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Lenze MOBILE Advanced DCU, Hardware Manual

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Lenze MOBILE Advanced DCU Hardware Manual Download Page 4

Contents

i

Ò

 4

EDSMDAG  EN  2.0

5.3

Water cooling

 43

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.4

EMC−compliant installation

 44

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.4.1

Equipotential bonding

 44

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.4.2

Shielding  

 45

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.4.3

HV on−board cable

 45

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.4.4

Motor cable

 46

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.4.5

Control cables

 47

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.4.6

Detecting and eliminating EMC interferences

 47

. . . . . . . . . . . . . . . . . . . . . 

5.5

Electrical installation

 48

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.5.1

Basic circuit diagrams

 48

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.5.2

Fuses and cable cross−sections

 51

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.5.3

Wiring the CAN bus

 52

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.6

Connections of MOBILE DCU, PSU, DCU PSU

 54

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.6.1

PE conductor

 54

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.6.2

HV on−board supply system

 54

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.6.3

Motor

 55

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.6.4

Feedback

 56

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.6.5

LV on−board supply system

 57

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.6.6

Control system

 58

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.6.7

Addressing CAN bus nodes

 59

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.6.8

Activating the terminating resistor

 61

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.7

Connections of MOBILE DCU S

 62

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.7.1

PE conductor

 62

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.7.2

HV on−board supply system

 62

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.7.3

Motor

 63

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.7.4

Control system

 63

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.7.5

Addressing CAN bus nodes

 64

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5.7.6

Activating the terminating resistor

 66

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

6

Commissioning 

 67

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

7

Diagnostics

 68

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

7.1

Device status

 68

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

7.1.1

MOBILE DCU, PSU, DCU PSU

 68

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

7.1.2

MOBILE DCU S

 68

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

8

Accessories (overview)

 69

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

8.1

Prefabricated cables and plug accessories

 70

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

8.1.1

MOBILE DCU, PSU, DCU PSU

 70

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

8.2

Individual parts for the electrical installation

 71

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

8.2.1

MOBILE DCU, PSU, DCU PSU

 71

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

8.2.2

MOBILE DCU S

 72

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

9

Index

74

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Summary of Contents for MOBILE Advanced DCU

Page 1: ...EDSMDAG Rt Rt Hardware Manual MOBILE EMDxGxxxxxxxxxxx1x MOBILE DCU MOBILE PSU MOBILE DCU PSU MOBILE DCU S Mobile Drive...

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

Page 3: ...ype code 21 4 Technical data 22 4 1 General data and operating conditions 22 4 2 Rated data of the devices for HV on board supply system 800 V 26 4 2 1 Product finder 26 4 2 2 DC AC inverter 27 4 2 3...

Page 4: ...5 6 4 Feedback 56 5 6 5 LV on board supply system 57 5 6 6 Control system 58 5 6 7 Addressing CAN bus nodes 59 5 6 8 Activating the terminating resistor 61 5 7 Connections of MOBILE DCU S 62 5 7 1 PE...

Page 5: ...1 Target group This manual is intended for all persons who dimension install commission and adjust drives with the MOBILE product platform 1 2 Validity information This manual is valid for the compone...

Page 6: ...mentation uses the following conventions to distinguish between different types of information Spelling of numbers Decimal separator Point In general the decimal point is used For instance 1234 56 Tex...

Page 7: ...le chassis Performance electronics Rectification DC bus and DC AC converter LV on board supply system Low voltage on board system ISO 6469 3 voltage class A MC Motor Controller MOBILE Product platform...

Page 8: ...viations used 1 8 EDSMDAG EN 2 0 Description Term DC bus level Energy storage between rectification and DCAC conversion for one or more controllers DC bus connection DC bus operation Interconnection o...

Page 9: ...erous 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 through a gene...

Page 10: ...pare parts from Lenze Observe all regulations for the prevention of accidents directives and laws applicable on the site of installation Transport installation commissioning and maintenance work must...

Page 11: ...tions can be obtained from the nameplate and the documentation They must be strictly observed Commissioning i e start of the operation as intended of devices installed in vehicles is only permissible...

Page 12: ...evices according to the valid safety regulations e g law on technical equipment regulations for the prevention of accidents The devices can be adapted to your application by parameter settings Please...

Page 13: ...equency or voltage settings in the motor parameters especially with 120 Hz motors Protection of the machine system Drives can reach dangerous overspeeds e g setting of high output frequencies in conne...

Page 14: ...ic motors MOBILE DCU PSU DCU PSU DCU S Device type Double inverter for two motors l DC DC converter converter HV on board supply system LV on board supply system l l Combination of single inverter for...

