on the system. – the power terminals +UG, −UG, U, V and W remain live while the motor is rotating. – Batteries and energy storages can carry hazardous voltage over a longer period of

time.

Device protection

ƒ Connect/disconnect all pluggable terminals only in deenergised condition!

ƒ Detach the controllers from the installation, e.g. from the motor or mounting wall,

only in deenergised condition!

Motor protection

ƒ With some settings of the controller, the connected motor can be overheated.

– E.g. longer operation of the DC injection brake. – Longer operation of self−ventilated motors at low speed. – Wrong frequency or voltage settings in the motor parameters (especially with

120 Hz motors).

Protection of the machine/system

ƒ Drives can reach dangerous overspeeds (e.g. setting of high output frequencies in

connection with motors and machines unsuitable for such conditions): – The controllers do not offer any protection against such operating conditions. Use

additional components for this purpose.

Symbol Description

} '

}

{

Long discharge time: All power terminals remain live for a few minutes after mains disconnection! The duration is given under the warning symbol on the device.

High leakage current: Carry out fixed installation and PE connection according to EN 6180051!

Electrostatic sensitive devices: Before working on the device, the personnel must be free of

electrostatic charge!

Hot surface: Risk of burns! Hot surfaces should not be touched without wearing protective gloves.

Read the documentation: Before working on the device, the personnel must read and act in

accordance with the documentation supplied with the product, especially the warnings and the safety instructions!

Dangerous voltage: Before working on the device, switch off the HV on−board voltage completely!

EDSMDAG EN 2.0

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Product description

System overview

3 Product description

3.1 System overview

The components from the MOBILE modular system are used to realise auxiliary unit applications in commercial vehicles by means of electric motors:

Device type

Double inverter for two motors l ˘ ˘ ˘

DC/DC converter (converter HV on−board supply system/LV on−board supply system)

Combination of single inverter for one motor and DC/DC converter

Single inverter for one motor ˘ ˘ ˘ l

Application

Simple drives of pumps and fans l ˘ l l

Controlled and positioning drives l l l

Charging the LV on−board supply system with regenerative energy of drives

MOBILE

DCU PSU DCU PSU DCU S

˘ l l ˘

˘ ˘ l ˘

˘ l l ˘

EDSMDAG EN 2.0

Page 15

MOBILE DCU

X33

X32

Product description

System overview

X11

X31

LED

X12

X13

2×

^ 55

^ 56

^ 54

Fig. 1 MOBILE DCU (EMDxG2...)

Connections and elements Info

0 Connection of water cooling ^ 43

X11 Connection of HV system 800 V DC ^ 54

X12 Connection of motor A

X13 Connection of motor B

X31 Vehicle interface, connection of control voltage, control signals, CAN ^ 58

X32 Connection of resolver and temperature monitoring of motor A

(by default sealed with plug)

X33 Connection of resolver and temperature monitoring of motor B

(by default sealed with plug)

+ PE connection ^ 44

LED LED status display ^ 68

EMDAG013a

EDSMDAG EN 2.0

Page 16

Product description

System overview

MOBILE PSU

X11

X31

X21/B-

Fig. 2 MOBILE PSU (EMDxG3...)

Connections and elements Info

0 Connection of water cooling ^ 43

X11 Connection of HV system 400 VDC or 800 VDC ^ 54

X21/B+ X21/B−

X31 Vehicle interface, connection of control voltage, control signals, CAN ^ 58

+ PE connection ^ 44

LED LED status display ^ 68

X21/B+

A LED

LV mains 14 VDC or 28 VDC Connection of the on−board battery

^ 57

^ 54

{ Danger!

Dangerous electrical voltage

The terminal X13 carries electrical voltage.

Possible consequences:

ƒ Death or severe injury if the power terminals are touched.

Protective measures:

ƒ Do not remove the blanking plug from X13.

EMDAG012a

EDSMDAG EN 2.0

Page 17

MOBILE DCU PSU

X33

Product description

System overview

X11

X31

X21/B-

Fig. 3 MOBILE DCU/PSU (EMDxG4...)

Connections and elements Info

0 Connection of water cooling ^ 43

X11 Connection of HV system 400 VDC or 800 VDC ^ 54

X13 Motor connection ^ 55

X21/B+ X21/B−

X31 Vehicle interface, connection of control voltage, control signals, CAN ^ 58

X33 Connection of resolver and motor temperature monitoring

+ PE connection ^ 44

LED LED status display ^ 68

X21/B+

LV mains 14 VDC or 28 VDC Connection of the on−board battery

(by default sealed with plug)

LED

X13

^ 57

^ 56

^ 54

EMDAG011a

EDSMDAG EN 2.0

Page 18

Product description

System overview

MOBILE DCU S

Fig. 4 MOBILE DCU S (EMDxG5...)

Connections and elements Info

0 Connection of water cooling ^ 43

X1 Vehicle interface, connection of control voltage, control signals, CAN ^ 63

X2 Connection of HV on−board supply system 800 V DC ^ 62

X3 Motor connection ^ 63

+ PE connection ^ 62

EMDAG028b

^ 44

EDSMDAG EN 2.0

Page 19

3.2 Device features

Device feature EMDAG2... EMDAG3... EMDAG4... EMDAG5...

Power range (Peak Power)

DC/AC inverter 2 ˘ 1 1

DC/DC converter ˘ 1 1 ˘

Approval acc. to ECE R10 l l l l

Degree of protection IP6K9K IP6K9K IP6K9K IP6K9K

Cooling Water / glycol (^ 36)

Mounting type free

12/24−V voltage for maintaining the control functionality in the case of mains failure

Digital inputs 4 4 4 4

configurable as analog input 2 2 2 2

configurable as frequency input 2 2 2 ˘

Digital outputs 4 4 4 ˘

Resolver connection 2 ˘ 1 ˘

Motor temperature monitoring PT1000, KTY83/110, KTY84/130, thermostat (normally−closed contact)

Public CAN l l l l

Baud rate kbps 125 ... 500 125 ... 500 125 ... 500 125 ... 500

Private CAN l l l l

Baud rate kbps 125 ... 1000 125 ... 1000 125 ... 1000 125 ... 500

Operation in generator mode (optional)

Loop−through of HV system l l l ˘

Overload cycle at 1.8 × I

Overload cycle at 1.5 × I

Motor speed range rpm −32000 ... 32255 ˘ −32000 ... 32255 −32000 ... 32255

Technology application

Actuator speed l ˘ l l

Switch−off positioning m ˘ m ˘

Absolute positioning m ˘ m ˘

rated

Product description

Device features

kW 7.5 ... 60 2.8 ... 5.6 2.8 ... 60 7.5 ... 22

l l l l

acc. to DIN44080, PTC acc. to DIN44081

l ˘ l l

10 s ˘ 10 s 10 s

60 s ˘ 60 s 60 s

EDSMDAG EN 2.0

l Included as standard m Optionally available

˘ Not available

Page 20

Product description

Identification

3.3 Identification

Each device is marked with a clear nameplate. The following data on the nameplate serves to identify each device:

ƒ Type designation (product key)

ƒ Technical data

ƒ Serial number (SN)

   

MOBILE

Type: SN:

ÄIDNummer123456789ä

-ECER10-

Xxx Xxx Xxx



Fig. 5 Nameplate

 Product name  Type designation  Serial number  Manufacturer  Warning symbol: discharge time, dangerous electrical voltage, ESD, hot surface  Approval identification  Technical data



EMDAG051

Note

Via the type designation, detailed device properties can be identified using the following type code. The list containing the type code, features, and device properties does not take any restrictions with regard to possible combinations into consideration.

