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

Contentsi
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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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300−I−9052003−EN−04/07.2021
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 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.2 MOBILE DCU S 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Index 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About this documentation
Target group
1
>
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
>7
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
>
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
>9
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