Page 15: ...11 Connection of HV system 800 V DC 54 X12 Connection of motor A 55 X13 Connection of motor B X31 Vehicle interface connection of control voltage control signals CAN 58 X32 Connection of resolver and...

Page 16: ...r 800 V DC 54 X21 B X21 B LV mains 14 V DC or 28 V DC Connection of the on board battery 57 X31 Vehicle interface connection of control voltage control signals CAN 58 PE connection 44 54 LED LED statu...

Page 17: ...on of water cooling 43 X11 Connection of HV system 400 V DC or 800 V DC 54 X13 Motor connection 55 X21 B X21 B LV mains 14 V DC or 28 V DC Connection of the on board battery 57 X31 Vehicle interface c...

Page 18: ...X1 X3 A EMDAG028b Fig 4 MOBILE DCU S EMDxG5 Connections and elements Info 0 Connection of water cooling 43 X1 Vehicle interface connection of control voltage control signals CAN 63 X2 Connection of HV...

Page 19: ...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 44080 PTC acc to DIN 44081 Pub...

Page 20: ...789 ECER10 Xxx Xxx Xxx EMDAG051 Fig 5 Nameplate Product name Type designation Serial number Manufacturer Warning symbol discharge time dangerous electrical voltage ESD hot surface Approval identificat...

Page 21: ...put 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 power...

Page 22: ...oard supply system and 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 circui...

Page 23: ...ollution 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 shock tested with 500 m s2...

Page 24: ...ommendation 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 sup...

Page 25: ...istic l Operation of socket applications with V I characteristic Sensorless vector control for asynchronous motors SLVCI l Dynamic control in all quadrants Vector control for synchronous motors VCS l...

Page 26: ...BILE 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 EMDAG456...

Page 27: ...Hz 2 kHz permanent 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...

Page 28: ...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 4 14...

Page 29: ...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 22 5 32 3...

Page 30: ...d output voltage V DC 14 28 Output voltage range V DC 6 16 6 32 Max output current A 200 200 Diagram of the output voltage of the DC DC converter 360 V Umax UN Umax UN 850 V EMDAGxxxxxxxT EMDAGxxxxxxx...

Page 31: ...A 1 2 5 0 5 1 3 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 4 3 2 Digital inputs Digital inputs LV on board sup...

Page 32: ...y kHz 0 1 Response time ms 95 Reference potential TRM31 Diagnostics option Wire breakage short circuit 4 3 4 Potential free output Digital switching output LV on board supply system 12 V 24 V Max swit...

Page 33: ...J1939 Baud rate kbps 125 250 500 Max cable length at 125 kbps S 250 at 250 kbps m 250 at 500 kbps m 100 Loop delay of all nodes ns 300 Private CAN Protocol CANopen Baud rate kbps 125 250 500 1000 Max...

Page 34: ...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 8 Cur...

Page 35: ...ontact acc to DIN 44080 Diagnostics option Wire breakage short circuit Resistance measuring range W 280 3050 Limit frequency of input filter Hz 10 Resolution Bit 12 4 4 4 CAN bus Public CAN and Privat...

Page 36: ...vertical installation from the lower to 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...

Page 37: ...ylene 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 Fig 4...

Page 38: ...Technical data Dimensions 4 38 EDSMDAG EN 2 0 4 6 Dimensions Dimensions and weights can be found in the Mechanical installation chapter 41...

Page 39: ...re working on them Stop No device protection if the HV on board voltage or mains voltage is too high The input for the HV on board supply system or the mains is not fused internally Possible consequen...

Page 40: ...40 EDSMDAG EN 2 0 Stop The device contains components that can be destroyed by electrostatic discharge Before working on the device the personnel must ensure that they are free of electrostatic charge...

Page 41: ...mechanical connection The fixing points are dimensioned 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...

Page 42: ...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 g3 g3 h g3 c3 d 3 r g 4 M6...

Page 43: ...ed in the factory and checked for tightness The water cooling has to be dimensioned according the technical data 36 How to connect a proper cooling system Remove the protective caps from the adaptors...

Page 44: ...o 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 star shap...

Page 45: ...PSU 24 V supply Digital signals inputs and outputs We recommend to use shielded cables for a cable length from approximately 5 m on or in environments with strong interferences Connection system Pref...

Page 46: ...the cable cross section Install contactors terminals etc spatially separated from other components with a min distance of 100 mm Install the shield of the motor cable directly before and behind the p...

