Bucher EMD G 0 Series User manual

MOBILE Drives
300−I−9052003−EN−04/07.2021
Hardware Manual
MOBILE
>
EMDxGxxxxxxxxxxx0x, EMDxGxxxxxxxxxxx1x
MOBILE DCU
MOBILE PSU
MOBILE DCU PSU
MOBILE DCU S

0Fig. 0Tab. 0

Contents i
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300−I−9052003−EN−04/07.2021
1 About this documentation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Target group 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Information regarding the validity 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Document history 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Conventions used 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 Terminology used and abbreviations 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Notes used 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Safety instructions 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 General safety and application notes for Bucher MOBILE devices 11. . . . . . . . . . . . .
2.2 Residual hazards 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Product description 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 System overview 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Device 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 finder 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.2 DC/AC inverter 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.3 DC/DC converter 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Control of MOBILE DCU, PSU, DCU PSU 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1 Voltage supply 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.2 Digital inputs 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.3 Digital outputs 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.4 Interlock 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.5 Feedback 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.6 CAN bus 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Control of MOBILE DCU S 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 Voltage supply 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.2 Digital inputs 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.3 Interlock 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.4 Thermal sensor input 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.5 CAN bus 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Water cooling 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 Dimensions 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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5 Installation 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Important notes 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Mechanical installation 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Water cooling 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 EMC/compliant installation 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.1 Equipotential bonding 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.2 Shielding 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.3 LV on−board cable 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.4 HV on−board cable 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.5 Motor cable 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.6 Control cable 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.7 Detect and eliminate EMC interferences 50. . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Electrical installation 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.1 Basic circuit diagrams 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.2 Fuses and cable cross−sections 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 Feedback 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.5 LV on−board supply system 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.6 Control 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.7 Addressing CAN bus nodes 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.8 Activating the terminating resistor 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7 Connections of MOBILE DCU S 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7.1 PE conductor 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7.2 HV on−board supply system 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7.3 Motor 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7.4 Control 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7.5 Addressing CAN bus nodes 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7.6 Activating the terminating resistor 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Commissioning 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Diagnostics 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Device status 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1 MOBILE DCU, PSU, DCU PSU 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.2 MOBILE DCU S 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents i
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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 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.2 MOBILE DCU S 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Index 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About this documentation
Target group
1
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6 300−I−9052003−EN−04/07.2021
1 About this documentation
This manual contains the complete information on the intended use of components of the
MOBILE product platform in mobile applications in or on vehicles.
ITip!
Information and tools regarding the Bucher products can be found in the
download area under:
www.bucherdrives.com
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 valid for the components with the type designation:
Device type Type designation from SW
MOBILE Advanced DCU EMDAG2xxxxxxxxxx1x 06.0
MOBILE Advanced PSU EMDAG3xxxxxxxxxx1x 06.0
MOBILE Advanced DCU PSU EMDAG4xxxxxxxxxx1x 06.0
MOBILE DCU S EMDAG5xxxxxxxxxx0x 06.0
Accessories EMDAZ... ˘
The breakdown of the type designation can be found in the "Product description" chapter.
(¶22)

About this documentation
Document history
1
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300−I−9052003−EN−04/07.2021
1.3 Document history
Version Description
4.0 07.2021 Rebranding to Bucher Hydraulics AG
3.0 11.2020 Revision of the device manual for the hardware version x1x
1.1 10.2014 Corrections
1.0 09.2014 First edition
1.4 Conventions 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: 1234.56
Text
Program name » « PC software
For example: »MOBILE Engineer«
Icons
Page reference ^Reference to another page with additional
information
For example: ^16 = see page 16
Documentation reference ,Reference to another documentation with
additional information
For example: ,EDKxxx = see
documentation EDKxxx

About this documentation
Terminology used and abbreviations
1
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8 300−I−9052003−EN−04/07.2021
1.5 Terminology used and abbreviations
Term Description
AppC Application Controller
CAN Controller Area Network or electric circuit for CAN with its own current
supply
DC Direct current
DCU DC/AC inverter
Drive Control Unit
DCU PSU Combined device
Double inverter Inverter for two motors or two drives
Single inverter Inverter for one motor or one drive
HCU Host Control Unit (also Vehicle Control Unit or Machine Control Unit)
HV on−board supply system High−voltage (on−board) system
engl.: High Voltage
ISO 6469−3, voltage class B
IT Isolé Terre system (star point not earthed)
TRM15 Terminal 15: Terminal 15 is the original contact "Ignition on" at the
steering lock which switches on the MOBILE PSU/DCU by a switch−on
pulse (LOW−HIGH 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 potentially
connected to the vehicle 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 Product platform for automotive drive solutions
»MOBILE Engineer« Engineering tool, software solution for easy engineering in all phases
Module Electronic unit or device
engl.: Unit
Motor A First motor controlled by MC
Motor B Second motor controlled by MC (optional)
n. c. Not connected
engl.: not connected
PE Chassis
Protective earth
Private CAN Real time CAN Bus which is used for controlling drives.
PSU DC/DC converter
Power Supply Unit
Public CAN CAN bus on the vehicle side which is used for integrating the MOBILE
PSU/DCU into vehicles.
Control electronics Open−loop control, closed−loop control, setpoint generation, monitoring
SM Synchronous motor
Tn Terre Neutre system (star point is earthed)
DC bus DC bus
SLVCI Sensorless vector control for asynchronous motors
SLVCS Sensorless vector control for synchronous motors
SLVFCI Sensorless V/f characteristic control for asynchronous motors
Ctrl Control
VCI Vector control for asynchronous motors
VCS Vector control for synchronous motors

