Mobile Drive Hardware Manual

EDSMDAG.PC;

Ä.PC;ä

Hardware Manual

MOBILE

�

EMDxGxxxxxxxx

MOBILE DCUMOBILE PSUMOBILE DCU PSU

Mobile Drive

0Fig. 0Tab. 0

Contents i

� 3EDSMDAG EN 1.1

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

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

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

1.5 Document history 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 Conventions used 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7 Terms and abbreviations used 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8 Notes used 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Safety instructions 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 General safety and application notes for Lenze MOBILE devices 11. . . . . . . . . . . . . .

2.2 Residual hazards 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Product description 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 System overview 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Device features 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Identification 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 Type code 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 Overview of control terminals 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

4.3 Rated data 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.1 Voltage supply 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.2 Overview 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.3 Motor connection for HV on−board supply system 800 V 27. . . . . . . . . . . .

4.3.4 Motor connection for HV on−board supply system 400 V 29. . . . . . . . . . . .

4.3.5 Connection for charging the low voltage on−board supply system 31. . . .

4.3.6 Connection of high−voltage on−board supply system 33. . . . . . . . . . . . . . .

4.4 Water cooling 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Terminal description 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.1 Overview 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 Power terminals 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.1 Connection of high−voltage on−board supply system 38. . . . . . . . . . . . . . .

4.6.2 Motor connection 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.3 Connection for charging the low voltage on−board supply system 39. . . .

Contentsi

� 4 EDSMDAG EN 1.1

4.7 Control terminals 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.1 Vehicle connection 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.2 Voltage supply 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.3 Digital inputs 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.4 Digital outputs 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.5 Connection for digital switching output 43. . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.6 Identification 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.7 Communication connection 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 Feedback connection 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9 Dimensions 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Installation 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Important notes 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 EMC−compliant installation 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.1 Shielding 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.2 HV mains cable 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.3 Motor cable 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.4 Control cables 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.5 CAN interface 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.6 Detecting and eliminating EMC interferences 53. . . . . . . . . . . . . . . . . . . . .

5.4 Mechanical installation 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Water cooling 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Electrical installation 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6.1 Power connections 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6.2 Wiring of control connections 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Commissioning 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Diagnostics 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Accessories (overview) 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 Prefabricated cables and plug accessories 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 Single parts list for the electrical installation 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.1 High−voltage on−board supply system at X11 64. . . . . . . . . . . . . . . . . . . . . .

8.2.2 Motors at X12 and/or X13 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.3 Shield connection at X11, X12 and X13 65. . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.4 Low−voltage on−board supply system at X21 B+ and X21 B− 66. . . . . . . . . .

8.2.5 Vehicle interface at X31 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.6 Motor rotary transducer feedback at X32 and/or X33 66. . . . . . . . . . . . . . .

9 Index 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About this documentationTarget group

1

� 5EDSMDAG EN 1.1

1 About this documentation

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

� Tip!

Information and auxiliary devices related to the Lenze products can be foundin the download area at

http://www.Lenze.com

1.1 Target group

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

1.2 Validity information

This manual applies to the components with the type designation:

Type Type designation From HW From SW

Variant

MOBILE DCU

MOBILE DCU(Advanced)

EMDAG1xxxxxxxxEMDAG2xxxxxxxx

0x50 05.00

MOBILE B DCU(Basic)

EMDBG1xxxxxxxxEMDBG2xxxxxxxx

0x50 05.00

MOBILE PSU

MOBILE PSU(Advanced)

EMDAG3xxxxxxxx 0x80 −

MOBILE B PSU(Basic)

EMDBG3xxxxxxxx 0x80 −

MOBILE DCU PSU

MOBILE DCU PSU(Advanced)

EMDAG4xxxxxxxx 0x80 05.00

MOBILE B DCU PSU(Basic)

EMDBG4xxxxxxxx 0x80 05.00

Accessories EMDAZ... − −

The breakdown of type designations is included in the chapter "Productdescription".(� 19).

About this documentationDocument history

1


1.3 Document history

Material number Version Description

.PC; 1.1 10/2014 TD15 Corrections

13473426 1.0 10/2014 TD15 First edition

About this documentationConventions used

1

� 7EDSMDAG EN 1.1

1.4 Conventions used

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

Spelling of numbers

Decimal separator Point In general, the decimal point is used.For instance: 1234.56

Text

Program name » « PC softwareFor example: »Engineer«, »Global DriveControl« (GDC)

Icons

Page reference � Reference to another page with additionalinformationFor instance: � 16 = see page 16

Documentation reference � Reference to another documentation withadditional informationFor example: � EDKxxx = seedocumentation EDKxxx

About this documentationTerms and abbreviations used

1


1.5 Terms and abbreviations used

Term Description

MOBILE Product platform for automotive drive solutions

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

DCU MOBILE inverterDrive Control Unit

PSU MOBILE−DC/DC converterPower Supply Unit

PSU DCU Combined device

ControllersMotor module

General designation for servo controllers and frequency inverters

Frequency inverter Electronic controller for position, speed and/or torque

Single inverterSingle inverter

Controller for one motor / one drive

Double inverterMultiple inverter

Inverter for two motors / two drives

Module Electronic unit or device

Motor AMotor B

Naming the first (A) or second (B) drive in case of double inverters

Power electronics Rectification, DC bus and DC−AC converter

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

DC−bus operation,DC−bus connection

Interconnection of several inverters on the DC−bus level

DC−bus level Energy store between rectification and DC−AC conversion, for one or morecontrollers

About this documentationTerms and abbreviations used

1

� 9EDSMDAG EN 1.1

Term Description

APPC Application Controller

ASM Asynchronous machine

OBC On−board converters (14 V or 28 V DC/DC converters for charging theon−board battery)

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

CiA CAN in AUTOMATION

DC direct current

DC link direct current link (DC bus)

DSP Digital Signal Processor (is used identically with MC)

DWR Double inverter (variant without BNW)

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

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

IGBT Insulated gate bipolar transistor

IT system Isole Terre system (star point not earthed)

TRM15 Terminals 15: Terminal 15 is the original contact �Ignition onˆ at thesteering lock which switches on the MOBILE PSU/DCU by a switch−onpulse (pos. edge).

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

TRM31 negative voltage of the voltage supply (0 V). This signal is potentiallyconnected to the vehicle chassis.

MC Motor Controller

Motor A first motor controlled by MC

Motor B second motor controlled by MC (optional)

NodeID Device identifiers according to CANOpen. These serve to calculate thetelegram identifiers for SDOs and PDOs.

n. c. not assigned

n. a. not assembled

PE Protective earth (chassis)

PowerDown Switch−off process for shutting down the MOBILE PSU/DCU

PowerUp Power up process when switching on the MOBILE PSU/DCU

PRGPS Precharge Power Supply (precharge of DC bus)

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

Public CAN CAN bus on the vehicle side which is used for integrating theMOBILE PSU/DCU into vehicles.

SM Synchronous machine

TN system Terre Neutre system (star point is earthed)

DC bus DC bus

SLVCI Sensorless vector control for asynchronous motors

SLVFCI Sensorless V/f characteristic control for asynchronous motors

VCS Vector control for synchronous motors

About this documentationNotes used

1


1.6 Notes used

The following pictographs and signal words are used in this documentation to indicatedangers 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 dangeroussituations)

Pictograph and signal word Meaning

� Danger!

Danger of personal injury through dangerous electrical voltage.Reference to an imminent danger that may result in death orserious personal injury if the corresponding measures are nottaken.

� Danger!

Danger of personal injury through a general source of danger.Reference to an imminent danger that may result in death orserious personal injury if the corresponding measures are nottaken.

Stop!Danger of property damage.Reference to a possible danger that may result in propertydamage if the corresponding measures are not taken.

Application notes

Pictograph and signal word Meaning

Note! Important note to ensure troublefree operation

� Tip! Useful tip for simple handling

� Reference to another documentation

Safety instructionsGeneral safety and application notes for Lenze MOBILE devices

2

� 11EDSMDAG EN 1.1

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 anddischarged:

– 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 lawsapplicable on the site of installation.

ƒ Transport, installation, commissioning and maintenance work must only be carriedout by qualified personnel.

– Observe IEC 364 and CENELEC HD 384 or DIN VDE 0100 and IEC report 664 orDIN VDE 0110 and all national regulations for the prevention of accidents.

– According to this basic safety information, qualified, skilled personnel are personswho are familiar with the assembly, installation, commissioning, and operation ofthe 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 ofthe specified product features.