Page 47: ...the own or other devices and measuring systems Unshielded HV mains cable Unshielded motor cable Use shielded cables Shield contact is not extensive enough Carry out optimal shielding as specified Shie...

Page 48: ...tallation Basic circuit diagrams 5 48 EDSMDAG EN 2 0 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 UG UG U...

Page 49: ...grams 5 49 EDSMDAG EN 2 0 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 X21 E...

Page 50: ...Basic circuit diagrams 5 50 EDSMDAG EN 2 0 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 1 21...

Page 51: ...that the occurring short circuit currents caused by the internal resistances of the energy sources are sufficiently high to safely trip the fuses Otherwise there is no reliable switch off in case of s...

Page 52: ...ough the 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 t...

Page 53: ...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 the sh...

Page 54: ...xxxxxxxx DC4 xxxxx xxxxxxxx 8 Eco Fix 10 6 3 Nm EMDAG017a 5 6 2 HV on board supply system X11 Umax V DC mm2 AWG 2 3 4 1 1 UG 848 2 5 12 12 6 2 UG 3 UG EMDAG020b 4 UG Per potential the terminal contain...

Page 55: ...Motor 5 55 EDSMDAG EN 2 0 5 6 3 Motor X12 X13 MOBILE DCU EMDxG2 l l MOBILE PSU EMDxG3 MOBILE DCU PSU EMDxG4 l X12 X13 Umax 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...

Page 56: ...PTC thermistors may be connected in series Monitored short circuit and cable breakage Thermostats are not monitored Each connection is assigned to a motor connection The MOBILE DCU assignment is conf...

Page 57: ...d supply system 5 57 EDSMDAG EN 2 0 5 6 5 LV on board supply system X21 MOBILE DCU EMDxG2 MOBILE PSU EMDxG3 l MOBILE DCU PSU EMDxG4 l X21 X21 Umax V mm2 AWG M10 32 70 000 with ring cable lug EMDAGxxxx...

Page 58: ...device 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...

Page 59: ...ion and diagnostic environments of the single OEM s By default the control is carried out according to SAE J1939 and the diagnostics is carried out according to UDS Unified Diagnostic Services which i...

Page 60: ...MC channel 2 77 The address offset is defined by wiring ID Pin1 ID Pin4 to X31 Thanks to the combinations 14 different address offsets are possible which means that up to 14 MOBILE devices can be ope...

Page 61: ...nating 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 4 X31...

Page 62: ...7 Connections of 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 boar...

Page 63: ...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 voltage...

Page 64: ...nd diagnostic environments of the single OEM s By default the control is carried out according to SAE J1939 and the diagnostics is carried out according to UDS Unified Diagnostic Services which is imp...

Page 65: ...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 defined by...

Page 66: ...nected 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_L EMDAG5 CAN_H CAN_H CAN_L_TERM 9 1...

Page 67: ...serve the notes regarding residual hazards 13 The MOBILE Engineer tool supports you during the commissioning phase You are led through the commissioning steps and obtain additional information on the...

Page 68: ...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 Precharg...

Page 69: ...y 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 comply with the cl...

Page 70: ...CU EMDY901A0100E22A00 MOBILE DCU Motor cable EMD X13 4 6 mm2 10 m DCU EMDY901A0100E23A00 MOBILE DCU Motor cable EMD X13 4 6 mm2 10 m PSU EMDY901A0100E24A00 MOBILE DCU PSU Motor cable EMD X12 4 4 mm2 1...

Page 71: ...o manufacturer information Use 4 orange or black single conductor seals and 3 green blanking plugs per receptacle housing Motor at X12 X13 Name Additional information Type Manufacturer Use 7 pole rece...

Page 72: ...x Contact MOBILE DCU MOBILE DCU PSU 8 2 2 MOBILE DCU S Here the required material for plugs plug parts and cables are listed and assigned to terminals Control at X1 Name Type Manufacturer Socket housi...

Page 73: ...er 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 mm2 217...

Page 74: ...our personal safety 10 H HV on board cable 45 I Identification 20 Installation 39 electrical 48 mechanical 41 water cooling 36 43 Interferences eliminating EMC interferences 47 M Maintenance and servi...

Page 75: ...Index 9 75 EDSMDAG EN 2 0 V Validity 5 Voltage supply 31 34 W Water cooling installation 36 43...

Page 76: ...orn Switzerland Service Lenze Service GmbH Breslauer Stra e 3 D 32699 Extertal Germany 41 71 46611 11 0080002446877 24 h helpline 41 71 46611 10 49 5154 82 1112 Info Lenze Schmidhauser ch Service Lenz...

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