About this documentation
Terminology used and abbreviations
1
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300−I−9052003−EN−04/07.2021
DescriptionTerm
DC−bus level Energy storage between rectification and DCAC conversion, for one or
more controllers
DC−bus connection, DC−bus
operation
Interconnection of several inverters on the DC−bus level

About this documentation
Notes used
1
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10 300−I−9052003−EN−04/07.2021
1.6 Notes used
The following pictographs and signal words are used in this documentation to indicate
dangers and important information:
Safety instructions
Layout of the safety instructions:
}Danger!
(characterises the type and severity of danger)
Note
(describes the danger and gives information about how to prevent dangerous
situations)
Pictographs and signal words Meaning
{Danger!
Danger of personal injury through dangerous electrical voltage
Reference to an imminent danger that may result in death or
serious personal injury if the corresponding measures are not
taken.
}Danger!
Danger of personal injury through a general source of danger
Reference to an imminent danger that may result in death or
serious personal injury if the corresponding measures are not
taken.
(Stop!
Danger of property damage
Reference to a possible danger that may result in property
damage if the corresponding measures are not taken.
Application notes
Pictographs and signal words Meaning
)Note! Important note to ensure trouble−free operation
ITip! Useful tip for easy handling
,Reference to another document

Safety instructions
General safety and application notes for Bucher MOBILE devices
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300−I−9052003−EN−04/07.2021
2 Safety instructions
2.1 General safety and application notes for Bucher 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
ƒFor devices with ECE R10 approval, the ECE regulation no. 100 has to be observed.
For your personal safety
ƒOnly use the devices as directed.
ƒNever commission the devices in the event of visible damage.
ƒNever commission the devices before they have been completely mounted.
ƒOnly separate or plug connectors if the high−voltage mains is switched off and
discharged:
– Power connector (marked with a warning sign on the cover)
– Signal connector
ƒDo not open the housing of the devices. If the housing is opened, the warranty is
void.
ƒDo not carry out any technical changes on the devices.
ƒOnly use the accessories approved for the devices.
ƒOnly use original spare parts from Bucher.
ƒObserve all regulations for the prevention of accidents, directives and laws
applicable on the site of installation.
ƒTransport, installation, commissioning and maintenance work must only be carried
out by qualified personnel.
– Observe IEC 364 and CENELEC HD 384 or DIN VDE 0100 and IEC report 664 or DIN
VDE 0110 and all national regulations for the prevention of accidents.
– According to this basic safety information, qualified, skilled personnel are persons
who are familiar with the assembly, installation, commissioning, and operation of
the product and who have the qualifications necessary for their occupation.
ƒObserve all specifications in the documentation.
– Carry out installation and operation in accordance with the documentation.
– This is the condition for safe and trouble−free operation and the achievement of
the specified product features.
– The procedural notes and circuit details described in the documentation are only
proposals. It is up to the user to check whether they can be transferred to the
particular applications. Bucher Hydraulics AG does not accept any liability for the
suitability of the procedures and circuit proposals described.

