Conductix-Wampfler MPU 3.0 Parts list manual

TNB_0085_MPU30
www.conductix.com
Technical Description
MPU 3.0
Mobile Power Unit
Item number WNR
3267229 CWA-60691000

TNB_0085, 2, en_GB
Translation of the original
© 2023 Conductix-Wampfler Automation GmbH
Conductix-Wampfler Automation GmbH
Handelshof 16 A
14478 Potsdam
Germany
Telephone: [phone]
Fax: [phone]
Email: [email protected]
Internet: www.conductix.com

Table of contents
1 Information on the description.................................................................. 7
1.1 Revision history............................................................................. 7
1.2 How to use and store the description............................................ 7
1.3 Applicable documents................................................................... 7
1.4 Copyright protection...................................................................... 8
1.5 Illustrations.................................................................................... 8
1.6 Brands........................................................................................... 8
2 Warranty and liability.................................................................................. 9
2.1 Warranty........................................................................................ 9
2.2 Limitation of liability....................................................................... 9
3 Safety instructions................................................................................... 10
3.1 Warning concept.......................................................................... 10
3.1.1 Arrangement of warnings............................................................ 10
3.1.2 Structure of warnings................................................................... 10
3.1.3 Signal words................................................................................ 11
3.1.4 Hazard symbols........................................................................... 11
3.1.5 Suggestions and recommendations............................................ 11
3.2 Intended use................................................................................ 12
3.3 Foreseeable incorrect use........................................................... 12
3.4 Modifications and alterations....................................................... 13
3.5 Responsibility of the operator...................................................... 14
3.6 Personnel and qualifications........................................................ 14
3.7 Special hazards........................................................................... 17
3.8 Safety devices............................................................................. 18
4 Wireless Charger WC 3.0 - system overview......................................... 19
4.1 Components................................................................................ 19
4.2 How it works................................................................................ 20
4.3 Control circuit............................................................................... 21
4.4 Controlling the charging process................................................. 21
4.4.1 Charging process - Continuous................................................... 23
4.4.2 Charging process - controlled by BMS controller........................ 24
4.4.3 Charging process - controlled by BMS and PLC......................... 25
4.4.4 Charging process - controlled by PLC......................................... 26
4.4.5 Charging process - controlled by AGV controller........................ 27
4.5 Enable commands for charging process..................................... 28
4.6 Inductive communication............................................................. 29
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5 Product description.................................................................................. 30
5.1 Structure...................................................................................... 30
5.2 Function....................................................................................... 30
5.3 Type label.................................................................................... 31
5.4 Scope of delivery......................................................................... 31
5.4.1 Device.......................................................................................... 31
5.4.2 Product sets................................................................................. 31
6 Transport and storage.............................................................................. 33
6.1 Transport..................................................................................... 33
6.2 Transport inspection.................................................................... 33
6.3 Storage........................................................................................ 34
7 Mechanical installation............................................................................ 35
7.1 Installation location and position.................................................. 37
7.2 Open spaces and cooling............................................................ 38
7.3 Installation................................................................................... 40
8 Electrical installation................................................................................ 41
8.1 Electrical connections.................................................................. 43
8.1.1 Connection overview................................................................... 43
8.1.2 Pin configuration.......................................................................... 43
8.1.2.1 X1 - IMP-Power...................................................................... 44
8.1.2.2 X2 - IMP-Signal...................................................................... 44
8.1.2.3 X3 - CAN bus/fan................................................................... 44
8.1.2.4 X4 - Ethernet.......................................................................... 45
8.1.2.5 XBatt+ / XBatt- - Battery......................................................... 45
8.2 Floor conductivity......................................................................... 46
9 Commissioning......................................................................................... 47
10 Operation................................................................................................... 48
10.1 Switching the device on and off................................................... 50
10.1.1 Switching on the device............................................................... 50
10.1.2 Switching off the device............................................................... 50
10.2 Status indicators.......................................................................... 50
10.3 Operating modes......................................................................... 52
10.4 Charging process........................................................................ 53
10.4.1 Automatic adjustment of the primary current............................... 53
10.4.2 Temperature generation during the charging process................. 53
10.4.3 Power reduction with temperature increase................................ 54
10.4.4 Power reduction in case of pad displacement............................. 55
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11 Faults......................................................................................................... 56
11.1 Warning indicators....................................................................... 58
11.2 Fault indicators............................................................................ 60
12 Maintenance and cleaning....................................................................... 64
12.1 Maintenance................................................................................ 64
12.2 Cleaning...................................................................................... 65
13 Information on disposal and environmental regulations...................... 66
14 Technical Data........................................................................................... 67
14.1 Dimensions.................................................................................. 67
14.2 Weight......................................................................................... 67
14.3 Material........................................................................................ 67
14.4 Cooling........................................................................................ 67
14.5 Environmental conditions............................................................ 68
14.6 Input data..................................................................................... 69
14.7 Output data.................................................................................. 69
14.8 Cable lengths and specifications................................................. 70
14.9 Approvals and standards............................................................. 72
15 Customer service and addresses........................................................... 73
16 Index.......................................................................................................... 75
Appendix................................................................................................... 77
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1 Information on the description
1.1 Revision history
We reserve the right to make changes to the information present in this
document, which result from our constant effort to improve our products.