– The procedural notes and circuit details described in the documentation are onlyproposals. It is up to the user to check whether they can be transferred to theparticular applications. Lenze Schmidhauser does not accept any liability for thesuitability of the procedures and circuit proposals described.


2


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 ofmeasurement.

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

Application as directed

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 industrialpurposes according to EN 61000−3−2.

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

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

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

ƒ The vehicle corresponds to the valid vehicle standards (ECE R100); EN 60204 isobserved.

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

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 therespective documentation. The equipotential bonding has to be dimensioned sufficientlyand protected against corrosion.

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

Ensure proper handling and avoid excessive mechanical stress.

Do not touch any electronic components and contacts. The devices contain electrostaticsensitive devices that can be damaged easily by improper handling. Damaged devicesmust not be commissioned.


2


Electrical connection

When working on live devices, observe the applicable national regulations for theprevention 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 obtainedfrom the documentation.

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

Operation

If necessary, systems including these devices must be equipped with additionalmonitoring and protection devices according to the valid safety regulations (e.g. law ontechnical equipment, regulations for the prevention of accidents). The devices can beadapted to your application by parameter settings. Please observe the correspondinginformation given in the documentation.

After the devices have been disconnected from the supply voltage, all live components andconnectors 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 areobserved.

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

Disposal

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

Safety instructionsResidual hazards

2


2.2 Residual hazards

Protection of persons

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

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

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

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 with120 Hz motors).

Protection of the machine/system

ƒ Drives can reach dangerous overspeeds (e.g. setting of high output frequencies inconnection with motors and machines unsuitable for such conditions):

– The controllers do not offer any protection against such operating conditions. Useadditional components for this purpose.

� Icon Description

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

� High leakage current: Carry out fixed installation and PE connection according to EN 61800−5−1!

� Electrostatic sensitive devices: Before working on the device, the personnel must be free ofelectrostatic charge!

� Hot surface: Risk of burns! Hot surfaces should not be touched without wearing protectivegloves.

Product descriptionSystem overview

3


3 Product description

3.1 System overview

The components of the MOBILE product platform serve to implement ancillary unitapplications in commercial vehicles by means of electric motors.

Currently, the MOBILE product platform includes the following components:

ƒ MOBILE DCUInverters for a motor and inverters for two motors

ƒ MOBILE PSUDC/DC onboard converter, from the HV to the LV system

ƒ MOBILE DCU PSUDC/DC onboard converter in combination with inverter for a motor

ƒ Advanced device versionwith approval according to ECE R10, for demanding applications withcomprehensive functions and interfaces

ƒ Basic device versionwithout approval according to ECE R10, for simple applications with limitedfunctions and interfaces

ƒ coordinated accessories

Applications:

ƒ simple drives of pumps and fans

ƒ controlled and positioning drives

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

In the following, we provide a first overview of the components:

�

�

�

�

E...

DCU inverter� Connecting cables and plugs for DCU, prefabricated� DC/DC on−board converter PSU� Connecting cables and plugs for PSU, prefabricated

Product descriptionDevice features

3


3.2 Device features

Features of the Advanced version:

MOBILE, Advanced version

Version

Features DCU PSU DCU PSU

Power range(Peak Power)

7.5 ... 60 kW 2 x 7.5 ... 60 kW 2.8 ... 5.6 kW 2.8 ... 5.6 kW /7.5 ... 60 kW

Number of motor connections 1 2 − 1

ECE approval �

Type of protection IP6K9K

Cooling Water / glycol (� 35)

Mounting type free

12/24−V supply

12/24−V voltage(for maintaining the controlfunctionality in the case of mainsfailure)KL15: On / off

� � � �

Interfaces

Digital inputs, 4 4 4 4

can be configured analog inputs 2 2 2 2

Digital outputs 2 2 2 2

Resolver 1 2 − 1

Motor temperature monitoring(� 48)

PT..., KTY... PT..., KTY... − PT..., KTY...

CAN private � � � �

CAN public � � � �

Optional:

Operation in generator mode possible possible − possible

Operation

DC bus looping through � � � �

180 % overload current for 10 s 10 s − 10 s


Technology applications

Speed actuating drive � � − �

Switch−off positioning Optional Optional − Optional

Absolute positioning Optional Optional − Optional

Product descriptionDevice features

3


Deviating features of the Basic version:

MOBILE B, Basic version

Version

Features DCU PSU DCU PSU

Approval ECE, E1 No

Type of protection IP65

Interfaces

can be configured analog inputs − − − −

Resolver 1 1 − 1

Motor temperature monitoring NTC NTC − NTC

CAN private − − − −

CAN public(fixed baud rate: 250 kbps)

� � � �

Operation



Maximum speed 3000 rpm 3000 rpm − 3000 rpm

Product descriptionIdentification

3


3.3 Identification

Each device is labelled with a non−ambiguous nameplate.

The data on the nameplate serves to identify each device.

The data to be observed for identification are:

ƒ Type designation (product key)

ƒ Technical data

ƒ Serial number (SN)

The example shows where the data and other information can be found on the nameplate.

MOBILEType:SN:

ÄIDNummer123456789ä

-EC

ER

10-

Xxx Xxx Xxx

� � � �

��EMDAG051

� Product name� Type designation� Serial number� Manufacturer� Warning symbols: Discharge period, dangerous electrical voltage, ESD, hot surface� Approval identification Technical data

Note

The type designation serves to identify detailed device properties with the following typecode. The listing of the type code, features, and device properties does not consider anylimitations of possible combinations.

Product descriptionType code

3


3.4 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

MOBILE product platformA = AdvancedB = Basic

Version1 = DCU: Single inverter2 = DCU: Double inverter3 = PSU: DC/DC on−board converter4 = DCU PSU: Combined device

Drive A output power (X11) / PSU X21/22Example:

104 = 10 * 104 W = 100 kW562 = 56 * 102 W = 5.6 kW(DCU = peak power, PSU = continuous power)

Drive B output power (X12)Example:

503 = 50 * 103 W = 50 kW(DCU = peak power)

Voltage range LV on−board supply system / HV on−boardsupply systemU = 12 ... 24 V / 800 V (only DCU)V = 12 ... 24 V / 400 V (only DCU)P = 12 V / 400 VT = 12 V / 800 VS = 24 V / 400 VC = 24 V / 800 V

CommunicationN = not relevant0 = CANopen (Private CAN), J1939 (Public CAN)

Special version0 = standard

Hardware / Software version

Product descriptionOverview of control terminals

3


3.5 Overview of control terminals

DCU EMDxG1... DCU EMDxG2...

1×

X11

X32

X31

XXXX

XX

X12

�

�

2×

X11

X13X12

X33

X31

X32

XX XX

XX

�

�

EMDAG014 EMDAG013

PSU EMDxG3... DCU PSU EMDxG4...

XXX21/B-

X11

X31

XXX21/B+

XX

�

�

X33

XXX21/B-

X11

X13

X31

XXX21/B+

XX

�

�

EMDAG012 EMDAG011

Product descriptionOverview of control terminals

3


Connections and elements Info

Cover for connections of feedback system � 54

� Cover for connections of power and control � 54

� Water cooling � 35

X11 HV DC bus 400/800 V � 33

X12 Motor A� 31

X13 Motor B

X21 B+LV on−board supply system PSU (charge of the 12/24−V board battery) � 39

X21 B−

X31 Vehicle interface (12/24 V, control signals, CAN) � 40

X32 Resolver feedback system / motor A temperature monitoring � 48

X33 Resolver feedback system / motor B temperature monitoring � 48

� PE conductor � 56

� Shield connection (functional earth) � 51

LED LED status display � 62

Technical dataGeneral data and operating conditions

4


4 Technical data

4.1 General data and operating conditions

Conformity and approval

Approval

ECE R10 Rev. 4 � R10 − 047105 (see nameplate)

Protection of persons and equipment

Type of protection DIN 40050−9ISO 20653

IP 6K9K Plug mounted Cover sheet mounted

IP 67 Plug mounted Without cover sheet

Insulation resistance IEC 60664−1 Overvoltage category II

Control circuit isolation EN 61800−5−1IEC 60644−1

Safe isolation by double/reinforced insulation towards thehigh voltage on−board supply system

Short−circuit strength Motor connection: Limited, the controller is inhibited, erroracknowledgement required.Control terminals: full

Protective measuresagainst

Short circuit Earth fault Overvoltage Motor stalling Motor overtemperature

(PTC or thermal contact, I2t−monitoring)

Leakage current EN 61800−5−1 > 3.5 mA AC, > 10 mA DC Observe regulations and safetyinstructions!

