Bucher EMD G 0 Series Hardware Manual Download

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Installation

Mechanical installation

300−I−9052003−EN−04/07.2021

EMDAG5...

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

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

M6 cheese head, Torx, acc. to ISO 14579

4×

EMDAG026

[mm]

[kg]

EMDxG5...

250

254

109

232

237

210

180

Ø 6.7

106

3.9

Summary of Contents for EMD G 0 Series

Page 1: ...MOBILE Drives 300 I 9052003 EN 04 07 2021 Hardware Manual MOBILE EMDxGxxxxxxxxxxx0x EMDxGxxxxxxxxxxx1x MOBILE DCU MOBILE PSU MOBILE DCU PSU MOBILE DCU S...

Page 2: ...0Fig 0Tab 0...

Page 3: ...e features 20 3 3 Identification 21 3 4 Type code 22 4 Technical data 23 4 1 General data and operating conditions 23 4 2 Rated data of the devices for HV on board supply system 800 V 28 4 2 1 Product...

Page 4: ...ections 54 5 5 3 Polarity reversal protection 54 5 5 4 Wiring the CAN bus 55 5 6 Connections of MOBILE DCU PSU DCU PSU 57 5 6 1 PE conductor 57 5 6 2 HV on board supply system 57 5 6 3 Motor 59 5 6 4...

Page 5: ...7 2021 8 Accessories overview 73 8 1 Prefabricated cables and plug accessories 74 8 1 1 MOBILE DCU PSU DCU PSU 74 8 2 Individual parts for the electrical installation 75 8 2 1 MOBILE DCU PSU DCU PSU 7...

Page 6: ...om 1 1 Target group This manual is intended for all persons who dimension install commission and adjust drives with the MOBILE product platform 1 2 Information regarding the validity This manual is va...

Page 7: ...used This documentation uses the following conventions to distinguish between different types of information Spelling of numbers Decimal separator Point The decimal point is always used For example 1...

Page 8: ...chassis Performance electronics Rectification DC bus and DC AC converter LV on board supply system Low voltage on board system engl Low Voltage ISO 6469 3 voltage class A MC Motor Controller MOBILE P...

Page 9: ...reviations 1 9 300 I 9052003 EN 04 07 2021 Description Term DC bus level Energy storage between rectification and DCAC conversion for one or more controllers DC bus connection DC bus operation Interco...

Page 10: ...rough 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 Danger of personal injury thro...

Page 11: ...e devices Only use original spare parts from Bucher Observe all regulations for the prevention of accidents directives and laws applicable on the site of installation Transport installation commission...

Page 12: ...served An insulation monitoring unit according to IEC 61557 8 must be available in the IT network on the system side The connecting cables used must meet the fire safety requirements of ECE R118 Commi...

Page 13: ...ations 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 give...

Page 14: ...nger operation of self ventilated motors at low speeds Incorrect frequency or voltage settings in the motor parameters especially for 120 Hz motors Protection of the machine plant Drives can reach dan...

Page 15: ...batteries which in conventional vehicles was performed by an alternator Overview of possible device dependent applications MOBILE DCU PSU DCU PSU DCU S Device type Double inverter for two motors l DC...

Page 16: ...11 Connection of HV system 800 V DC 57 X12 Connection of motor A 59 X13 Connection of motor B X31 Vehicle interface connection of control voltage control signals CAN 62 X32 Connection of resolver and...

Page 17: ...r 800 V DC 57 X21 B X21 B LV mains 14 V DC or 28 V DC Connection of the on board battery 61 X31 Vehicle interface connection of control voltage control signals CAN 62 PE connection 47 57 LED LED statu...

Page 18: ...on of water cooling 46 X11 Connection of HV system 400 V DC or 800 V DC 57 X13 Motor connection 59 X21 B X21 B LV mains 14 V DC or 28 V DC Connection of the on board battery 61 X31 Vehicle interface c...

Page 19: ...X2 XX X1 X3 A EMDAG028b Fig 4 MOBILE DCU S EMDxG5 Connections and elements Info 0 Connection of water cooling 46 X1 Vehicle interface connection of control voltage control signals CAN 67 X2 Connection...

Page 20: ...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 acc to DIN...

Page 21: ...Nummer123456789 IP 10 R X X X EMDAG051 Fig 5 Nameplate Product name Type designation Serial number Manufacturer Warning symbol discharge time dangerous electrical voltage ESD hot surface Approval iden...