EDSMDAG EN 2.0

Page 21

3.4 Type code

Device version

A = Advanced

Device type

1 = DCU: single inverter 2 = DCU: double inverter 3 = PSU: DC/DC converter 4 = DCU PSU: single inverter,

5 = DCU S: single inverter

DCU: peak output power at X12 DCU PSU: output power at X21 PSU: output power at X21 DCU S: peak output power at X3

Example: 603 = 60 × 10 562 = 56 × 10

DC/DC converter

W = 60 kW

W = 5.6 kW

Product description

Type code

Position 1 ... 5 6 7, 8, 9 10, 11, 12 13 14 15 16, 17, 18

EMDxG X xxx xxx x x x xxx

DCU: peak output power at X13 DCU PSU: peak output power at X13

Example: 303 = 30 × 10

PSU: 000 DCU S: 000

Voltage range LV system / HV system

U = 14 or 28 V / 800 V V = 14 or 28 V / 400 V P = 14 V / 400 V T = 14V / 800 V S = 28 V / 400 V C = 28 V / 800 V

Communication

N = not relevant 0 = CANopen (Private CAN), J1939 (Public CAN)

Special version

0 = standard

Hardware version

x0x = 1st version x1x = 2nd version

W = 30 kW

EDSMDAG EN 2.0

Page 22

Technical data

General data and operating conditions

4 Technical data

4.1 General data and operating conditions

Conformity and approval

Approval

ECE

Protection of persons and equipment

Degree of protection ISO 20653

Insulation test EN 61800−5−1 Final test with 2.6kVDC between HV on−board supply

Insulation of control circuits

Short−circuit strength Motor connection: limited short−circuit strength, the inverter

Protective measures against

Leakage current EN 61800−5−1 IAC>3.5 mA

On/off switching MOBILE devices are suitable for frequent on/off switching,

R10 Rev. 5

EN 61800−5−1 IEC 60664−1

ß 10R − 05 7105 (see nameplate)

ß 10R − 05 8467 (see nameplate)

IP 6K9K

IP 6K7

system/LV on−board supply system and HV on−board supply system/PE

Safe isolation by double/reinforced insulation to the HV on−board supply system

is disabled, error acknowledgement is required Control terminals: full short−circuit strength

l Short circuit l Overvoltage l Motor Connection Test l Device overtemperature l Motor overtemperature

(PTC or thermal contact, I

>10 mA

e.g. in the setting−up operation.

MOBILE DCU MOBILE PSU MOBILE DCU PSU

MOBILE DCU S

l Plug mounted l Cover sheet mounted

l Plug mounted l Without cover sheet

t monitoring)

Observe regulations and safety instructions!

EDSMDAG EN 2.0

Page 23

Technical data

General data and operating conditions

Ambient conditions

Climate

Storage IEC/EN 60721−3−1 1K3 (−25 ... +60 °C)

Transport IEC/EN 60721−3−2 2K4 (−40 ... +85 °C)

Operation

Inverter, DC/DC converter

Coolant +30 ... +65 °C Coolant pump switches on at a

Service life 50000h at a coolant temperature of

Humidity, relative 5 ... 100 %

Altitude

MOBILE DCU MOBILE PSU MOBILE DCUPSU

MOBILE DCU S EN 61800−5−1

Pollution EN 61800−5−1

Vibration resistance (9.81 m/s

Transport Operation

EN 61800−5−1

= 1 g)

ISO 16750−3, code L

−40 ... +85 °C

coolant temperature of +30 °C

55°C

0 ... 2000 m amsl Overvoltage categoryII

2000 ... 4000m amsl Overvoltage categoryI

0 ... 3000 m amsl Overvoltage categoryII

3000 ... 4000 m amsl Overvoltage categoryI

Degree of pollution 4 all plugs closed

Degree of pollution 2 Plugs opened

vertical, tested with 57.9 m/s

horizontal, tested with 57.9 m/s

mechanical shock, tested with 500 m/s2 for 6 ms

Mounting conditions

Mounting place in commercial vehicles (spring−loaded masses)

Mounting position All positions are permissible

Mounting clearances

In the connection area

Supply conditions

HV on−board supply system

DC−bus operation l Permissible

Power systems

IT Standard

TT, TN On request

Motors Only use motors that are suitable for operation on the

³ 150 mm Observe bend radii for cables and hoses.

No special requirements

Direct connection to the HV on−board supply system When switching elements are used in the HV on−board supply system, the DC−bus capacitors must be precharged.

l Observe maximum contact load. l Only use devices with the same voltage range.

inverter.

EDSMDAG EN 2.0

Page 24

Technical data

General data and operating conditions

Requirements related to cables for HV on−board supply system and motor

Capacitance per unit length

£2.5 mm2/AWG 14 C

³4 mm2/AWG 12 C

Electric strength

VDE 0250−1 V0/V = 0.6/1.0 kV

UL V³600 V

Cable type

Recommendation l RADOX® cable 155S

EMC

Interference emission ECE R10, Rev. 5 l radiated broad and narrow−band electromagnetic

Immunity to interference ECE R10, Rev. 5 l Immunity to radiated electromagnetic fields

(V0 = r.m.s. value external conductor to PE, V = r.m.s. value external conductor/external conductor)

(V = r.m.s. value external conductor/external conductor)

l Huber & Suhner

l cable−guided transient noise emissions on the supply

l Immunity to injected interferences on the supply cables

core−core

interferences

cables

core−shie ld

<75/150 pF/m

<150/300 pF/m

DC bus EMDAG2... EMDAG3... EMDAG4... EMDAG5...