Version Date Comment/reason for change
1 11.2022 Corrections to content (based on TNB_0074)
2 01.2023 First released version
1.2 How to use and store the description
To work safely with the product, it is necessary to observe the safety notes
and action instructions. All persons working with the product must have
understood the user information in this description and apply it conscien-
tiously. The operator must fulfil his duty of care and ensure that all persons
working with the product have read and understood the user information
and are implementing it.
This description forms part of the product and must be accessible to all per-
sons working with the product at all times.
1.3 Applicable documents
The documents contained in the project documentation also apply if the
device / system is part of a project-specific system plan.
Their own documentation applies to connected devices and components.
Hardware Related description
IPS 3.0
Inductive Power Supply TNB_0083_IPS30
ISP 3.0
Inductive Stationary Pad
TNB_0073_ISP30_IMP30
IMP 3.0
Inductive Mobile Pad
MPU 3.0
Mobile Power Unit TNB_0085_MPU30
Software Related description
Wireless Charger 3.0
Web Interface SWB_0021_Wireless-Charger-Web-Interface_User_Admin
Subject to
changes
Technical doc-
umentations
Information on the description
Applicable documents
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The documents are included in the scope of delivery of the respective
device or can be downloaded from our website www.conductix.com.
1.4 Copyright protection
The contents, texts, drawings, pictures and other illustrations of this
description are protected by copyright and subject to intellectual property
rights. Any misuse is punishable by law.
Reproduction in whole or in part of this description is only permitted within
the limits of the legal provisions of the copyright law. Any modification or
shortening of the text is prohibited without the explicit written consent of
Conductix-Wampfler Automation GmbH.
1.5 Illustrations
The illustrations that accompany this description have been purposely
selected. They are provided for basic understanding and may differ from
the actual design. No claims shall be accepted for possible discrepancies.
1.6 Brands
The popular names, trade names, production descriptions, etc. used in this
description may constitute trademarks even without special designations
and as such may be subject to legal requirements.
Information on the description
Brands
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2 Warranty and liability
2.1 Warranty
The warranty only covers production defects and faulty components.
The manufacturer assumes no responsibility for damages caused during
transport or unpacking. In no case and under no circumstances will the
manufacturer be liable for defects or damages caused by misuse, incorrect
installation or inadequate environmental conditions or from dust or corro-
sive substances.
Consequential damages are excluded from the warranty.
Should you have further questions regarding the warranty, please contact
the supplier.
2.2 Limitation of liability
All information and notes in this description have been compiled taking into
account the applicable standards and regulations, the state of the art and
our many years of knowledge and experience.
Conductix-Wampfler Automation GmbH assumes no liability for damage
and malfunctions during operation due to:
nFailure to comply with the description
nNon-intended use
nUse by untrained personnel
nUnauthorised alteration or modification
nUse of the product, despite negative transport inspection
Furthermore, Conductix-Wampfler Automation GmbH's warranty obligation
will cease to exist in case of a failure to comply with the description.