Page 22: ...ak output power at X12 DCU PSU output power at X21 PSU output power at X21 DCU S peak output power at X3 Example 603 60 103 W 60 kW 562 56 102 W 5 6 kW DCU peak output power at X13 DCU PSU peak output...

Page 23: ...nd HV on board supply system PE Insulation of control circuits EN 61800 5 1 IEC 60664 1 Safe isolation by double reinforced insulation to the HV on board supply system Short circuit strength l Motor c...

Page 24: ...plugs closed Degree of pollution 2 Plugs opened Vibration resistance 9 81 m s2 1 g Transport Operation ISO 16750 3 code L vertical tested with 57 9 m s2 horizontal tested with 57 9 m s2 mechanical sho...

Page 25: ...mmendation l RADOX cable 155S l Huber Suhner EMC Interference emission ECE R10 Rev 5 l radiated broad and narrow band electromagnetic interferences l cable guided transient noise emissions on the supp...

Page 26: ...0 5 1 s 300 300 300 180 No active discharge available Rad L Rpd Cx Cy Cy Riso Riso HV HV EMDAG060 Fig 4 1 Equivalent circuit diagram of DC bus HV HV DC HV electric circuit Riso Riso Resulting resistan...

Page 27: ...ocking zone at low negative speeds and positive torque l Blocking zone at low positive speeds and negative torque Sensorless vector control for synchronous motors SLVCS l Dynamic control in all quadra...

Page 28: ...X21 MOBILE DCU EMDAG2603603U 60 kW 60 kW EMDAG2303303U 30 kW 30 kW EMDAG2303153U 30 kW 15 kW EMDAG2153752U 15 kW 7 5 kW MOBILE PSU EMDAG3562000C 5 6 kW 24 V EMDAG3282000T 2 8 kW 12 V MOBILE DCU PSU EM...

Page 29: ...t A 8 11 15 21 5 32 58 4 kHz permanent A 6 4 8 8 12 17 2 25 6 46 4 8 kHz permanent A 4 8 6 6 9 12 9 19 2 34 8 16 kHz permanent A 2 4 3 3 4 5 6 5 9 6 17 4 4 kHz auto A 8 11 15 21 5 32 58 8 kHz auto A 7...

Page 30: ...32 3 48 87 4 kHz permanent A 9 2 12 7 17 3 24 7 36 8 66 7 8 kHz permanent A 5 6 7 7 10 5 15 1 22 4 40 6 16 kHz permanent A 3 2 4 4 6 8 6 12 8 23 2 4 kHz auto A 12 16 5 22 5 32 3 48 87 8 kHz auto A 10...

Page 31: ...2 92 8 4 kHz permanent A 10 13 8 18 8 26 9 40 72 5 8 kHz permanent A 6 4 8 8 12 17 2 25 6 46 4 16 kHz permanent A 3 6 5 6 8 9 7 14 4 26 1 4 kHz auto A 12 8 17 6 24 34 4 51 2 92 8 8 kHz auto A 12 16 5...

Page 32: ...voltage range V DC 6 16 6 32 Max output current A 200 200 Efficiency typical 92 Valid for operating point DC 500 V AC 28 V 100 A 2 8 kW 40 C Diagram of the output voltage of the DC DC converter 360 V...

Page 33: ...scent current at Tamb 25 C mA 40 60 40 60 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 FLX_IN LV on board supply system 12...

Page 34: ...ts FLX_OUT LV on board supply system 12 V 24 V Rated output voltage V DC 12 24 Voltage range V DC 8 36 8 36 Digital HIGH V DC 8 10 8 21 6 Digital LOW V DC 0 5 0 5 Output current HIGH A 0 2 Output curr...

Page 35: ...the HV system The MOBILE DCU and PSU devices feature intelligent HVIL interlock functionality that is activated when the cover is removed With the two pins InterLock1 and InterLock2 on X31 of the MOB...

Page 36: ...rmostat normally closed contact acc to DIN 44080 Diagnostics option Wire breakage short circuit Resistance measuring range W 280 3050 Measuring current mA max 0 2 Limit frequency of input filter Hz 10...

Page 37: ...0 4 0 9 0 2 0 6 Quiescent current at Tamb 25 C mA 40 60 40 60 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...

Page 38: ...iately opens the HV main relay s thus switching off the HV system The MOBILE DCU S device has a fixed HVIL interlock connection in connector X2 The HVIL interlock connection is disconnected when conne...

Page 39: ...the higher connection in case of horizontal or pending installation Not relevant 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 withou...