Rated voltage − HV on−board supply system

DC−bus capacity mF 240 120 120 80

Discharge resistance kW 300 300 300 573

Capacity against PE nF 9.4 18.8 18.8 9.4

Max. discharge time (acc. to EN61800−5−1)

Insulation resistance − DC bus/LV on−board supply system

V DC

s 300 300 300 180

MW 10 10 10 >25

800 800 800 800

EDSMDAG EN 2.0

Page 25

General data and operating conditions

Open and closed loop control

Open and closed loop control processes

Sensorless V/f characteristic control for asynchronous motors (SLVFCI)

l Operation with linear load torque characteristic l Operation with square−law load torque characteristic l Operation of socket applications with V/I characteristic

Sensorless vector control for asynchronous motors (SLVCI)

l Dynamic control in all quadrants

Vector control for synchronous motors (VCS)

l Dynamic control in all quadrants

Switching frequency

4 kHz, 8 kHz, 16 kHz, Either fixed or variable

Output frequency

Range −599 Hz ... +599 Hz

Absolute resolution 0.00024 Hz

Digital setpoint selection

Accuracy Speed 0.00006 rpm

Absolute torque 0.00024 Nm Standard torque 0.1 % Voltage (PSU) 0.00195 V Current (PSU) 0.015625 A

Technical data

EDSMDAG EN 2.0

Page 26

Technical data

Rated data of the devices for HV on−board supply system 800 V Product finder

4.2 Rated data of the devices for HV on−board supply system 800 V

4.2.1 Product finder

How to find the data for the desired MOBILE device:

Device Type DC/AC inverter DC/DC converter

X12 X13 X21

MOBILE DCU

MOBILE PSU

MOBILE DCU PSU

MOBILE DCU S

How to find the data: ^ 27 ^ 30

EMDAG2603603U 60 kW 60 kW ˘

EMDAG2303303U 30 kW 30 kW ˘

EMDAG2303153U 30 kW 15 kW ˘

EMDAG2153752U 15 kW 7.5 kW ˘

EMDAG3562000C ˘ ˘ 5.6 kW, 24 V

EMDAG3282000T ˘ ˘ 2.8 kW, 12 V

EMDAG4562603C ˘ 60 kW 5.6 kW, 24 V

EMDAG4282603C ˘ 60 kW 2.8 kW, 24 V

EMDAG4562303C ˘ 30 kW 5.6 kW, 24 V

EMDAG4282303T ˘ 30 kW 2.8 kW, 12 V

EMDAG4562153C ˘ 15 kW 5.6 kW, 24 V

EMDAG4282153T ˘ 15 kW 2.8 kW, 12 V

EMDAG5223000U 22 kW ˘ ˘

EMDAG5153000U 15 kW ˘ ˘

EMDAG5113000U 11 kW ˘ ˘

EMDAG5752000U 7.5 kW ˘ ˘

EDSMDAG EN 2.0

Page 27

Technical data

Rated data of the devices for HV on−board supply system 800 V

DC/AC inverter

4.2.2 DC/AC inverter

DC/AC inverter 7.5 kW 11 kW 15 kW 22 kW 30 kW 60 kW

Input voltage − HV on−board supply system

Rated voltage V DC 800

Voltage range V DC 100...848

Output voltage 3 AC 0V...510V

Output frequency f

Switch−off at short−circuit current A 24 36.1 48.1 72.1 96.2 192.3

Continuous operation

Current consumption − HV on−board supply system

Output power kW 5 7.3 10 14.7 20 40

Output current at

<5Hz

out

Output current at

>5Hz

out

Output current for "socket" application (VAC)

<10Hz, VAC 16 kHz,

out

>10Hz, VAC 16 kHz,

out

2 kHz, permanent

4 kHz, permanent

8 kHz, permanent

16 kHz, permanent

4 kHz auto A 8 11 15 21.5 32 58

8 kHz auto A 7.2 9.9 13.5 19.4 28.8 52.2

16 kHz auto A 4.4 6.1 8.3 11.8 17.6 31.9

2 kHz, permanent

4 kHz, permanent

8 kHz, permanent

16 kHz, permanent

4 kHz auto A 10 13.8 18.8 26.9 40 72.5

8 kHz auto A 8 11 15 21.5 32 58

16 kHz auto A 4.8 6.6 9 12.9 19.2 34.8

permanent

Hz −599...+599

A 9.8 13.5 18.4 26.3 39.2 71

A 8 11 15 21.5 32 58

A 6.4 8.8 12 17.2 25.6 46.4

A 4.8 6.6 9 12.9 19.2 34.8

A 2.4 3.3 4.5 6.5 9.6 17.4

A 12.8 17.6 24 34.4 51.2 92.8

A 10 13.8 18.8 26.9 40 72.5

A 7.2 9.9 13.5 19.4 28.8 52.2

A 4 5.5 7.5 10.8 16 29

A 2.8 3.9 5.3 7.5 10.6 18.6

A 5 6.9 9.5 13.5 18.9 34.2

EDSMDAG EN 2.0

Page 28

Technical data

Rated data of the devices for HV on−board supply system 800 V DC/AC inverter

60 kW30 kW22 kW15 kW11 kW7.5 kWDC/AC inverter

Overcurrent cycle 60s

Operation for 60s with up to 150% of the continuous output current if afterwards a recovery time of 120s with max. 50% of the continuous output current is observed.

Current consumption − HV on−board supply system

Max. output power kW 7.5 11 15 22 30 60

Max. output current at f

<5Hz

out

Max. output current at f

>5Hz

out

Max. output current for "socket" application (VAC)

<10Hz, VAC 16 kHz,

out

>10Hz, VAC 16 kHz,

out

2 kHz, permanent

4 kHz, permanent

8 kHz, permanent

16 kHz, permanent

4 kHz auto A 12 16.5 22.5 32.3 48 87

8 kHz auto A 10.4 14.3 19.5 28 41.6 75.4

16 kHz auto A 8 11 15 21.5 32 58

2 kHz, permanent

4 kHz, permanent

8 kHz, permanent

16 kHz, permanent

4 kHz auto A 14.8 20.4 27.8 39.8 59.2 107.3

8 kHz auto A 12 16.5 22.5 32.3 48 87

16 kHz auto A 8 11 15 21.5 32 58

permanent

A 14.7 20.2 27.6 39.5 58.8 106.6

A 12 16.5 22.5 32.3 48 87

A 9.2 12.7 17.3 24.7 36.8 66.7

A 5.6 7.7 10.5 15.1 22.4 40.6

A 3.2 4.4 6 8.6 12.8 23.2

A 16 22 30 43 64 116

A 12 16.5 22.5 32.3 48 87

A 8.8 12.1 16.5 23.7 35.2 63.8

A 5.2 7.2 9.8 14 20.8 37.7

A 3.4 4.6 6.3 9.0 12.8 22

A 6.1 8.4 11.4 16.3 22.7 41.2

EDSMDAG EN 2.0

Page 29

Technical data

Rated data of the devices for HV on−board supply system 800 V

DC/AC inverter

60 kW30 kW22 kW15 kW11 kW7.5 kWDC/AC inverter

Overcurrent cycle 10s

Operation for 10s with up to 180% of the continuous output current if afterwards a recovery time of 20s with max. 120% of the continuous output current is observed.