Mains switching More frequent switching on/off, e.g. during setting−upoperation, does not harm the controllers.

Starting current � 2 x Irated

Supply conditions

HV mains operation Direct connection to DC HV on−board supply systemsWith switching elements in the HV on−board supply system, acontrolled precharge of the DC−bus capacitors is required.

Power systems

IT

On requestTT

TN

DC−bus operation Permissible Loop−through possible at X11 Observe maximum contact load according to rated data

X11 (� 4.2.6). Only use devices with similar voltage range HV on−board

supply system (DC bus).

Motors Only use motors suitable for the inverter operation.


4


Ambient conditions

Climate

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

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

Operation

Controllers −40 ... +85 °C

Coolant +30 ... +65 °C normalSwitch−on temperature forcoolant pump: +30 °C

−40 ... +85 °C Short−time, maximum 300 s

Humidity, relative 5 ... 100 %

Site altitude 0 ... 2000 m amsl, no restrictions

Pollution EN 61800−5−1 Degree of pollution 4 All plugs are blocked

Degree of pollution 2 Plug open

Vibration resistance (9.81 m/s2 = 1 g)

TransportOperation

ISO 16750−3, code L vertical, checked with 57.9 m/s2

horizontal, checked with 57.9 m/s2

checked with mechanical shock up to 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 � 150 mmObserve bend radii for cables and hoses.

More pages No special requirements

Requirements on the cables for motor and HV system

Capacitance per unit length

� 2.5 mm2/AWG 14 CCore/core/CCore/shield < 75/150 pF/m

� 4 mm2/AWG 12 CCore/core/CCore/shield < 150/300 pF/m

Electric strength

VDE 0250−1 U0/U = 0.6/1.0 kV(U0 = r.m.s. value external − conductor/PE, U = r.m.s. value − external conductor/external conductor)

UL U � 600 V(U = r.m.s. value external conductor/external conductor)

Cable type (recommended)

comparable"RADOX® cable 155S, Huber+Suhner"

performance−related, 4 x 10, 6 or 2.5 mm2

EMC

Noise emission ECE R10, Rev. 4 radiated broad and narrow−band electromagneticinterferences

cable−guided transient noise emissions on the supplycables

Noise immunity ECE R10, Rev. 4 Noise immunity against radiating electromagnetic fields Noise immunity against injected interferences on the

supply cables


4


Open and closed loop control

Open and closed loop control processes

Sensorless V/f characteristic control for asynchronous motors (SLVFCI) Operation with linear load torque characteristic Operation with square−law load torque characteristic Operation of socket applications with V/I characteristic

Sensorless vector control for asynchronous motors (SLVCI) Dynamic control in all quadrants

Vector control for synchronous motors (VCS) Dynamic control in all quadrants

Switching frequency

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

Output frequency

Range −600 Hz ... +600 Hz

Absolute resolution 0.00024 Hz

Digital setpoint selection

Accuracy Speed 0.00006 rpmAbsolute torque 0.00024 NmStandard torque 0.1 %Voltage (PSU) 0.00195 VCurrent (PSU) 0.015625 A

Technical dataRated data

Voltage supply

4


4.2 Rated data

4.2.1 Voltage supply

Control electronics minimum typical maximum

Comment

X31/21/22 (terminal 30 (KL30, +))X31/20 (terminal 30 (KL31, −))

Supply voltage [VDC] 10 24 36

Current consumption [A] 0.5 1.3 UKL30 = 24 V

[A] 1.0 2.5 UKL30 = 12 V

Standby current [�A] 40 60 Tamb = 25 °C

absolute min./max. [VDC] 6 60 Pulse types: ISO 7637−1Behaviour: ISO 16750−1

Terminal 15 (KL15)

Switching threshold on/off [VDC] 8 independent of UKL30

Current consumption [mA] 1.7 UKL30 = 24 V

4.2.2 Overview

The rated data is grouped in tables according to relevant characteristics. The following table guidesyou to the matching rated data via the type designation or nominal values of the devices. The �column refers to the following numbered tables.

Example:

The EMDAG4562603Cxxxxx device is given in line 9 with spaces for an easier detection ofessential type key components: EMD�A�G4�562�603�C�xxxxx.

ƒ A stands for a device of the Advanced version. The table is grouped accordingly.

ƒ G4 stands for the DCU PSU version. The table is grouped accordingly.

ƒ 562 indicates the power of the PSU. The � column refers to the table �.

ƒ 562 indicates the power of the DCU. The � column refers to the table �.

ƒ C is the key for the combination of LV and HV on−board voltage. The � columnrefersto the tables � and .

On the following pages, the tables with the designation �, �, � and contain the validrated data.

Technical dataRated dataOverview

4


Device group Drive Converter HV system

Version X12 X13 X21+/− X11

Type Ppeak [kW] � Ppeak [kW] � Pr [kW] ar [V] � ar [V] �

DCU

Advanced

EMD�A�G2�603�603�U�xxxxx 60 � 60 � − − −

800�

EMD�A�G2�303�303�U�xxxxx 30 � 30 � − − −

EMD�A�G2�303�153�U�xxxxx 30 � 15 � − − −

EMD�A�G2�153�752�U�xxxxx 15 � 7.5 � − − −

Basic

EMD�B�G2�603�603�U�xxxxx 60 � 60 � − − −

800�

EMD�B�G2�303�303�U�xxxxx 30 � 30 � − − −

EMD�B�G2�303�153�U�xxxxx 30 � 15 � − − −

EMD�B�G2�153�752�U�xxxxx 15 � 7.5 � − − −

DCU PSU

Advanced

EMD�A�G4�562�603�C�xxxxx − − 60 � 5.6 28 �

800�

EMD�A�G4�282�603�T�xxxxx − − 60 � 2.8 14 �

EMD�A�G4�562�303�C�xxxxx − − 30 � 5.6 28 �

EMD�A�G4�282�303�T�xxxxx − − 30 � 2.8 14 �

EMD�A�G4�562�153�C�xxxxx − − 15 � 5.6 28 �

EMD�A�G4�282�153�T�xxxxx − − 15 � 2.8 14 �

EMD�A�G4�562�303�S�xxxxx − − 30 5.6 28 �

400�

�

EMD�A�G4�282�303�P�xxxxx − − 30 2.8 14 �

EMD�A�G4�562�153�S�xxxxx − − 15 � 5.6 28 �

EMD�A�G4�282�153�P�xxxxx − − 15 � 2.8 14 �

Basic

EMD�B�G4�562�603�C�xxxxx − − 60 � 5.6 28 �

800�

EMD�B�G4�562�303�C�xxxxx − − 30 � 5.6 28 �

EMD�B�G4�282�303�C�xxxxx − − 30 � 2.8 28

EMD�B�G4�562�153�C�xxxxx − − 15 � 5.6 28 �

EMD�B�G4�282�153�C�xxxxx − − 15 � 2.8 28

EMD�B�G4�562�303�S�xxxxx − − 30 5.6 28 �

400�

�

EMD�B�G4�282�303�S�xxxxx − − 30 2.8 28

EMD�B�G4�562�153�S�xxxxx − − 15 � 5.6 28 �

EMD�B�G4�282�153�S�xxxxx − − 15 � 2.8 28

PSU

Advanced

EMD�A�G3�562�000�C�xxxxx − − − − 5.6 28 �800 �

EMD�A�G3�282�000�T�xxxxx − − − − 2.8 14 �

EMD�A�G3�562�000�S�xxxxx − − − − 5.6 28 �400 �

EMD�A�G3�282�000�P�xxxxx − − − − 2.8 14 �

Basic

EMD�B�G3�562�000�C�xxxxx − − − − 5.6 28 �800 �

EMD�B�G3�282�000�C�xxxxx − − − − 2.8 28

EMD�B�G3�562�000�S�xxxxx − − − − 5.6 28 �400 �

EMD�B�G3�282�000�S�xxxxx − − − − 2.8 28


Motor connection for HV on−board supply system 800 V

4


4.2.3 Motor connection for HV on−board supply system 800 V

� ...603..., motor A and/or B

Rated data minimum typical maximum

Comment

Urated N DC bus [V] 800 DC−bus voltage

Output power [kWp] 60 Peak power

Output current [A] 58 continuous current

8 kHz, auto[A] 87 60 s ¯ 150 %

[A] 104 10 s ¯ 180 %

4 kHz, constant value [A] 72.5 104 Switching frequency−dependent,without adapting the switchingfrequencyStator frequency fS > 5 Hz