Safety instructions
General safety and application notes for Bucher MOBILE devices
2
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ƒThe 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.
ƒBefore touching conductive components, ensure isolation from supply by means of
measurement.
The device−specific safety and application notes given in the chapter "Residual hazards"
of this documentation must be observed.
Application as directed
ƒThe devices meet the requirements of the Low−Voltage Directive 2006/95/EC. The
harmonised standard EN 61800−5−1 applies to the devices.
ƒThe devices marked with E1 are components which are designed for installation in
vehicles (ECE approval). They are not to be used as domestic appliances, but only for
industrial purposes according to EN 61000−3−2.
ƒThe technical data and supply conditions can be obtained from the nameplate and
the documentation. They must be strictly observed.
ƒAn insulation monitoring unit according to IEC 61557−8 must be available in the IT
network on the system side.
ƒThe connecting cables used must meet the fire safety requirements of ECE R118.
ƒCommissioning (i.e. start of the operation as intended) of devices installed in
vehicles is only permissible if the following has been verified:
– The vehicle corresponds to the valid vehicle standards (e.g. ECE R100, safety
requirements with respect to the electric power train of road vehicles); EN 60204 is
observed.
– The EMC Directive 2004/104/EC (last supplemented by 2009/19/EC) is complied
with.
Transport, storage
Please observe the notes on transport, storage, and appropriate handling.
Observe the climatic conditions according to the technical data.
Installation
You have to mount, connect and cool the devices according to the specifications of the
respective documentation. The equipotential bonding has to be dimensioned sufficiently
and protected against corrosion.
When plug connections are open, the degree of pollution 2 must not be exceeded
according to EN 61800−5−1.
Ensure proper handling and avoid excessive mechanical stress.
Do not touch any electronic components and contacts. The devices contain electrostatic
sensitive devices that can be damaged easily by improper handling. Damaged devices
must not be commissioned.

Safety instructions
General safety and application notes for Bucher MOBILE devices
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Electrical connection
When working on live devices, observe the applicable national regulations for the
prevention of accidents and technical measures for occupational safety and health.
The electrical installation must be carried out according to the appropriate regulations (e.g.
cable cross−sections, fuses, PE connection). Additional information can be obtained from
the documentation.
The documentation contains notes concerning wiring according to EMC regulations
(shielding, earthing, filters and cable routing). The compliance with limit values required
by the EMC legislation is the responsibility of the manufacturer of vehicles or systems or
machines.
Operation
If necessary, systems including these devices must be equipped with additional
monitoring and protection devices according to the valid safety regulations (e.g. law on
technical equipment, regulations for the prevention of accidents). The devices can be
adapted to your application by parameter settings. Please observe the corresponding
information given in the documentation.
After the devices have been disconnected from the supply voltage, all live components and
connectors must not be touched immediately because capacitors can still be charged.
Please observe the corresponding stickers on the devices.
Ensure that all protection covers are closed and screwed during operation.
Maintenance and servicing
The devices do not require any maintenance if the prescribed operating conditions are
observed.
The external cleaning of the devices has to be made in the course of the general care of the
vehicles, machines, or systems.
Depending on the mounting place and the possible pollution, the cover sensor has to be
cleaned regularly.
Position of the cover sensor:
ƒMOBILE DCU (EMDxG2...) (¶16)
ƒMOBILE PSU (EMDxG3...) (¶17)
ƒMOBILE DCU/PSU (EMDxG4...) (¶18)
Disposal
For a professional disposal and utilisation of the devices, please comply with the valid
regulations, e.g. 2000/53/EC (last amended by 2011/37/EC).

Safety instructions
Residual hazards
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2.2 Residual hazards
Protection of persons
ƒSwitch off the high voltage on−board voltage completely before working on the
devices.
ƒBefore working on the device, check whether all power terminals are deenergised
because
– after disconnection, the power terminals U, V and W remain live for at least 5
minutes depending on the system.
– the power terminals +UG, −UG, U, V and W remain live while the motor is rotating.
– Batteries and energy storages can carry hazardous voltage over a longer period of
time.
Device protection
ƒConnect or disconnect all pluggable connection terminals only in de−energized state!
ƒOnly disconnect the inverters from the installation, e.g. from the motor or the
mounting wall, in a de−energized state!
ƒClose all unused connectors with protective caps or blind plugs.
Motor protection
ƒWith certain inverter settings, the connected motor may overheat:
– E.g. longer operation of the DC−injection brake.
– Longer 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
ƒDrives can reach dangerous overspeeds (e.g. setting of high output frequencies with
unsuitable motors and machines):
– The inverters offer no protection against such operating conditions. Use additional
components for this purpose.
Symbol Description
ÞLong discharge time: All power terminals remain live for a few minutes after mains disconnection!
The duration is given under the warning symbol on the device.
}High leakage current: Carry out fixed installation and PE connection according to EN 6180051!
'Electrostatic sensitive devices: Before working on the device, the personnel must be free of
electrostatic charge!
|Hot surface: Risk of burns! Hot surfaces should not be touched without wearing protective gloves.
}
¶
Read the documentation: Before working on the device, the personnel must read and act in
accordance with the documentation supplied with the product, especially the warnings and the
safety instructions!
{Dangerous voltage: Before working on the device, switch off the HV on−board voltage completely!