Current consumption − HV on−board supply system

Max. output power kW 9 13.2 18 26.4 36 72

Max. output current at f

<5Hz

out

Max. output current at f

>5Hz

out

Max. output current for "socket" application (VAC)

<10Hz, VAC 16 kHz,

out

>10Hz, VAC 16 kHz,

out

2 kHz, permanent

4 kHz, permanent

8 kHz, permanent

16 kHz, permanent

4 kHz auto A 12.8 17.6 24 34.4 51.2 92.8

8 kHz auto A 12 16.5 22.5 32.3 48 87

16 kHz auto A 9.6 13.2 18 25.8 38.4 69.6

2 kHz, permanent

4 kHz, permanent

8 kHz, permanent

16 kHz, permanent

4 kHz auto A 18 24.8 33.8 48.4 72 130.5

8 kHz auto A 14.4 19.8 27 38.7 57.6 104.4

16 kHz auto A 9.6 13.2 18 25.8 38.4 69.6

permanent

A 17.6 24.2 33.1 47.4 70.5 127.9

A 12.8 17.6 24 34.4 51.2 92.8

A 10 13.8 18.8 26.9 40 72.5

A 6.4 8.8 12 17.2 25.6 46.4

A 3.6 5 6.8 9.7 14.4 26.1

A 17.6 24.2 33 47.3 70.4 127.6

A 14.4 19.8 27 38.7 57.6 104.4

A 10 13.8 18.8 26.9 40 72.5

A 6 8.3 11.3 16.1 24 43.5

A 3.5 4.8 6.6 9.5 13.1 23.2

A 6.3 8.7 11.9 17 23.7 42.9

EDSMDAG EN 2.0

Page 30

Technical data

Rated data of the devices for HV on−board supply system 800 V DC/DC converter

4.2.3 DC/DC converter

DC/DC converter 2.8 kW 5.6 kW

Input data − HV on−board supply system

Rated voltage V DC 800 800

Voltage range V DC 100...848 100...848

Max. current consumption A 16.5 18.3

Output data

Max. output power kW 2.8 5.6

Rated output voltage V DC 14 28

Output voltage range V DC 6 ... 16 6 ... 32

Max. output current A 200 200

Diagram of the output voltage of the DC/DC converter

U [V]

LV,out

EMDAGxxxxxxxC...

max

EMDAGxxxxxxxT...

360 V

100 200 300 400 500 600 700 800 900

max

850 V

Fig. 4−1 DC/DC converter: output voltage with reference to the HV on−board voltage

V V V V

HV,in

LV,o ut rated max

Voltage of HV on−board supply system Output voltage of DC/DC converter Rated output voltage Max. output voltage

U [V]

HV,in

EMDAG0043b

EDSMDAG EN 2.0

Page 31

4.3 Control of MOBILE DCU, PSU, DCU PSU

The MOBILE device is controlled via the X31 terminal.

4.3.1 Voltage supply

Technical data

Control of MOBILE DCU, PSU, DCU PSU

Voltage supply

Supply voltage TRM30

Rated voltage

Voltage range V DC 8 ... 36 8 ... 36

Absolute voltage (Pulse forms: ISO 16750−2) (Behaviour: ISO 16750−1)

Current consumption A 1 ... 2.5 0.5 ... 1.3

Quiescent current at T

Switch on/off device TRM15

Switching threshold V DC 8 8

Current consumption mA 1.7 1.7

4.3.2 Digital inputs

Digital inputs

Rated input voltage V DC 12 24

Voltage range V DC 8 ... 36 8 ... 36

Digital HIGH V DC 7.8 ... 9 15.6 ... 18.2

Digital LOW V DC 3 ... 4.5 6.2 ... 8.8

Hysteresis V DC 3.3 ... 6 6.8 ... 12

Input resistance kW 4.75

Reference potential TRM31

Diagnostics option Wire breakage/short circuit

Digital frequency inputs FLX_IN3, FLX_IN4

Frequency range kHz 0 ... 10

Response time ms 90

Analog inputs FLX_IN1, FLX_IN2

Input frequency Hz 0 ... 500

Resolution Bit 4096

LV on−board supply system

12 V 24 V

V DC 12 24

Min. V DC 6 6

Max. V DC 60 60

= 25 °C mA 40 ... 60 40 ... 60

amb

LV on−board supply system

12 V 24 V

EDSMDAG EN 2.0

Page 32

Technical data

Control of MOBILE DCU, PSU, DCU PSU Digital outputs

4.3.3 Digital outputs

Digital outputs

Rated output voltage V DC 12 24

Voltage range V DC 8 ... 36 8 ... 36

Digital HIGH V DC 8 ... 10.8 ³21.6

Digital LOW V DC 0 ... 5 0 ... 5

Output current HIGH A 0 ... 2

Output current LOW A 0 ... −0.5

Output frequency kHz 0 ... 1

Response time ms 95

Reference potential TRM31

Diagnostics option Wire breakage/short circuit

4.3.4 Potential−free output

Digital switching output

Max. switching voltage V DC 60 60

Voltage potential to X31/20, X31/21 V DC −60 ... 60 −60 ... 60

Max. permissible capacitive load

InterLock−OK (closed)

Contact resistance W 6 ... 15 6 ... 15

InterLock−NOK (open)

Max. fault current mA 1 1

In case of a higher capacitive load, provide for an external current limitation, e.g. by means of a resistor in series connection

LV on−board supply system

12 V 24 V

LV on−board supply system

12 V 24 V

mF 22 22

EDSMDAG EN 2.0

Page 33

Technical data

Control of MOBILE DCU, PSU, DCU PSU

CAN bus

4.3.5 CAN bus

Public CAN

Protocol

Baud rate kbps 125, 250, 500

Max. cable length

at 125kbps S 250

at 250kbps m 250

at 500kbps m 100

Loop delay of all nodes ns <300

Private CAN

Protocol CANopen

Baud rate kbps 125, 250, 500, 1000

Max. cable length

at 125kbps m 250

at 250kbps m 250

at 500kbps m 100

at 1000kbps m 20

Loop delay of all nodes ns <300

SAE J1939

EDSMDAG EN 2.0

Page 34

Technical data

Control of MOBILE DCU S Voltage supply

4.4 Control of MOBILE DCU S

The MOBILE device is controlled via the X1 terminal.

4.4.1 Voltage supply

Voltage supply

Supply voltage TRM30

Rated voltage

Voltage range V DC 8 ... 36 8 ... 36

Absolute voltage (Pulse forms: ISO 16750−2) (Behaviour: (ISO 16750−1)

Current consumption A 0.4 ... 0.9 0.2 ... 0.6

Quiescent current at T

Switch on/off device TRM15

Switching threshold V DC 8 8

Current consumption mA 1.7 1.7

Secondary Wake Up (SWUP)

Switching threshold V DC 8 8

Current consumption mA 1.7 1.7

4.4.2 Digital inputs

Digital inputs

Rated input voltage V DC 12 24

Voltage range V DC 8 ... 36 8 ... 36

Digital HIGH V DC 7.8 ... 9 15.6 ... 18.2

Digital LOW V DC 3 ... 4.5 6.2 ... 8.8

Hysteresis V DC 3.3 ... 6 6.8 ... 12

Input resistance kW 4.75

Reference potential TRM31

Diagnostics option Wire breakage/short circuit

Use as analog inputs

Input frequency Hz 0 ... 500

Resolution Bit 4096

LV on−board supply system

12 V 24 V

V DC 12 24

Min. V DC 6 6

Max. V DC 60 60

= 25 °C mA 40 ... 60 40 ... 60

amb

LV on−board supply system

12 V 24 V

EDSMDAG EN 2.0

Page 35

4.4.3 Thermal sensor input

Thermal sensor input Value

Evaluable thermal sensors PT1000, KTY83/110, KTY84/130,

Diagnostics option Wire breakage/short circuit

Resistance measuring range W 280 ... 3050

Limit frequency of input filter Hz 10

Resolution Bit 12

4.4.4 CAN bus

Public CAN and Private CAN communicate via a bus cable.