8 kHz, fixed [A] 52.2 72.5

16 kHz, fixed [A] 29.0 43.5

4 kHz, auto [A] 72.5 130 Adapting the switching frequencyas a function of the current andthe stator frequency.Stator frequency fS > 5 Hz

8 kHz, auto [A] 58.0 104

16 kHz, auto [A] 34.8 69.6



Comment




8 kHz, auto[A] 48 60 s ¯ 150 %

[A] 57.6 10 s ¯ 180 %

4 kHz, constant value [A] 40.0 57.6 Switching frequency−dependent,without adapting the switchingfrequencyStator frequency fS > 5 Hz

8 kHz, fixed [A] 28.8 40.0

16 kHz, fixed [A] 16.0 24.0

4 kHz, auto [A] 40.0 72.0 Adapting the switching frequencyas a function of the current andthe stator frequency.Stator frequency fS > 5 Hz

8 kHz, auto [A] 32.0 57.6

16 kHz, auto [A] 19.2 38.4



Comment




8 kHz, auto[A] 22.5 60 s ¯ 150 %

[A] 27 10 s ¯ 180 %


8 kHz, fixed [A] 13.5 18.8

16 kHz, fixed [A] 7.5 11.3


8 kHz, auto [A] 15.0 27.0

16 kHz, auto [A] 9.0 18.0

Technical dataRated dataMotor connection for HV on−board supply system 800 V

4


� ...752..., motor B


Comment


Output power [kWp] 7.5 Peak power


8 kHz, auto[A] 12 60 s ¯ 150 %

[A] 14.4 10 s ¯ 180 %


8 kHz, fixed [A] 7.2 10.0

16 kHz, fixed [A] 4.0 6.0


8 kHz, auto [A] 8.0 14.4

16 kHz, auto [A] 4.8 9.6

Output currentItypical Rated value of continuous output currentImaximum Max. output current

Periodic load change at a switching frequency setting of 8 kHz, auto: 150 %Itypical for 60 s, with a recovery time of 120 s with 50 % Itypical

Switchingfrequency

In the setting "x kHz, auto" and when Itypical (> 100 %, overload) is exceeded,the switching frequency is reduced to the next smaller switching frequency.

X12 and/or X13

Motor connection minimum typical maximum

Comment

Output voltage [VAC eff] 565 600 Urated DC bus = 800 VEMDxGxxxxxxxUxxxxx

EMDxGxxxxxxxTxxxxx

EMDxGxxxxxxxCxxxxx[VAC eff] 320 400 440

Clamping limit [%] 74 77 80100 % = maximum current

Overcurrent limit [%] 92 95 98

Switching frequencies(PWM)

[kHz] 2 8 16 Two modes: Automatic switching frequency

reduction when maximumcurrent has been reached

Fixed switching frequency

Output frequencies [Hz] 0 600

Cable length [m] 1 10 20 > 10 m: Derating 0.8 % ¯ Irated /m

Cable cross−section [mm2] 2.5 10 12

Note!

The indicated output voltage will not be reached under certain operatingconditions.

ƒ Low HV DC−bus voltage

ƒ Output power in the maximum range

ƒ High switching frequencies


Motor connection for HV on−board supply system 400 V

4


4.2.4 Motor connection for HV on−board supply system 400 V

...303..., motor B


Comment




8 kHz, auto[A] 87 60 s ¯ 150 %

[A] 104 10 s ¯ 180 %

4 kHz, constant value [A] 72.5 104 Switching frequency−dependent,without adapting the switchingfrequencyStator frequency fS > 5 Hz

8 kHz, fixed [A] 52.2 72.5

16 kHz, fixed [A] 29.0 43.5

4 kHz, auto [A] 72.5 130 Adapting the switching frequencyas a function of the current andthe stator frequency.Stator frequency fS > 5 Hz

8 kHz, auto [A] 58.0 104

16 kHz, auto [A] 34.8 69.6

� ...153..., motor B


Comment




8 kHz, auto[A] 48 60 s ¯ 150 %

[A] 57.6 10 s ¯ 180 %


8 kHz, fixed [A] 28.8 40.0

16 kHz, fixed [A] 16.0 24.0


8 kHz, auto [A] 32.0 57.6

16 kHz, auto [A] 19.2 38.4

Output currentItypical Rated value of continuous output currentImaximum Max. output current

Periodic load change at a switching frequency setting of 8 kHz, auto: 150 %Itypical for 60 s, with a recovery time of 120 s with 50 % Itypical

Switchingfrequency

In the setting "x kHz, auto" and when Itypical (> 100 %, overload) is exceeded,the switching frequency is reduced to the next smaller switching frequency.

Technical dataRated dataMotor connection for HV on−board supply system 400 V

4


� X12 or X13

Motor connection minimum typical maximum

Comment

Output voltage [VAC eff] 282 300 Urated DC Bus = 400 VEMDxGxxxxxxxPxxxxx

EMDxGxxxxxxxSxxxxx[VAC eff] 184 230 253

Clamping limit [%] 74 77 80100 % = maximum current

Overcurrent limit [%] 92 95 98

Switching frequencies(PWM)

[kHz] 2 8 16 Two modes: Automatic switching frequency

reduction when maximumcurrent has been reached

Fixed switching frequency

Output frequencies [Hz] 0 600

Cable length [m] 1 10 20 > 10 m: Derating 0.8 % ¯ Irated /m


Note!

The indicated output voltage will not be reached under certain operatingconditions.

ƒ Low HV DC−bus voltage

ƒ Output power in the maximum range

ƒ High switching frequencies


Connection for charging the low voltage on−board supply system

4


4.2.5 Connection for charging the low voltage on−board supply system

� ...562..., DC/DC onboard converter


Comment

Output power [kW] 5.6 Continuous power

Output voltage [VDC] 16 28 30

Output current [ADC] 200 continuous current

DC−bus voltage � / � Urated DC bus

� ...282..., DC/DC onboard converter


Comment


Output voltage [VDC] 8 14 15.5



...282..., DC/DC onboard converter


Comment





Technical dataRated dataConnection for charging the low voltage on−board supply system

4


The graph shows the course of the LV charging voltage at a decreasing HV on−boardvoltage.

0 100 200 300 400 500 600 700 800 900 [V]

[V]

4

8

12

16

20

24

28

32

ULV

_o

ut

UHV_in

800 V 28 V

800 V 14 V

400 V 28 V

400 V 14 V

EMDAG_PSU05

Fig. 4−1 LV charging voltage as a function of the HV on−board voltage

UHV_in HV on−board voltageULV_out LV charging voltage

800 V −> 28 V Voltage range LV/HV on−board supply system, EMDxGxxxxxxCxxxxx

800 V −> 14 V Voltage range LV/HV on−board supply system, EMDxGxxxxxxTxxxxx

400 V −> 28 V Voltage range LV/HV on−board supply system, EMDxGxxxxxxSxxxxx

400 V −> 14 V Voltage range LV/HV on−board supply system, EMDxGxxxxxxPxxxxx


Connection of high−voltage on−board supply system

4


4.2.6 Connection of high−voltage on−board supply system

� − ...U...


Comment

HV system [VDC] 200 800 850

Capacity [�F] 240 Advanced: EMDAG2...

160 Basic: EMDBG2...

Current consumption [A] −56 56 per contact, two available eachin generator mode: < 0 A

Discharge resistance,internal

[k�] 330

Discharge time [s] 250 300 Labelling according toEN 61800−5−1

Capacity [nF] 9.4 against PE


� − ...T..., ...C...


Comment

HV system [VDC] 200 800 850 Dependence according to� Fig. 4−1has to be observed.

Capacity [�F] 120 Advanced: EMDAG...

60 Basic: EMDBG...



[k�] 330




� − ...P..., ...S...


Comment

HV system [VDC] 100 400 425 Dependence according to� Fig. 4−1has to be observed.

Capacity [�F] 240 Advanced: EMDAG...

120 Basic: EMDBG...



[k�] 330




Technical dataRated dataConnection of high−voltage on−board supply system

4


Fuses and cable cross−sections

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

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

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

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

Technical dataWater cooling

4


4.3 Water cooling

The devices of the MOBILE product platform are provided with an integrated water cooler.For cooling the devices, a connection to vehicle−typical cooling circuits has to beestablished.