Page 40: ...ter ethylene glycol in a ratio of 50 50 and at a coolant temperature of 60 C MOBILE DCU PSU DCU PSU 0 5 10 15 20 10 20 30 50 60 70 Q l min 40 p mbar 25 80 90 100 MOBILE PSU DCU PSU MOBILE DCU EMDAG030...

Page 41: ...Technical data Dimensions 4 41 300 I 9052003 EN 04 07 2021 4 6 Dimensions Dimensions and weights can be found in the Mechanical installation chapter 44...

Page 42: ...d off all power terminals continue to carry electrical voltage for some time e g from capacitors Possible consequences Death or severe injury if the power terminals are touched Protective measures Swi...

Page 43: ...s Stop The input for the HV on board supply system or the mains does not have an electrical polarity reversal protection Possible consequences Destruction of the device is the HV on board supply syste...

Page 44: ...a permanent basis The fixing points are designed for M10 cheese head screw hexagon socket according to DIN 912 ISO 4762 M10 cheese head screw torx according to ISO 14579 g3 g3 g3 b g b1 h c3 d 3 c4 c...

Page 45: ...nsure the mechanical connection on a permanent basis The fixing points are designed for M6 cheese head hexagon socket acc to DIN 912 ISO 4762 M6 cheese head Torx acc to ISO 14579 h c3 d 3 r g t M6 4 r...

Page 46: ...cording the technical data 39 How to connect a proper cooling system Remove the protective caps from the adaptors delivery status Connect suction and pressure hoses Fix and secure the hoses with suita...

Page 47: ...off to protect the systems 5 4 1 Equipotential bonding Conditions for a working EMC concept Avoid current loops because they cause induced voltage differences Arrange the equipotential bonding in sta...

Page 48: ...ts and outputs From approx 5 m cable length or in heavily disturbed environments we recommend the use of shielded cables Connection system Prefabricated cables for the motor connection and the connect...

Page 49: ...ted from mains cables and control cables it only crosses mains cables and control cables at right angles it is not interrupted If the motor cable must be opened all the same e g due to contactors or t...

Page 50: ...h 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 Lay control cables and LV cables as separately as possible from HV cabl...

Page 51: ...ion Basic circuit diagrams 5 51 300 I 9052003 EN 04 07 2021 5 5 Electrical installation 5 5 1 Basic circuit diagrams MOBILE DCU X11 26 8 3 M U V W X12 X321 8 U V W X13 X331 8 EMDxG2 800 V DC X31 1 26...

Page 52: ...52 300 I 9052003 EN 04 07 2021 MOBILE PSU EMDxG3 B B X21 12 24 V DC 800 V DC X11 26 X31 1 26 UG UG UG UG Strg EMDAGS0038b 800 V DC 12 24 V DC B B X21 EMDxG3 X11 UG UG UG UG 26 X31 1 26 12 24 V DC B B...

Page 53: ...ircuit diagrams 5 53 300 I 9052003 EN 04 07 2021 MOBILE DCU PSU 800 V DC 12 24 V DC B B X21 EMDxG4 X11 UG UG UG UG 26 X31 1 26 X331 8 U V W X13 8 3 M Strg EMDAG0038d MOBILE DCU S 800 V DC EMDxG5 20 X1...

Page 54: ...igh 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...

Page 55: ...he signals CAN_HIGH and CAN_LOW avoid double crimping For this purpose the Public CAN is provided with two pins each Stubs are 0 2 m Ideally stubs are avoided The cable length matches the data transfe...

Page 56: ...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 Connect the shield on one side to PE Connect...

Page 57: ...the HV on board cable Connection with non insulated ring cable lug M6 10 000 MOBILE DCU PSU MOBILE PSU Connection with non insulated ring cable lug M6 xxxxx xxxxxxxx DC4 xxxxx xxxxxxxx 8 Eco Fix 10 6...

Page 58: ...Possible consequences Destruction of the device is the HV on board supply system or the mains is connected incorrectly Protective measures Check wiring for possible polarity reversal Stop Wrong param...

Page 59: ...4 l X12 X13 Vmax V AC mm2 AWG 2 3 4 1 1 W 600 2 5 12 12 6 2 V 3 U 4 EMDAG020b PE 2 5 12 12 6 EMDxG3 Danger Dangerous electrical voltage The terminal X13 carries electrical voltage Possible consequence...

Page 60: ...C 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 configu...

Page 61: ...MDAG10_b Note The input for the LV on board supply system has an electrical polarity reversal protection The polarity is only checked at power on not during operation Stop Exchanging the battery phase...