Public CAN, Private CAN

Protocol

Public CAN SAE J1939

Private CAN CANopen

Baud rate kbps 125, 250, 500

Max. cable length

at 125kbps m 250

at 250kbps m 250

at 500kbps m 100

Loop delay of all nodes ns <200

Technical data

Control of MOBILE DCU S

Thermal sensor input

PTC acc. to DIN44081,

thermostat (normally−closed contact) acc. to

DIN44080

EDSMDAG EN 2.0

Page 36

Technical data

Water cooling

4.5 Water cooling

For cooling the MOBILE device, the integrated water cooler is connected to the vehicle−specific cooling circuit.

EMDAG2... EMDAG3...

EMDAG4...

Connection of suction and pressure hoses

Securing the hoses Suitable hose clamps

Flow direction

in case of vertical installation from the lower to the higher connection

in case of horizontal or pending installation

Fluid volume l 0.09 0.16 0.12

Composition of the cooling fluid

Water/ethylene glycol % 50/50 50/50 50/50

Flow rate Derating at a lower flow rate

Permissible pressure in the cooling system

Max. test pressure bar 5 5 5

Permissible temperatures of the cooling fluid in continuous operation

Recommended switch−on temperature for coolant pump

l/min 15 ... 25 15 ... 25 15 ... 25

bar 1 ... 2 1 ... 2 1 ... 2

°C 30 ... 65 30 ... 65 30 ... 65

°C 30 30 30

DN 20 (internal)

Not relevant

EMDAG5...

EDSMDAG EN 2.0

Page 37

Technical data

Water cooling

Decrease in pressure in the water cooler

Decrease in pressure in the water cooler of the MOBILE device with a coolant mixture of water/ethylene glycol in a ratio of 50:50 and at a coolant temperature of 60°C.

MOBILE DCU, PSU, DCU PSU

p [mbar]

100

MOBILE PSU, DCU PSU

MOBILE DCU

0 510 15 20

Fig. 4−2 Typical decrease in pressure in the water cooler

MOBILE DCU S

p [mbar]

0 510 15 20

Fig. 4−3 Typical decrease in pressure in the water cooler

Q [l/min]

EMDAG030

Q [l/min]

EMDAG048

EDSMDAG EN 2.0

Page 38

4.6 Dimensions

Technical data

Dimensions

Dimensions and weights can be found in the "Mechanical installation" chapter. (¶ 41)

EDSMDAG EN 2.0

Page 39

5 Installation

5.1 Important notes

{ Danger!

Dangerous electrical voltage

Even after the HV on−board voltage or mains voltage has been switched off, all power terminals continue to carry electrical voltage for some time, e.g. from capacitors.

Possible consequences:

ƒ Death or severe injury if the power terminals are touched.

Protective measures:

ƒ Switch off the HV on−board supply system or power supply and wait until

the power terminals are discharged before working on them.

ƒ Make sure that all power terminals are deenergised before working on

them.

Installation

Important notes

( Stop!

No device protection if the HV on−board voltage or mains voltage is too high

The input for the HV on−board supply system or the mains is not fused internally.

Possible consequences:

ƒ Destruction of the device if the HV on−board voltage or the mains voltage is

too high.

Protective measures:

ƒ Observe the maximum permissible HV on−board voltage or mains voltage. ƒ Fuse the device correctly on the supply side against mains fluctuations and

voltage peaks.

( Stop!

The input for the HV on−board supply system or the mains does not have an electrical polarity reversal protection

Possible consequences:

ƒ Destruction of the device is the HV on−board supply system or the mains is

connected incorrectly.

Protective measures:

ƒ Check wiring for possible polarity reversal.

EDSMDAG EN 2.0

Page 40

Installation

Important notes

( Stop!

The device contains components that can be destroyed by electrostatic discharge!

Before working on the device, the personnel must ensure that they are free of electrostatic charge by using appropriate measures.

EDSMDAG EN 2.0

Page 41

5.2 Mechanical installation

EMDAG2..., EMDAG3..., EMDAG4...

The mounting material must ensure a durable mechanical connection. The fixing points are dimensioned for:

ƒ M10 cheese head screw, hexagon socket, according to DIN 912/ISO 4762

ƒ M10 cheese head screw, torx, according to ISO 14579

Installation

Mechanical installation

X11 / X12 / X13

M10

3×

EDSMDAG EN 2.0

h b t b

EMDAG002

r Ý

[mm] [kg]

EMDxG2...

EMDxG3... 8.4

310

394 81 355 331 165.5 165.5 286 Ø 11 106

7.0

EMDxG4... 8.4

Page 42

Installation

Mechanical installation

EMDAG5...

The installation material must ensure the mechanical connection on a permanent basis. The fixing points are designed for:

ƒ M6 cheese head, hexagon socket, acc. to DIN 912/ISO 4762

ƒ M6 cheese head, Torx, acc. to ISO 14579

4×

EMDAG026

h b t b

g g

r Ý

[mm] [kg]

EMDxG5... 250 254 109 237 210 180 9 Ø 6.7 106 3.9

EDSMDAG EN 2.0

Page 43

5.3 Water cooling

For operating the Mobile devices, a working water cooling system is required.

Operation without water cooling is not permissible and destroys the devices.

A subsequent loosening or tightening of the screws in the cooling cover is not permissible. The water cooler is mounted in the factory and checked for tightness.

The water cooling has to be dimensioned according the technical data (¶ 36).

How to connect a proper cooling system:

ƒ Remove the protective caps from the adaptors (delivery status).

ƒ Connect suction and pressure hoses.

ƒ Fix and secure the hoses with suitable clips.

ƒ Fill and vent water cooling.

Prior to every switch−on, the proper functioning of the cooling needs to be ensured.

Installation

Water cooling

EMDAG2..., EMDAG3..., EMDAG4...

Æ 25 - 40 mm

20 mm (DN 20)

EMDAG5...

Æ 25 - 40 mm

20 mm (DN 20)

£ 2 bar

8 × 1.2 mm

EMDAG004

£ 2 bar

8 × 1.2 mm

EMDAG027

EDSMDAG EN 2.0

Page 44

Installation

EMC−compliant installation Equipotential bonding

5.4 EMC−compliant installation

EMC−compliant installation is a prerequisite for a safe and trouble−free operation of the devices.