[ ] DCU PSU, DCU PSU

Connection of suction and pressure hoses DN 19 (internal)

Fastening/securing the hoses Suitable hose clips

Liquid volume l 0.09 0.16

Composition of the cooling fluid

Water % 50

Ethylene glycol % 50

Flow direction

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

in case of lying or pending installation Not relevant

Flow rate

typical l/min 15

Pressure in the cooling system

typical bar 1

maximum bar < 2.0

Decrease in pressure

typical mbar 80

maximum mbar 100

Permissible temperatures of the cooling fluid

minimum °C 30Switch−on temperature for coolant pump: +30 °C

typical °C 55

maximum °C 65

Permissible temperatures of the cooling fluid, short−time for < 300 s, observe derating!

minimum °C −40

maximum, short−time for < 300 s °C 85

Temperature difference at the cooler K 0.7

Deviating data of the Basic version:

[ ] DCU PSU, DCU PSU

Permissible temperatures of the cooling fluid

minimum °C 30Switch−on temperature for coolant pump: +30 °C

typical °C 50

maximum °C 55

Technical dataTerminal descriptionOverview

4


4.4 Terminal description

4.4.1 Overview

DCU EMDxG1... DCU EMDxG2...

1×

X11

X32

X31

XXXX

XX

X12

�

�

2×

X11

X13X12

X33

X31

X32

XX XX

XX

�

�

EMDAG014 EMDAG013

PSU EMDxG3... DCU PSU EMDxG4...

XXX21/B-

X11

X31

XXX21/B+

XX

�

�

X33

XXX21/B-

X11

X13

X31

XXX21/B+

XX

�

�

EMDAG012 EMDAG011

Technical dataTerminal description

Overview

4


Connections and elements Info

Cover for connections of feedback system � 54

� Cover for connections of power and control � 54

� Water cooling � 35

X11 HV DC bus 400/800 V � 33

X12 Motor A� 31

X13 Motor B

X21 B+LV on−board supply system PSU (charge of the 12/24−V board battery) � 39

X21 B−

X31 Vehicle interface (12/24 V, control signals, CAN) � 40

X32 Resolver feedback system / motor A temperature monitoring � 48

X33 Resolver feedback system / motor B temperature monitoring � 48

� PE conductor � 56

� Shield connection (functional earth) � 51

LED LED status display � 62

Technical dataPower terminalsConnection of high−voltage on−board supply system

4


4.5 Power terminals

4.5.1 Connection of high−voltage on−board supply system

The MOBILE devices get the energy for the DC bus via the terminal X11 from the HV systemof the vehicles. The connection for looping through the DC−bus voltage is dimensionedwith two contacts per potential.

X11 Umax

[V] [mm2][AWG]

2 3 411 +UG

425/850

2.5 ... 1212 ... 6

2 +UG

3 −UG

EMDAG020b 4 −UG

4.5.2 Motor connection

Motors are connected via the terminals X12 and X13.

ƒ Two motors can be connected to double inverters EMDxG2... (DCU) (X12 and X13).

ƒ One motor can be connected to single inverters EMDxG1... (DCU) (X12).

ƒ One motor can be connected to combined devices EMDxG4... (PSU/DCU) (X13).

ƒ No motor can be connected to DC/DC on−board converters EMDxG3...(PSU).

X12 X13

MOBILE DCU EMDxG1... −

EMDxG2...

MOBILE PSU EMDxG3... − −

MOBILE DCU PSU EMDxG4... −

X12, X13 Umax

[V] [mm2][AWG]

2 3 41

1 W

6002.5 ... 1212 ... 6

2 V

3 U

4 ˘ ˘ ˘

EMDAG020b� PE ˘

2.5 ... 1212 ... 6

Technical dataPower terminals

Connection for charging the low voltage on−board supply system

4


4.5.3 Connection for charging the low voltage on−board supply system

In case of DC/DC on−board converters, the LV on−board supply system is connected via theterminals X21+ and X21−:

ƒ in case of DC/DC on−board converters EMDxG3...(PSU)

ƒ in case of combined devices EMDxG4... (PSU/DCU)

X21+, X21− Umax

[V] [mm2][AWG]

+ M10850

70000

with ring cable lug

EMDAGxxxx − M8

EMDAG10_b

Technical dataControl terminalsVehicle connection

4


4.6 Control terminals

4.6.1 Vehicle connection

X31 serves to establish the connection to the vehicle control system and is structured asfollows for description:

ƒ Voltage supply of the control electronics via KL30/31

ƒ Switching on/off the inverter via KL15

ƒ 4 digital/analog inputs (Basic: 2)

ƒ 4 digital outputs (Basic: 2)

ƒ Potential−free contact "Interlock" (not in case of Basic)

ƒ Device identification via ID pins

ƒ CAN bus "Public"

ƒ CAN bus "Private"

4.6.2 Voltage supply

Control electronics minimum typical maximum

Comment

X31/21/22 (terminal 30 (KL30, +))X31/20 (terminal 30 (KL31, −))

Supply voltage [VDC] 10 24 36

Current consumption [A] 0.5 1.3 UKL30 = 24 V

[A] 1.0 2.5 UKL30 = 12 V

Standby current [�A] 40 60 Tamb = 25 °C

absolute min./max. [VDC] 6 60 Pulse types: ISO 7637−1Behaviour: ISO 16750−1

Terminal 15 (KL15)

Switching threshold on/off [VDC] 8 independent of UKL30

Current consumption [mA] 1.7 UKL30 = 24 V

Technical dataControl terminals

Digital inputs

4


4.6.3 Digital inputs

4 inputs FLX_INx at X31 can be used for digital control signals.

Special functions can be set by parameterisation.

ƒ for FLX_IN1 and FLX_IN2: Analog input

ƒ for FLX_IN3 and FLX_IN4: Frequency input

Digital/analog inputs minimum typical maximum

Comment

X31/17 (FLX_IN1)

X31/16 (FLX_IN2)

X31/15 (FLX_IN3)not in case of Basic

X31/14 (FLX_IN4)

Input voltage [VDC] −8 12 36

UKL30 = 12 Vdigital HIGH [VDC] 7.8 8.4 9.0

digital LOW [VDC] 3.0 3.8 4.5

Hysteresis [VDC] 3.3 4.6 6.0

Input voltage [VDC] −8 24 36

UKL30 = 24 Vdigital HIGH [VDC] 15.6 16.9 18.2

digital LOW [VDC] 6.2 7.5 8.8

Hysteresis [VDC] 6.8 9.4 12

Digital input frequency [kHz] 0 10 FLX_IN3, FLX_IN4

Response time [�s] 90 FLX_IN3, FLX_IN4

Analog input frequency [Hz] 0 500 FLX_IN1, FLX_IN2

Analog resolution [bit] 4096 FLX_IN1, FLX_IN2

Input resistance [k�] 4.8

Reference potential KL31

Diagnostics option Open circuit Short circuit

Cable cross−section[mm2] 0.3 1.25

Only if the cross−sections in thegiven range are complied with,the plugs can be sealed.

Technical dataControl terminalsDigital outputs

4


4.6.4 Digital outputs

4 outputs FLX_OUTx at X31 can be used for digital control signals (2 in case of Basic).

Digital outputs minimum typical maximum

Comment

X31/26 (FLX_OUT1)

X31/25 (FLX_OUT2)

X31/24 (FLX_OUT3)not in case of Basic

X31/23 (FLX_OUT4)


UKL30 = 12 Vdigital HIGH [VDC] 8.0 10.8

digital LOW [VDC] 0 5.0


UKL30 = 24 Vdigital HIGH [VDC] 21.6

digital LOW [VDC] 0

Output current HIGH [ADC] 0 2

Output current LOW [mADC] 0 −0.5

Output frequency [kHz] 0 1

Response time [�s] 95

Reference potential KL31

Diagnostics option [�A] 3 Open circuit

[ADC] 8 Short circuit




Connection for digital switching output

4


4.6.5 Connection for digital switching output

2 terminals InterLockx at X31 can be used as potential−free contact (not in case of Basic).

Switching contact minimum typical maximum

Comment

X31/7 (InterLock1)not for Basic

X31/6 (InterLock2)

Switching voltage[VDC] 0

1260

UKL30 = 12 V

24 UKL30 = 24 V

Voltage potential toUKL30/UKL31

[VDC] −80 80 Functional insulation

InterLock−OK (locked)

Voltage drop [VDC] 1.05 1.34for DCU

permissible current [ADC] 0 0.05 0.2

Contact resistor [[�] 6 11.3 15 for PSU

InterLock−NOK (opened)

Fault current [�A] 1

Capacitive load

[�F] 22

In case of higher capacitive loads,provide for an external currentlimitation, e.g. by a resistor inseries connection.