Product description
System overview
3
>15
300−I−9052003−EN−04/07.2021
3 Product description
3.1 System overview
The components from the MOBILE modular system are used to realize auxiliary unit
applications in commercial vehicles by means of:
ƒElectric motors for air−conditioning compressors or air compressors
ƒA charging function for 12 V or 24 V 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/DC converter (converter HV on−board supply system/LV
on−board supply system)
˘l l ˘
Combination of single inverter for one motor and DC/DC
converter
˘ ˘ l˘
Single inverter for one motor ˘ ˘ ˘ l
Application
Simple drives of pumps and fans l˘l l
Controlled and positioning drives l l l
Charging the LV on−board supply system with regenerative
energy of drives
˘l l ˘

Product description
System overview
3
>
16 300−I−9052003−EN−04/07.2021
MOBILE DCU
2×
X11
X13
X12
X33
X31
X32
XX XX
+
ALED
EMDAG013a
Fig. 1 MOBILE DCU (EMDxG2...)
Connections and elements Info
0Connection of water cooling ^46
X11 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 temperature monitoring of motor A
(by default sealed with plug)
^60
X33 Connection of resolver and temperature monitoring of motor B
(by default sealed with plug)
+PE connection ^47
^57
LED LED status display ^72
Cover sensor

Product description
System overview
3
>17
300−I−9052003−EN−04/07.2021
MOBILE PSU
XX
X21/B-
X11
X31
XX
X21/B+ +
A LED
EMDAG012a
Fig. 2 MOBILE PSU (EMDxG3...)
Connections and elements Info
0Connection of water cooling ^46
X11 Connection of HV system 400 VDC or 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 status display ^72
Cover sensor
{Danger!
Dangerous electrical voltage
The terminal X13 carries electrical voltage.
Possible consequences:
ƒDeath or severe injury if the power terminals are touched.
Protective measures:
ƒDo not remove the blanking plug from X13.

Product description
System overview
3
>
18 300−I−9052003−EN−04/07.2021
MOBILE DCU PSU
X33
XX
X21/B-
X11
X13
X31
XX
X21/B+ +
ALED
EMDAG011a
Fig. 3 MOBILE DCU/PSU (EMDxG4...)
Connections and elements Info
0Connection 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, connection of control voltage, control signals, CAN ^62
X33 Connection of resolver and motor temperature monitoring
(by default sealed with plug)
^60
+PE connection ^47
^57
LED LED status display ^72
Cover sensor

Product description
System overview
3
>19
300−I−9052003−EN−04/07.2021
MOBILE DCU S
XX
X2
XX
+
X1
X3
A
EMDAG028b
Fig. 4 MOBILE DCU S (EMDxG5...)
Connections and elements Info
0Connection of water cooling ^46
X1 Vehicle interface, connection of control voltage, control signals, CAN ^67
X2 Connection of HV on−board supply system 800 V DC ^66
X3 Motor connection ^67
+PE connection ^66
^47

Product description
Device features
3
>
20 300−I−9052003−EN−04/07.2021
3.2 Device features
Device feature EMDAG2... EMDAG3... EMDAG4... EMDAG5...
Power range
(Peak Power)
kW 7.5 ... 60 2.8 ... 5.6 2.8 ... 60 7.5 ... 22
DC/AC inverter 2 ˘ 1 1
DC/DC converter ˘ 1 1 ˘
Approval acc. to ECE R10 l l l l
Degree of protection IP6K9K IP6K9K IP6K9K IP6K9K
Cooling Water / glycol (^39)
Standards fulfilled ASTM D 3306, AS 2108−2004, ASTM D 4985
BS 6580:2010, SAE J1034, SANS 1251:2005
CUNA NC 956−16, ÖNORM V 5123, AFNOR NFR 15−601
Mounting type free
Mounting with screws (see mounting instructions)
12/24−V voltage for maintaining the
control functionality in the case of
mains failure
l l l l
Digital inputs 4 4 4 4
configurable as analog input 2 2 2 2
configurable as frequency input 2 2 2 ˘
Digital outputs 444 ˘
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
Public CAN l l l l
Baud rate kbps 125 ... 500 125 ... 500 125 ... 500 125 ... 500
Private CAN l l l l
Baud rate kbps 125 ... 1000 125 ... 1000 125 ... 1000 125 ... 500
Operation in generator mode
(optional)
l˘l l
Loop−through of HV system lll ˘
Overload cycle at 1.8 × Irated 10 s ˘10 s 10 s
Overload cycle at 1.5 × Irated 60 s ˘60 s 60 s
Motor speed range rpm −32000 ... 32255 ˘−32000 ... 32255 −32000 ... 32255
Non−parameterizable functions
Interlock (HVIL) ˘˘˘l
Parameterizable functions
Interlock (HVIL) (see reference manual) ˘
Precharge (see reference manual) ˘
Technology application
Actuator speed l˘l l
Switch−off positioning m˘m˘
Absolute positioning m˘m˘
lIncluded as standard
mOptionally available
˘ Not available