EMC interferences can

ƒ interrupt the CAN communication,

ƒ cause the drives and on−board converters to be switched off to protect the systems.

5.4.1 Equipotential bonding

Conditions for a working EMC concept:

ƒ Avoid current loops because they cause induced voltage differences.

ƒ Arrange the equipotential bonding in star shape and avoid earth loops.

ƒ Install equipotential bonding conductors in parallel to the supply and

communication cables. – A equipotential bonding conductor in the motor cable extends the current

compensation by high−frequency currents and avoids an overload of the cable shield.

MOBILE device Equipotential bonding conductor

EMDAG041

EDSMDAG EN 2.0

Page 45

5.4.2 Shielding

ƒ The effectiveness of a shielded cable is reached by:

– Providing a good shield connection through large−surface shield contact. – Using only braided shields with low shield resistance made of tin−plated or

nickel−plated copper braid. – Using braided shields with an overlap rate > 70 % and an overlap angle of 90 °. – Keeping unshielded cable ends as short as possible.

Use system cables or shielded cables for these connections:

ƒ Motor

ƒ HV on−board supply system

The following connections need not be shielded:

ƒ LV on−board supply system (only PSU)

ƒ 24−V supply

Installation

EMC−compliant installation

Shielding

ƒ Digital signals (inputs and outputs).

– We recommend to use shielded cables for a cable length from approximately 5 m

on or in environments with strong interferences.

Connection system

Prefabricated cables for the motor connection and the connection to the HV on−board supply system are provided with cable glands and ensure an optimum connection of the shield to the vehicle mass. This guarantees an optimum EMC−compliant installation and the required environmental conditions are met.

ƒ When installing the motor cable and the HV on−board cable, slide the cable gland

into the respective holders and fix it by tightening the mounting bracket.

5.4.3 HV on−board cable

The descriptions in the next chapter regarding shielded motor cables analogously also apply to the HV mains cables (see next chapter).

EDSMDAG EN 2.0

Page 46

5.4.4 Motor cable

Installation

EMC−compliant installation Motor cable

ƒ Only use shielded motor cables with braids made of tinned or nickel−plated copper.

Shields made of steel braids are not suitable. – The overlap rate of the braid must be at least 70 % with an overlap angle of 90 °.

ƒ The cables used must correspond to the requirements at the location (e.g.

EN 60204−1).

ƒ Use Lenze system cables.

ƒ Extensively apply the shielding with the compressed cable gland and ensure

electrical conductivity.

ƒ The motor cable is optimally installed if

– it is separated from mains cables and control cables, – it only crosses mains cables and control cables at right angles, – it is not interrupted.

ƒ If the motor cable must be opened all the same (e.g. due to contactors, or terminals):

– The unshielded cable ends may not be longer than 100 mm (depending on the

cable cross−section). – Install contactors, terminals etc. spatially separated from other components (with

a min. distance of 100 mm). – Install the shield of the motor cable directly before and behind the point of

separation to the conducting mounting plate with a large surface.

ƒ Connect the shield with a large surface to PE in the terminal box of the motor at the

motor housing. – Metal EMC cable glands at the motor terminal box ensure a large surface

connection of the shield with the motor housing.

Wiring on the motor side

( Stop!

The motor cable is highly susceptible to interference. The following measures enable you to achieve an optimum wiring on the motor side:

ƒ Exclusively use shielded and low−capacitance motor cables. ƒ If possible, integrate the equipotential bonding conductor inside the motor

cable shield or install it in parallel to the motor cable.

ƒ Do not integrate any further cables (e.g. for blowers etc.). ƒ Shield the supply cable for temperature monitoring of the motor (PTC or

thermostat) and install it separately from the motor cable.

EDSMDAG EN 2.0

Page 47

5.4.5 Control cables

ƒ Shield control cables to minimise interference injections.

ƒ Connect the shield correctly:

– Connect the shield of digital input and output cables at both ends. – Connect the shield of analog input and output cables at one end of the inverter.

ƒ To achieve an optimum shielding effect (in case of very long cables, with high

interference) one shield end of analog input and output cables can be connected to PE potential via a capacitor (e.g. 10 nF/250 V).

5.4.6 Detecting and eliminating EMC interferences

Interference Cause Remedy

Interference of analog setpoints of the own or other devices and measuring systems

CAN time out or CAN Bus Heavy

Unshielded HV mains cable Unshielded motor cable

Shield contact is not extensive enough Carry out optimal shielding as specified

Shield of the motor cable is interrupted by terminal strips, switched, etc.

Install additional unshielded cables inside the motor cable (e.g. for motor temperature monitoring)

Too long and unshielded cable ends of the motor cable

CAN communication is disturbed l Use cable according to CAN

Installation

EMC−compliant installation

Control cables

Use shielded cables

l Separate components from other

component parts with a minimum distance of 100 mm

l Use motor choke/motor filter

Install and shield additional cables separately

Shorten unshielded cable ends to maximally 40 mm

specification

l Wire terminals completely l Connect the shield with a good

electric conductivity

l Check terminating resistor

EDSMDAG EN 2.0

Page 48

Installation

Electrical installation Basic circuit diagrams

5.5 Electrical installation

5.5.1 Basic circuit diagrams

MOBILE DCU

800 V DC

Strg

+UG +UG -UG -UG

3~ M

X11

X12

X31

EMDxG2...

X13

X32

X33

...

EMDAG0038a

EDSMDAG EN 2.0

Page 49

MOBILE PSU

800 V DC

Strg

Installation

Electrical installation

Basic circuit diagrams

800 V DC

12/24 V DC

+UG +UG -UG -UG

X11

X21

-B

+UG +UG -UG -UG

X11

X21

-B

EMDxG3...

...

X31

Strg Strg

+UG+UG -UG -UG

X11

X21

-B

EMDxG3...

X31

...

12/24 V DC

X31

EMDAGS0038b

...

EDSMDAG EN 2.0

EMDAG0038c

Page 50

Installation

Electrical installation Basic circuit diagrams

MOBILE DCU PSU

800 V DC

Strg

12/24 V DC

-B

MOBILE DCU S

800 V DC

+UG +UG -UG -UG

X11

X21

EMDxG4...

...

X31

...

X33

X13

3~ M

EMDAG0038d

+UG -UG

EMDxG5...

3~ M

Strg

...

EMDAG0038e

EDSMDAG EN 2.0

Page 51

Installation

Electrical installation

Fuses and cable cross−sections

5.5.2 Fuses and cable cross−sections

Installed cables have to be protected against short circuit and overload. The execution of these protective measures essentially depends on the available energy sources (generator, memory, connection to supply system, etc.) and is the responsibility of the vehicle manufacturer or the equipment suppliers.

Fuses and circuit breakers have to be dimensioned in such a way that the occurring short−circuit currents caused by the internal resistances of the energy sources are sufficiently high to safely trip the fuses. Otherwise, there is no reliable switch−off in case of short circuit.