Technical dataControl terminalsIdentification

4


4.6.6 Identification

CAN address allocation

Maximally 14 MOBILEs can be connected to a CAN bus. Each MOBILE has a CAN address forthe Public CAN and three CAN addresses for the Private CAN. The CAN addresses resultfrom an individual basic address (parameterisable) plus an address offset (0 ... 13).

The address offset is defined by bridges between the four connections at X31 which arecalled ID pins. The address offset set by the bridges has to be added to the basic address.If the four ID pins are not interconnected, the address offset is = 13.

Basic address Public−CAN (Lenze setting): 234

Basic addresses Private−CAN (Lenze setting):

A AppC = 32

B MC (channel 1) = 1

C MC (channel 2) = 64

Boot-LoaderStartup

10

12

11

13

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

5

7

6

8


0

2

1

3


4 9

CAN_Adressoffset_IDpins

ID−PIN1 X31/12ID−PIN2 X31/18ID−PIN3 X31/13ID−PIN4 X31/19Boot LoaderStartup

Device remains in the Boot Loader, firmware is not started.

The maximum length of the wire bridges should be 50 mm. In case of a double assignmentof the ID pins, a double crimping at the contact is required.

MOBILE device number

In order to address a certain device in the same network with several MOBILEs, eachMOBILE has a device number (1 ... 14) that corresponds to the set address offset (IDPins)plus 1.


Communication connection

4


4.6.7 Communication connection

Specification of the bus cable

For a trouble−free CAN communication, a CAN cable according to specification ISO 11898−2is required.

CAN cable according to specification at least fulfils these requirements:

ƒ Twisted core pairs (star quad)

ƒ Cable impedance 120 �

ƒ Shielded cable

ƒ Only for CAN signals

Cable lengths depend on the data transfer rate.

The CAN bus has to be wired completely. Non−connected terminals are not permissible.

CAN SAE J1939

Four terminals are provided at X31 to built up communication to the vehicle (Public CAN).

Public CAN minimum typical maximum

Comment

X31/2 (CAN_H_PUBLIC)X31/3 (CAN_L_PUBLIC)X31/9 (CAN_GND_PUBLIC)X31/1 (CAN_H_TERM_PUBLIC)

Protocol specific

Baud rate [kbps] 125 250 500

Cable length

at 250 kbps [m] < 250 Loop Delay of all nodes < 210 ns

at 500 kbps [m] < 100

CANopen

Four terminals are provided at X31 to built up communication to the diagnostics(Private CAN).

Private CAN minimum typical maximum

Comment

X31/10 (CAN_H_PRIVATE)X31/5 (CAN_L_PRIVATE)X31/4 (CAN_H_TERM_PRIVATE)X31/11 (CAN_GND_PRIVATE)

Protocol CANOpen SDO and PDO communication

Baud rate [kbps] 125 250 1000

Cable length

at 1000 kbps [m] 20 Loop Delay of all nodes < 210 ns

at 500 kbps [m] 100

Technical dataControl terminalsCommunication connection

4


Bus termination

In order to ensure a trouble−free operation, a 120−� terminating resistor has to beconnected to the last device of a CAN bus. The terminating resistors are already integratedin each device.

The terminating resistors are activated by a bridge.

ƒ CAN−PUBLIC: Bridge CAN_H_TERM_PUBLIC (X31/1) with CAN_L_PUBLIC (X31/3)

ƒ CAN−PRIVATE: Bridge CAN_H_TERM_PRIVATE (X31/4) with CAN_L_PRIVATE (X31/5)

Double crimping is required at the CAN_L_... contact.

EMDxG...

X31

10

4

5

11

120

CAN pub

CAN_H

CAN_L

CAN_GND

CAN_TERM

120

CAN priv

CAN_H

CAN_L

CAN_GND

CAN_TERM

3

2

9

1 2

2

Ctrl

n = 1 + x n = 1

EMDxG...

...

...

EMDAGCAN01


Communication connection

4


CAN Ground

The CAN connections of the MOBILE devices are isolated from KL31 and the housing. Thus,a high immunity to interference is achieved even at high transmission distances andcompensation currents via the CAN cable or the shield can be prevented.

In order to prevent interferences in the CAN bus (bus−off, bus−heavy, etc.), the use of a cablewith twisted cores is mandatory (CAN_H, CAN_L). Install the CAN cable along the LV on−board supply system and keep it separate from thepower cables. Do not connect CAN_GND to any MOBILE device (MOBILE: X31, Pin 9 and 11).

However, if interferences occur, shielded CAN cables can be used by connecting the shieldsto PE (chassis) on one or both sides. Here, shield currents might occur which are to beprevented by sufficient low−resistance PE connections in the system. �

Another interference suppression measure is to provide the CAN_GND core in shieldedCAN cables and connect it to all isolated CAN nodes (MOBILE: X31, pin 9 and 11). �

KL31

CAN CAN CAN

High

Low

HCU DCU DCU PSU

KL31 KL31

KL31

CAN CAN CAN

High

Low

HCU DCU DCU PSU

KL31 KL31

KL31

CAN CAN CAN

High

Low

HCU DCU DCU PSU

KL31 KL31

GND

EMDAG_CAN05

Technical dataFeedback connection

4


4.7 Feedback connection

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

ƒ Encoder type: Resolver

ƒ The thermal detectors PT1000, KTY83/110, KTY84/130 , thermostat (NCC) and thePTC thermistor are supported according to DIN 44081.

– Maximally three PTC thermistors may be connected in series.

– It is monitored with regard to short circuit and cable breakage.

– Thermostats are not monitored.

ƒ The Basic version only supports one encoder and only NTC thermal detectors.

The terminals are assigned to the drives:

ƒ X32 <=> drive A

ƒ X33 <=> drive B

ƒ The assignment can be changed by parameterisation.

The terminals are designed according to the number of available motor connections. ADC/DC on−board converter (PSU) without motor connection does not have a connection forfeedback systems.

X32, X33 (M12 female socket A−coding)

EMDAG020d

2

4 6

3

1

8 7

5 1 +Ref(+OSZ)

5 +COS

2 −Ref(−OSZ)

6 −COS

3 +Sin 7 +KTY(+TEMP)

KTY83/110 KTY84/130 PT1000 PTC (DIN 44081) �−Switch NC

4 −Sin 8 −KTY(−TEMP)

+REF

-REF

+COS

+SIN

-SIN

-COS

+KTY

-KTY

1

2

3

4

5

6

7

8

X32 / X33

KTY

2

4 6

3

1

8 7

5

EMDAG_X3233

Technical dataDimensions

4


4.8 Dimensions

g3

g3g3

b

gb1

hc3

d3

c4

t

c5

3× M10

r

X11 / X12 / X13

EMDAG002

h b t b1 c3 c4 c5 d3 g g3 r �

[mm] [kg]

EMDxG1...

310 391 81 355 331 177.5 153.5 286 20.7 11 106

7.3

EMDxG2... 7.4

EMDxG3... 8.6

EMDxG4... 8.7

InstallationImportant notes

5


5 Installation

5.1 Important notes

� Danger!

Hazardous electrical voltage

Even after mains disconnection, all power terminals remain live for a longerwhile, e.g. due to capacitors.

Possible consequences:

ƒ Death or severe injuries when touching the power terminals.

Protective measures:

ƒ Switch off the power supply and wait until the power terminals aredischarged before working on them.

ƒ Make sure that all power terminals are deenergised before working onthem.

Stop!

No device protection if the mains voltage is too high

The mains input is not internally fused.

Possible consequences:

ƒ Destruction of the device if the mains voltage is too high.

Protective measures:

ƒ Observe the maximally permissible mains voltage.

ƒ Fuse the device correctly on the supply side against mains fluctuations andvoltage peaks.

Stop!

The device contains components that can be destroyed by electrostaticdischarge!

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

InstallationEMC−compliant installation

Shielding

5


5.2 EMC−compliant installation

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

EMC interferences ...

ƒ can interrupt the CAN communication..

ƒ may cause a switch−off of the drives and the onboard converters to protect thesystems.

This chapter describes possible improvements and measures.

5.2.1 Shielding

Requirements

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 ornickel−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

ƒ Digital signals (inputs and outputs).

– We recommend to use shielded cables for a cable length from approximately 5 mon or in environments with strong interferences.

Connection system

Prefabricated cables for connecting the motors and the HV system provide for an optimumconnection of the shielded cables to functional earth. Only cables with prepared cableglands serve to achieve an optimum EMC−technical installation and the requestedenvironmental conditions.