Warranty and liability
Limitation of liability
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3 Safety instructions
This section contains information on all safety aspects for optimum protec-
tion of personnel and for safe operation without malfunctions.
To prevent dangers, these notes must be read and followed by personnel.
Only then can safe operation be guaranteed.
Of course, all legally applicable general safety and accident prevention reg-
ulations must be complied with.
Conductix-Wampfler Automation GmbH assumes no liability for damage or
accidents that were caused by non-observance of these safety notes.
3.1 Warning concept
This description contains notes that must be observed for your own per-
sonal safety and to avoid property damage. Notes regarding your personal
safety are highlighted by a warning triangle; notes regarding property
damage do not have a warning triangle.
When several hazard levels occur, the warning always refers to the highest
level. If a warning of injury to persons is indicated with a warning triangle,
the same warning might include an additional warning of property damage.
3.1.1 Arrangement of warnings
If warnings refer to an entire section, they are placed at the beginning of the
section (e.g. chapter start).
If warnings refer to a specific action instruction, they are placed in front of
the respective action instruction.
3.1.2 Structure of warnings
nSIGNAL WORD
n↳ Type of danger and its source
n↳ Possible consequences, if not observed
n↳ Danger avoidance measures
n↳ Preventive measures
Safety instructions
Warning concept > Structure of warnings
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3.1.3 Signal words
Warnings are indicated using signal words based on hazard levels.
Signal word Meaning
LWARNING! This combination of symbol and
signal word indicates a possible
dangerous situation that can result
in death or serious injury if it is not
avoided.
NOTICE! This combination of symbol and
signal word indicates a possible
dangerous situation that can result
in material damage if it is not
avoided.
3.1.4 Hazard symbols
Warnings of the groups 'danger' and 'warning' are content-based. They are
presented with clear danger symbols.
Warnings of the 'caution' group do not have a specific danger symbol.
Warning signs Type of danger
Warning – high-voltage.
Warning – non-ionising electromag-
netic radiation.
Warning – danger zone.
3.1.5 Suggestions and recommendations
This symbol indicates important information to help you handle the
product.
Safety instructions
Warning concept > Suggestions and recommendations
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3.2 Intended use
The device has been designed and constructed exclusively for the intended
use described below.
The mobile power supply MPU 3.0 (Mobile Power Unit)
nis a device designed for use in commercial and industrial transport sys-
tems.
nis part of the ‘Wireless Charger 3.0’ inductive charging system for
charging batteries in AGVs.
nconverts the current provided by the Inductive Power Supply IPS 3.0,
which is inductively transmitted via the pads into a current for charging
the batteries of the AGV.
The intended use includes compliance with all of the information in this
manual and the associated documents.
Any use beyond that intended or other types of use are regarded as
misuse.
3.3 Foreseeable incorrect use
Any use that goes beyond this description is forbidden.
L WARNING!
Hazard from non-intended use!
Any use of the device other than and/or beyond the intended use can
cause hazardous situations.
nOnly use the device as intended.
nIt is paramount to comply with all the specifications and permitted
conditions at the place of use.
nDo not use the device in potentially explosive atmospheres.
nDo not operate the device in environments with harmful oils, gases,
vapours, dusts, radiation, etc.
Safety instructions
Foreseeable incorrect use
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NOTICE!
Components of the charging system
The components of the charging system are coordinated with each other
and form a system unit. Operation with third-party equipment leads to
damage and failure of the system!
nThe system is not compatible with devices from other manufacturers.
nOperate the system only with the components intended for it.
3.4 Modifications and alterations
For the purpose of avoiding hazards and for ensuring optimum perform-
ance, any modifications, additions, or alterations to the device require Con-
ductix-Wampfler Automation GmbH's express consent.
L WARNING!
Injury hazard from structural modifications!
Unauthorised technical modifications can cause bodily harm or material
damage.
nReplace faulty devices.
nA faulty device should only be replaced by an identical device.
Safety instructions
Modifications and alterations
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3.5 Responsibility of the operator
The device is used in an industrial environment. The operator of the device
is therefore subject to statutory obligations regarding work safety.