When dimensioning fuses, consider the ambient conditions in such a way that the cables are protected from overload in the entire temperature range. Here, the type of installation and cooling of the cables have to be considered sufficiently.

If a memory with battery management is available that can switch off the short−circuit current reliably, no fuses are needed. In this case, the cables of the MOBILE devices have to be protected from overload by a suitable parameter setting.

EDSMDAG EN 2.0

Page 52

Installation

Electrical installation Wiring the CAN bus

5.5.3 Wiring the CAN bus

Wiring must meet the following requirements:

ƒ The CAN cable complies with the specification acc. to ISO 11898−2.

ƒ The CAN cable has twisted cores (CAN_H, CAN_L) to avoid interferences on the bus

(Bus−Off, Bus−Heavy, etc).

ƒ When looping through the signals "CAN_HIGH" and "CAN_LOW", avoid double

crimping. For this purpose, the Public CAN is provided with two pins each.

ƒ Stubs are <0.2m. Ideally, stubs are avoided.

ƒ The cable length matches the data transfer rate.

ƒ The CAN cable runs along the LV on−board cable and is installed separately from the

power cables.

ƒ The CAN bus is completely wired. Unwired terminals are not permissible.

ƒ The first and last node of the CAN bus are connected to the integrated terminating

resistor.

HCU

MOBILE 1

MOBILE 2

CAN

High

Low

CAN

EMDAG0034a

EDSMDAG EN 2.0

Page 53

Installation

Electrical installation

Wiring the CAN bus

Interferences on the CAN bus

In case of interferences on the CAN bus, a shielded cable must be used. The shield is connected to PE (chassis ground). The shield/PE connection must have a low resistance to avoid shield currents in the system.

ƒ Connect the shield on one side to PE.

ƒ Connect the shield on both sides to PE if interferences continue to occur in case the

shield is only connected on one side.

HCU

CAN

High

Low

MOBILE 1

CAN

MOBILE 2

CAN

EMDAG0034b

EDSMDAG EN 2.0

Page 54

Installation

Connections of MOBILE DCU, PSU, DCU PSU PE conductor

5.6 Connections of MOBILE DCU, PSU, DCU PSU

5.6.1 PE conductor

[mm2]

[AWG]

8 (Eco-Fix) 10

6.3 Nm

>10

>000

MOBILE DCU Same conductor cross−section as the HV on−board cable

Connection with non−insulated ring cable lug, M6

MOBILE DCU PSU MOBILE PSU

xxxxx

DC4

xxxxxxxx

Connection with non−insulated ring cable lug, M6

xxxxx xxxxxxxx

5.6.2 HV on−board supply system

X11

Per potential, the terminal contains two contacts for looping through the DC−bus voltage.

EMDAG020b

1 +UG

2 +UG

3 −UG

4 −UG

( Stop!

The input for the HV on−board supply system or the mains does not have an electrical polarity reversal protection

Possible consequences:

ƒ Destruction of the device is the HV on−board supply system or the mains is

connected incorrectly.

Protective measures:

ƒ Check wiring for possible polarity reversal.

max

[V DC] [mm2]

[AWG]

848

2.5 ... 12

12 ... 6

EMDAG017a

EDSMDAG EN 2.0

Page 55

Installation

Connections of MOBILE DCU, PSU, DCU PSU

Motor

5.6.3 Motor

X12 X13

MOBILE DCU EMDxG2... l l

MOBILE PSU EMDxG3... ˘ ˘

MOBILE DCU PSU EMDxG4... ˘ l

X12, X13

PE conductor

max

[V AC] [mm2]

[AWG]

1 W

EMDAG020b

2 V

3 U

4 ˘ ˘ ˘

PE ˘

600

3.6 Nm

2.5 ... 12

12 ... 6

2.5 ... 12

12 ... 6

xxxxx

DC4

xxxxxxxx

EMDAG005a

EDSMDAG EN 2.0

Page 56

Installation

Connections of MOBILE DCU, PSU, DCU PSU Feedback

5.6.4 Feedback

X32 and X33 serve to connect feedback systems for servo control and sensors for motor temperature monitoring.

ƒ Supported feedback system: resolver

ƒ Supported sensors for motor temperature monitoring: PT1000, KTY83/110,

KTY84/130, PTC acc. to DIN 44081, thermostat (normally−closed contact) acc. to DIN 44080.

– Maximally three PTC thermistors may be connected in series. – Monitored: short circuit and cable breakage. Thermostats are not monitored.

Each connection is assigned to a motor connection. The MOBILE DCU assignment is configurable.

ƒ X32 <=> motor connection X12

ƒ X33 <=> motor connection X13

MOBILE DCU EMDxG2... l l

MOBILE PSU EMDxG3... ˘ ˘

MOBILE DCU/PSU EMDxG4... ˘ l

X32 X33

X32, X33 (M12 female socket A−coding)

EMDAG020d

1 +Ref

(+OSZ)

2 −Ref

(−OSZ)

3 +Sin 7 +KTY

4 −Sin 8 −KTY

+REF

-REF

+COS

-COS

+SIN

-SIN

KTY

+KTY

-KTY

X32 / X33

5 +COS

6 −COS

l KTY83/110

(+TEMP)

(−TEMP)

l KTY84/130 l PT1000 l PTC (DIN 44081) l J−Switch NC

EMDAG035

EDSMDAG EN 2.0

Page 57

Installation

Connections of MOBILE DCU, PSU, DCU PSU

LV on−board supply system

5.6.5 LV on−board supply system

X21

MOBILE DCU EMDxG2... ˘

MOBILE PSU EMDxG3... l

MOBILE DCU/PSU EMDxG4... l

X21+, X21−

+ M10

EMDAGxxxx

X21/B− must be connected to "chassis ground" (TRM31).

− M8

max

[V] [mm2]

[AWG]

000

with ring cable lug

EMDAG10_b

EDSMDAG EN 2.0

Page 58

Installation

Connections of MOBILE DCU, PSU, DCU PSU Control system

5.6.6 Control system

X31 Description

20 14 8 1

EMDAG020c

1 CAN_H_TERM_PUBLIC Public CAN, bus termination CAN−High

2 CAN_H_PUBLIC

3 CAN_L_PUBLIC

4 InterLock2 Potential−free output, connection 2

5 CAN_L_PRIVATE

6 CAN_H_PRIVATE

7 InterLock1 Potential−free output, connection 1

8 TRM15 Switch on/off device

9 CAN_H_PUBLIC

10 CAN_L_PUBLIC

11 CAN_L_TERM_PUBLIC Public CAN, bus termination CAN−Low

12 ID_PIN1

13 ID_PIN3

14 FLX_IN4

15 FLX_IN3

16 FLX_IN2

17 FLX_IN1

18 ID_PIN2

19 ID_PIN4

20 TRM31 Vehicle mass, negative pole of the vehicle battery

21 TRM30

22 TRM30

23 FLX_OUT4

24 FLX_OUT3

25 FLX_OUT2

26 FLX_OUT1

Public CAN In

Private CAN

Public CAN Out

Address offset for setting the CAN address

Digital inputs

l Can also be parameterised as frequency inputs

Digital inputs

l Can also be parameterised as analog inputs

Address offset for setting the CAN address

Supply voltage for control electronics

Digital outputs

EDSMDAG EN 2.0

Page 59

Installation

Connections of MOBILE DCU, PSU, DCU PSU

Addressing CAN bus nodes

5.6.7 Addressing CAN bus nodes

The MOBILE devices can be operated via the following CAN bus systems:

ƒ Public CAN: Communication with vehicle or subsystem control (e.g. air conditioning

system). – The Public CAN is the customer interface provided for applications in commercial

vehicles which can be adapted to the respective communication and diagnostic

environments of the single OEM´s. By default, the control is carried out according

to SAE J1939 and the diagnostics is carried out according to UDS (Unified

Diagnostic Services) which is implemented in the Application Controller (AppC).