ƒ When installing the motor cable and the HV on−board cable, push the cable glandinto the respective holders and fix them by tightening the mounting brackets.

Further information can be found in the "Accessories" chapter.

InstallationEMC−compliant installationHV mains cable

5


5.2.2 HV mains cable

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

5.2.3 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 ensureelectrical 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 thecable cross−section).

– Install contactors, terminals etc. spatially separated from other components (witha min. distance of 100 mm).

– Install the shield of the motor cable directly before and behind the point ofseparation 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 themotor housing.

– Metal EMC cable glands at the motor terminal box ensure a large surfaceconnection of the shield with the motor housing.

Wiring on the motor side

Stop!

The motor cable is highly susceptible to interference. Therefore you willachieve an optimum wiring on the motor side if you

ƒ exclusively use shielded and low−capacitance motor cables.

ƒ do not integrate any further cable into the motor cable (e.g. for blowersetc.).

ƒ shield the supply cable for temperature monitoring of the motor (PTC orthermostat) and install it separately from the motor cable.

Special conditions allow you to integrate the supply cable for temperature monitoring ofthe motor into the motor cable: (� 52)

InstallationEMC−compliant installation

Control cables

5


5.2.4 Control cables

ƒ Control cables must be shielded 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 (at the drivecontroller).

ƒ To achieve an optimum shielding effect (in case of very long cables, with highinterference) one shield end of analog input and output cables can be connected toPE potential via a capacitor (e.g. 10 nF/250 V) (see sketch).

5.2.5 CAN interface

In order to achieve a sufficient noise immunity of the CAN connections:

ƒ Observe technical data and specification (� 4.6.7)

ƒ Always wire all CAN signal cables.

ƒ If CAN−GND is not used, establish a connection to the potential KL31.

ƒ Connect the first and last node to the CAN bus with the integrated terminatingresistor.

5.2.6 Detecting and eliminating EMC interferences

Fault Cause Remedy

Interferences of analogsetpoints of your own orother devices andmeasuring systems

Unshielded HV mains cableUnshielded motor cable

Use shielded cables

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

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

Separate components from othercomponent part with a minimumdistance of 100 mm

Use motor choke/motor filter

Install additional unshielded cablesinside the motor cable (e.g. for motortemperature monitoring)

Install and shield additional cablesseparately

Too long and unshielded cable ends ofthe motor cable

Shorten unshielded cable ends tomaximally 40 mm

CAN Time outorCAN Bus Heavy

CAN communication is disturbed Use cable according to CANspecification

Wire connections completely Connect the shield with a good

electric conductivity

InstallationMechanical installation

5


5.3 Mechanical installation

The mounting material must ensure a durable mechanical connection. The fixing pointsare 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

g3

g3g3

b

gb1

h

c3

d3

c4

t

c5

3× M10

r

X11 / X12 / X13

EMDAG002

h b t b1 c3 c4 c5 d3 g g3 r �

[mm] [kg]

EMDxG1...

310 391 81 355 331 177.5 153.5 286 20.7 11 106

7.3

EMDxG2... 7.4

EMDxG3... 8.6

EMDxG4... 8.7

InstallationWater cooling

5


5.4 Water cooling

For operating the Mobile devices, a working water cooling 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 (� 35).

How to connect a proper cooling:

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.

�

19 mm(DN 19)

8 × 1.2 mm

1.2.

� 25 - 40 mm� 2 bar

EMDAG004

InstallationElectrical installationPower connections

5


5.5 Electrical installation

5.5.1 Power connections

Principle circuit diagram

MOBILE DCU EMDxG1..., EMDxG2...

3~M

8

UVW

X13

X33 1...8

EMDxG2...

H-V-B

400/800 V DC

X11

+UG+UG -UG -UG

+

-

26C

AN

pu

bC

AN

pri

vST

RG

I/O

44

810

X311

...

26

8

3~M

UVW

X12

X32 1...8

EMDxG1...

EMDAGSP 1

InstallationElectrical installation

Power connections

5


MOBILE PSU EMDxG3...

H-V-B

400/800 V DC

X11

+UG+UG -UG -UG

+

-

26

CA

Np

ub

CA

Np

riv

STR

G

I/O

44

810

X311

...

26

12/24 V

DC+B

-BX21

+

-EMDAG3...

EMDAGSP 3

MOBILE PSU EMDxG3... || MOBILE PSU EMDxG3...

H-V-B

400/800 V DC

X11

+UG+UG -UG -UG

+

-

26

CA

Np

ub

CA

Np

riv

STR

G

I/O

44

810

X311

...

26

12/24 V

DC

+B

-BX21

+

- EMDAG3...

2

CA

Np

ub

CA

Np

riv

STR

G

I/O

44

810

X311

...

26

X11

+UG+UG -UG -UG

EMDAG3...

12/24 V

DC

+B

-BX21

+

-

EMDAGSP 3y

InstallationElectrical installationPower connections

5


MOBILE DCU PSU EMDxG4...

H-V-B

400/800 V DC

X11

+UG+UG -UG -UG

+

-

26

CA

Np

ub

CA

Np

riv

STR

G

I/O

44

810

X311

...

26

3~M

8

UVW

X13

X33 1...8

12/24 V

DC

+B

-BX21

+

- EMDxG4...

EMDAGSP 4

InstallationElectrical installation

Wiring of control connections

5


5.5.2 Wiring of control connections

2.

3.3.

4.

click

X32 / X33

X31

xxxxxxxxxxxxxxxx

DC4

5.

1.

EMDAG007

The deviating assignment of the Advanced version:

X31 d d

[mm2][AWG]

d [mm] [mm2][AWG]

d [mm]

201481

1 CAN_H_TERM_PUBLIC

0.5 ...1.25

20 ... 16

1.6 ...2.4

14 FLX_IN4

0.5 ...1.25

20 ... 16

1.6 ...2.4

2 CAN_H_PUBLIC 15 FLX_IN3

3 CAN_L_PUBLIC 16 FLX_IN2

4 CAN_H_TERM_PRIVATE

17 FLX_IN1

5 CAN_L_PRIVATE 18 ID_PIN2

6 InterLock2 19 ID_PIN4

7 InterLock1 20 KL310.85 ...

1.2518 ... 16

8 KL15 21 KL30

9 CAN_GND 22 KL30

10 CAN_H_PRIVATE 23 FLX_OUT4

0.5 ...1.25

20 ... 16

11 CAN_GND 24 FLX_OUT3

12 ID_PIN1 25 FLX_OUT2EMDAG020c 13 ID_PIN3 26 FLX_OUT1

InstallationElectrical installationWiring of control connections

5


The deviating assignment of the Basic version:

X31 d d

[mm2][AWG]

d [mm] [mm2][AWG]

d [mm]

201481

1 CAN_H_TERM_PUBLIC

0.5 ...1.25

20 ... 16

1.6 ...2.4

14 −

0.5 ...1.25

20 ... 16

1.6 ...2.4

2 CAN_H_PUBLIC 15 −

3 CAN_L_PUBLIC 16 FLX_IN2

4 CAN_H_TERM_PRIVATE

17 FLX_IN1

5 CAN_L_PRIVATE 18 ID_PIN2

6 − 19 ID_PIN4

7 − 20 KL310.85 ...

1.2518 ... 16

8 KL15 21 KL30

9 CAN_GND 22 KL30

10 CAN_H_PRIVATE 23 −

0.5 ...1.25

20 ... 16

11 CAN_GND 24 −

12 ID_PIN1 25 FLX_OUT2EMDAG020c 13 ID_PIN3 26 FLX_OUT1

Commissioning 6


6 Commissioning

Note!ƒ Please observe the general safety instructions (� 11).

ƒ Please observe the notes regarding residual hazards (� 14).

The »MOBILE Engineer« tool supports you during the commissioning phase.

You are led through the commissioning steps and obtain additional information on thesettings. This information is also contained in the MOBILE reference manual which isavailable in the download area.

Diagnostics7


7 Diagnostics

One/two LEDs at the device display the MOBILE the current device status:

LED1 LED2 Device status Notes

Switched−off −

Switched−on − no error No Public CAN messages are received.

Switched on − no error Public CAN messages are received.

Switched−on − Bootloaderactive

−

Switched−on − error For a more detailed diagnostics, read out the error memory orerror code.

Switched−on − error CAN communication is interrupted.Diagnostics via CAN is not possible.