Page 62: ...evice 9 CAN_H_PUBLIC Public CAN Out 10 CAN_L_PUBLIC 11 CAN_L_TERM_PUBLIC Public CAN bus termination CAN Low 12 ID_PIN1 Address offset for setting the CAN address 13 ID_PIN3 14 FLX_IN4 Digital inputs l...

Page 63: ...SAE J1939 and the diagnostics is carried out according to UDS Unified Diagnostic Services which is implemented in the Application Controller AppC The Public CAN is implemented twice on X31 This enable...

Page 64: ...nnel 1 1 MC channel 2 64 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 ca...

Page 65: ...terminating resistor must be connected externally HCU EMDAG2 4 X31 Public CAN CAN_H_PUBLIC CAN_L_TERM_PUBLIC CAN_H_PUBLIC 1 2 11 9 10 3 CAN_L_PUBLIC CAN_L_PUBLIC CAN_H_TERM_PUBLIC 60 60 n 1 x EMDAG2...

Page 66: ...MOBILE DCU S 5 7 1 PE conductor PE mm2 AWG 2 5 4 12 10 Connection with non insulated ring cable lug M6 8 Eco Fix 10 6 3 Nm xxxxx xxxxxxxx DC4 xxxxx xxxxxxxx EMDAG029b 5 7 2 HV on board supply system...

Page 67: ...CAN_H Public CAN and Private CAN network 2 CAN_L 3 CAN_L_TERM Bus terminating resistor for CAN 4 n c Do not use 5 TEMP_MA Analog thermal sensor 6 TEMP_MA 7 TRM15 Switch on off device 8 TRM30 Supply v...

Page 68: ...1939 and the diagnostics is carried out according to UDS Unified Diagnostic Services which is implemented in the Application Controller AppC The Public CAN is implemented twice on X31 This enables a s...

Page 69: ...64 Each device has one address for the Public CAN and three addresses for the Private CAN An address results from the addition of the basic address and the address offset 0 3 The address offset is def...

Page 70: ...be connected to the last device of a CAN bus The terminating resistor is integrated in each device It is activated by a bridge Bridge between X1 3 CAN_L_TERM and X1 9 CAN_H EMDAG5 CAN_H CAN_H CAN_L_TE...

Page 71: ...Please observe the notes on 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 t...

Page 72: ...tion is interrupted Diagnostics via CAN is not possible 1 blinking Invalid CAN address offset 4 blinking Initialisation of the internal flash failed 5 blinking Bootloader firmware incompatibility Prec...

Page 73: ...professionally complying with the respective standards and required approvals at the location Note Unused plug connections have to be sealed with covers or blanking plugs This is the only way to compl...

Page 74: ...LE DCU PSU Motor cable EMD X12 4 6 mm2 EMDY901AxxxxE22A00 MOBILE DCU Motor cable EMD X13 4 6 mm2 EMDY901AxxxxE23A00 MOBILE DCU Motor cable EMD X13 4 6 mm2 EMDY901AxxxxE24A00 MOBILE DCU PSU Motor cable...

Page 75: ...cific properties typical cross section 4 10 mm2 shielded 17 2 mm 841 370 53 Huber Suhner Tightness according to manufacturer information Use 4 light yellow orange or black single conductor seals and 3...

Page 76: ...pe Manufacturer Use M12 connector with prefabricated cable 8 0 25 mm2 AWG24 shielded A coded 90 angled M12 e g Phoenix Contact MOBILE DCU MOBILE DCU PSU 8 2 2 MOBILE DCU S Here the required material f...

Page 77: ...1 2 per X2 1 2103157 1 Spacer 1 per X2 2103153 1 Inner Ferrule Size C 1 per X2 1587723 3 Inner Housing 1 per X2 1587985 1 AMP MCP 2 8K Contact 4 mm2 silverplated 2 per X2 1 968853 3 Power Cable 2 4 m...

Page 78: ...r personal safety 11 H HV on board cable 48 I Identification 21 Installation 42 electrical 51 mechanical 44 water cooling 39 46 Interferences Eliminate EMC interferences 50 Interlock DCU S 38 DCU PSU...

Page 79: ...Index 9 79 300 I 9052003 EN 04 07 2021 Type code find 21 V Validity 6 Voltage supply 33 37 W Water cooling installation 39 46...

Page 80: ...rvice Lenze Service GmbH Breslauer Stra e 3 DE 32699 Extertal Germany 41 41 757 03 33 0080002446877 24 h helpline Phone Email Phone Email service lenze com 2021 by Bucher Hydraulics AG CH 8590 Romansh...

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