ƒ Private CAN: Communication with subsystem or other drives.

– The Application Controller (AppC) and the Motor Controller (MC) are connected via

the Private CAN (CAN2.0A) and communicate in accordance with CANopen, Drive

Profile DS 402. This Private CAN interface enables the Application Controller to

transmit the control commands received via the Public CAN to the Motor

Controller(s).

EDSMDAG EN 2.0

Page 60

Installation

Connections of MOBILE DCU, PSU, DCU PSU Addressing CAN bus nodes

Setting the address offset

Each MOBILE device has one address for the Public CAN and three addresses for the Private CAN. An address consists of the basic address and the address offset (address = basic address + address offset).

ƒ Lenze setting of the address offset: 13 (ID pins are not wired)

ƒ Lenze setting of the basic address for Public−CAN: 247

ƒ Lenze setting of the basic addresses Private−CAN:

– AppC: 45 – MC (channel 1): 14 – MC (channel 2): 77

The address offset is defined by wiring ID−Pin1...ID−Pin4 to X31. Thanks to the combinations, 14 different address offsets are possible which means that up to 14 MOBILE devices can be operated at a CAN bus.

ID-Pin1 ID-Pin2 ID-Pin3 ID-Pin4Offset

Fig. 5−1 Wiring at X31

ID−PIN1 X31/12 ID−PIN2 X31/18 ID−PIN3 X31/13 ID−PIN4 X31/19 Offset 13 Lenze setting Boot Loader Startup Device remains in the Boot Loader, firmware is not started. The length of the wire jumpers may be maximally 50 mm. If the ID pins are double assigned, the

contact must be double crimped.

ID-Pin1 ID-Pin2 ID-Pin3 ID-Pin4Offset

Boot-

Loader

Startup

ID-Pin1 ID-Pin2 ID-Pin3 ID-Pin4Offset

EMDAG033

EDSMDAG EN 2.0

Page 61

Connections of MOBILE DCU, PSU, DCU PSU

5.6.8 Activating the terminating resistor

In order to ensure a troublefree operation, a 120 W terminating resistor must be connected to the last device of a CAN bus.

ƒ For Public CAN, the terminating resistor is integrated in each device. It is activated by

two bridges: – Bridge between X31/1 (CAN_H_TERM_PUBLIC) and X31/2 (CAN_H_PUBLIC) – Bridge between X31/11 (CAN_L_TERM_PUBLIC) and X31/10 (CAN_L_PUBLIC)

ƒ For Private CAN. no terminating resistor is integrated. The terminating resistor must

be connected externally.

Installation

Activating the terminating resistor

CAN_H_PUBLI

X31

EMDAG2 ... 4

Public CAN

CAN_H_PUBLI

CAN_L_TERM_PUBLI

CAN_H_TERM_PUBLI

12119

CAN_L_PUBLICCAN_L_PUBLI

103

CAN_H_PUBLI

X31

EMDAG2 ... 4

Public CAN

CAN_H_PUBLI

Fig. 5−2 Public CAN: activate terminating resistor

n = 1 + x n = 1

EMDAG2 ... 4

Private CAN

EMDAG2 ... 4

Private CAN

n = 1 + x

CAN_L_TERM_PUBLI

CAN_H_TERM_PUBLI

12119

CAN_L_PUBLICCAN_L_PUBLI

103

EMDAG2 ... 4

Public CAN

CAN_H_PUBLI

X31

EMDAG2 ... 4

Private CAN

n = 1

CAN_H_TERM_PUBLI

12119

CAN_L_TERM_PUBLI

CAN_L_PUBLICCAN_L_PUBLI

103

HCU

EMDAG044

EDSMDAG EN 2.0

ATE

CAN_L_PRIV

X31 6

120

ATE

CAN_H_PRIV

X31 6

ATE

CAN_H_PRIV

CAN_L_PRIV

Fig. 5−3 Private CAN: activate terminating resistor

ATE

CAN_L_PRIV

X31 6

ATE

CAN_H_PRIV

HCU

EMDAG050

Page 62

Installation

Connections of MOBILE DCU S PE conductor

5.7 Connections of MOBILE DCU S

5.7.1 PE conductor

[mm2]

[AWG]

+ 2.5 ... 4

12 ... 10

8 (Eco-Fix) 10

6.3 Nm

Connection with non−insulated ring cable lug, M6

xxxxx

DC4

xxxxxxxx

xxxxx xxxxxxxx

5.7.2 HV on−board supply system

1 +UG

EMDAG049b

2 −UG

max

[V DC] [mm2]

[AWG]

848

2.5 ... 4

12 ... 10

EMDAG029b

EDSMDAG EN 2.0

Page 63

Installation

Connections of MOBILE DCU S

Motor

5.7.3 Motor

1 2

ƒ In addition, a equipotential bonding between motor and DC/AC inverter is required.

ƒ Install the equipotential bonding conductor in parallel to the motor cable.

5.7.4 Control system

X1 Description

716

13 19

EMDAG049c

EMDAG049a

max

[V AC] [mm2]

[AWG]

1 U

2 V

3 W

1 CAN_H

2 CAN_L

3 CAN_L_TERM Bus terminating resistor for CAN

4 n.c. Do not use

5 TEMP_MA+

6 TEMP_MA−

7 TRM15 Switch on/off device

8 TRM30 Supply voltage for control electronics

9 CAN_H

10 CAN_L

11 FLX_IN4

12 FLX_IN3

13 n.c. Do not use

14 SWUP Secondary Wake up

15 TRM31 Vehicle mass, negative pole of the vehicle battery

16 FLX_IN1

17 FLX_IN2

18 ID_PIN1

19 ID_PIN2

20 ID_PIN3

21 n.c. Do not use

600

2.5

Public CAN and Private CAN network

Analog thermal sensor

Public CAN and Private CAN network

Digital inputs

Address offset for setting the CAN address

EDSMDAG EN 2.0

Page 64

Installation

Connections of MOBILE DCU S Addressing CAN bus nodes

5.7.5 Addressing CAN bus nodes