Precharge / discharge active Slowly blinking

Only in Advanced versionDC bus is charged UDC−bus > 50 V

Cover is not closed Blinking fast

LED offLED is permanently onLED blinking every 0.4−sLED blinking every 0.2−sLED blinking pattern: Blinking once or several times with a break of 1 sgreen − red − yellow

With an established CAN communication, the device status can also be read via the bus.

More diagnostics is possible with the »MOBILE Engineer«.

Accessories (overview)Prefabricated cables and plug accessories

8


8 Accessories (overview)

For a proper installation according to ECE R10, materials have to be processedprofessionally complying with the respective standards and required approvals at thelocation.

Note!

Unused plug connections have to be closed with covers or blanking plugs.

This is the only way to comply with the class of protection and prevent waterfrom entering.

8.1 Prefabricated cables and plug accessories

Prefabricated cables and plug accessories provide for a fast implementation of MOBILEinstallations.

The table informs about the types available for order.

Function Type Name Used for ...

HV system EWLW001 Cable harness EMD for X11, 4 x 10 mm2, 10 m DCUDCU PSUPSU

Motor EWLW002 Cable harness EMD for X12, 4 x 10 mm2, 10 m,DCU

DCUEWLW003 Cable harness EMD for X13, 4 x 10 mm2, 10 m,DCU(on the device side: 77 mm)

EWLW004 Cable harness EMD for X13, 4 x 10 mm2, 10 m, PSU(on the device side: 192 mm)

DCU PSU

HV system, motor EZAEVE027 Plug EMD spare part set for X11, X12, X13 DCUDCU PSUPSUControl plug EZAEVE028 Plug EMD accessories set 26 pole cpl. for X31

Resolver at X32, X33 EWLW005 Sensor cable SAC−8P−M12MR/ 1.5−PUR SH

DCUDCU PSU

EWLW006 Sensor cable SAC−8P−M12MR/ 3.0−PUR SH



Operation without drive EZAMSK002 Plug of power connector for X12, X13

Accessories (overview)Single parts list for the electrical installation

8


8.2 Single parts list for the electrical installation

The required material for plugs, plug parts, and cables are listed here and assigned to theterminals.

8.2.1 High−voltage on−board supply system at X11

Manufacturer

Part Name Type

Supplement

Kostal

Socket housing LSK8 3−1437290−7

(Tightness according to manufacturer information: Insert sealingplugs)

Receptacles 8 ... 12 mm2 502 533 36

6 ... 10 mm2 502 532 60

4 ... 6 mm2 502 532 61

2.5 ... 4 mm2 502 532 64

Single conductor sealing 2.5 ... 4 mm2 502 820 26

6 ... 12 mm2 502 820 27

Sealing plugs LSK 1.5 502 820 30

Huber & Suhner

Cable with vehicle−specificproperties

Radox® 155 84 090 412 A

Typical cross−section: 4 x 10 mm2, shielded, Ø ~ 17.2 mm

Typical demand per X11

Socket housing LSK 8 1 x

Receptacles According to cross−section 3 x

Single conductor sealing According to cross−section 3 x

Sealing plugs LSK 8 1 x

LSK 1.5 3 x


8


8.2.2 Motors at X12 and/or X13

Manufacturer

Part Name Type

Supplement

Kostal

Socket housing LSK8 3−1437290−7

(Tightness according to manufacturer information: Insert sealingplugs)

Receptacles 8 ... 12 mm2 502 533 36

6 ... 10 mm2 502 532 60

4 ... 6 mm2 502 532 61

2.5 ... 4 mm2 502 532 64

Single conductor sealing 2.5 ... 4 mm2 502 820 26

6 ... 12 mm2 502 820 27

Sealing plugs LSK 8 502 820 59

LSK 1.5 502 820 30

Huber & Suhner

Cable with vehicle−specificproperties

Radox® 155 84 090 412 A

Typical cross−section: 4 x 10 mm2, shielded, Ø ~ 17.2 mm

Typical requirement per X12 or X13

Socket housing LSK 8 1 x

Receptacles According to cross−section 3 x

Single conductor sealing According to cross−section 3 x

Sealing plugs LSK 8 1 x

LSK 1.5 3 x

8.2.3 Shield connection at X11, X12 and X13

Manufacturer

Part Name Type

Supplement

Lenze drawing

Shield connection Brass sleeve

adjusted to the cable diameterPotting sleeve and cable provides for tightness.

Not defined

Compression mould Cembre 45

Distribution shrink cap 502K033−S

If required, a distribution shrink cap can be attached, e.g. Raychem.The contact point of the cable gland (collar), however, has to be keptfree for a flawless contact transition.

Cable gland Example: Mounted


8


8.2.4 Low−voltage on−board supply system at X21 B+ and X21 B−

Manufacturer

Part Name Type

Supplement

Not defined

Cable 1 x 70 mm2

Ring cable lug for X21 B+ M10 for 70 mm2, 90 ° angled

Ring cable lug for X21 B− M8 for 70 mm2, 90 ° angled

8.2.5 Vehicle interface at X31

Manufacturer

Part Name Type

Supplement

AMP / Tyco Electronics / TE Connectivity

Socket housing Superseal 1.0, 26−pole 3−1437290−7

(Tightness according to manufacturer information: Observe stranddiameter)

Crimp sockets 0.75 ... 1.25 mm2 3−1447221−3

0.5 mm2 3−1447221−4

0.3 mm2 3−1447221−5

Sealing plugs 4−1437284−3

Not defined

Strands suitable for vehicles 0.3 ... 1.25 mm2Strand diameter 1.6 ... 2.2 mm

3−1437290−7

CAN cable In accordance with ISO 11898−2

8.2.6 Motor rotary transducer feedback at X32 and/or X33

Manufacturer

Part Name Type

Supplement

Not defined

M12 connector withprefabricated cable

M12 plug A−coded, 90 ° angled8 x 0.25 mm2 (AWG24)with shielding

Comparable: Phoenix Contact

Index 9


9 Index

AAccessories, 63

Application as directed, 12

CCable

− For control connections, 53

− for the HV mains connection, 52

− for the motor connection, 52

Cable specification, 45

Cables

− cross−sections, 34

− fuses, 34

Commissioning, 61

Communication connection, 45

Communication, connection, 45

Connection

− HV on−board supply system, 33, 38

− on−board supply system, 31, 39

Control cable, 53

Control terminals, 40

DDC−bus operation, 22

Definition of notes used, 10

Definitions, Terms, 8

Device protection, 14, 50

Diagnostics, 62

Digital inputs, 41

Digital outputs, 42

Disposal, 13

EElectrical installation, 56

− communication connection, 45

− wiring of control connections, 59

EMC, what to do in case of interferences, 53

FFor your personal safety, 11

Fuses, 34

HHV mains cable, 52

IIdentification, 18, 44

Installation, 50

− electrical, 56

− mechanical, 54

− water cooling, 35, 55

Interferences, eliminating EMC interferences, 53

MMaintenance and servicing, 13

Mechanical installation, 54

Motor

− cable length, 28, 30

− connection, 38

Motor cable, 52

− capacitance per unit length, 23

− requirements, 23

Motor connection

− output current, 27, 28, 29, 31

− output voltage, 28, 30

− peak power, 27, 28, 29

Motor protection, 14

Mounting clearances, 23

Mounting position, 23

NNameplate, 18, 44

Notes, definition, 10

Ooutput voltage, reduced, 28, 30

output voltage , 28, 30

Overspeeds, 14

Overview

− Accessories, 63

− control terminals, 20

− terminals, 36

PPower terminals, 38

Index9

�68 EDSMDAG EN 1.1

Product description, 15

Protection of persons, 14

RRequirements, motor cable, 23

Residual hazards, 14

SSafety instructions, 11

− basic, 11

− definition, 10

− layout, 10

Specification of the bus cable, 45

Supply conditions, 22

Switching frequencies, 28, 30

TTechnical data, 22

Terminals, 36

Terms, definitions, 8

Transport, storage, 12

Type code, 44

− finding, 18

VValidity, 5

Voltage supply, 25, 40

WWater cooling, installation, 35, 55

Wiring of control connections, 59

�© 10/2014

� Lenze SchmidhauserObere Neustrasse 1CH−8590 RomanshornSwitzerland

Service Lenze Service GmbHBreslauer Straße 3D−32699 ExtertalGermany

� +41�71 46611−11 � 0080002446877 (24 h helpline)

� +41�71 46611−10 � +49�5154�82−1112

� Info@Lenze−Schmidhauser.ch � [email protected]

� www.Lenze.com

EDSMDAG � .PC; � EN � 1.1 � TD15

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