In addition to the work safety instructions in this description, the safety,
accident prevention and environmental regulations applicable to the area
where the device is used must be complied with.
The following applies in particular:
nThe operators must familiarise themselves with the applicable work
safety regulations and must also determine the dangers that are posed
by the particular work conditions at the location of use by means of a
risk assessment. This must be realised in the form of operating instruc-
tions for operation.
nThis description must be kept within easy reach of the device and be
accessible to those persons working with it at all times.
nThe specifications of the description must be adhered to fully and
unconditionally!
nThe device may only be operated when in a perfect and operationally
safe condition. It must be checked for detectable defects prior to each
time it is put into service.
nThe owner must ensure that the responsibilities for activities performed
on the device are clearly defined. Only sufficiently qualified personnel
who are familiar with the operating instructions and safety instructions
may work with and on the device.
3.6 Personnel and qualifications
The product / system belonging to this description may only be handled by
personnel qualified for the respective task. This is done taking into account
the descriptions associated with the particular task, especially the safety
and warning information contained therein.
Due to their training and experience, qualified personnel are able to recog-
nize risks and avoid possible hazards when dealing with this product /
system.
Responsibility
of the operator
Safety instructions
Personnel and qualifications
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L WARNING!
Danger posed by faulty installation and initial commissioning
The installation and initial commissioning of the device must be always
performed by trained specialist personnel with sufficient experience. Mis-
takes during installation may lead to potentially fatal situations or consid-
erable material damage.
nHave installation and initial commissioning carried out only by
employees of the manufacturer or by trained personnel authorised by
it.
nHave work on electrical components carried out by qualified electri-
cians or persons instructed and supervised by a qualified electrician
in accordance with the electrical engineering regulations.
nWhenever working on the device, disconnect it from the power supply
and secure it against being switched on again.
nPrior to commissioning, make sure that all safety equipment is
installed and functioning properly.
Installation and
commissioning
Safety instructions
Personnel and qualifications
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L WARNING!
Danger to life from electrical current!
Contact with live parts poses an immediate danger to life.
Touching open terminals and wires can result in death or serious injury.
nOnly have work on electrical components or operating equipment car-
ried out by a qualified electrician.
nDe-energise system parts to work on them.
nCheck that all exposed components are de-energised before carrying
out any work.
nCheck that exposed system components are de-energised before
carrying out any work on them.
nDo not open any covers during operation.
nOnly carry out work on live parts under the supervision of a second
person. The supervisor must be able to operate the emergency stop
button or main switch in the event of an emergency.
nSome components of the device may still be live even after the
system has been switched off. Be sure to follow the notes on their
label when working on these components!
nOnly use voltage-insulated tools.
nThe device must be fitted with protective earth (PE) if connected
directly to the mains.
L WARNING!
Injury hazard from insufficient qualification!
Improper handling can cause substantial bodily harm or material
damage.
nOnly allow the device to be operated and maintained by trained and
instructed personnel.
nOnly have work on electrical components carried out by a qualified
electrician.
Electrical work
Operation and
maintenance
Safety instructions
Personnel and qualifications
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3.7 Special hazards
L WARNING!
Live parts
Contact with live parts poses an immediate danger to life. Damage to the
insulation or individual components can be life-threatening.
nIn case of damage to the insulation, turn off power supply immedi-
ately.
nCheck devices and connected components regularly. Any loose con-
nections, damaged cables and insulations as well as all damages that
could pose a risk to safety must be rectified immediately. Any faulty
protection against accidental contact must be repaired immediately.
nWorks on electric components may only be carried out by qualified
electricians or persons instructed and supervised by a qualified elec-
trician in accordance with the electro-technical regulations.
nBefore carrying out any kind of work on the control system, make
sure it is de-energised and secured against accidental reconnection.
nAlways use insulated tools.
L WARNING!
Electromagnetic fields
Death or serious injuries
Electromagnetic fields can affect and interfere with pacemakers and
defibrillators.
nIf you carry a pacemaker, keep sufficient distance.
nWarn people wearing pacemakers before they get close.
Electrical cur-
rent
Electromag-
netic field
Safety instructions
Special hazards
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3.8 Safety devices
L WARNING!
Danger to life from non-functioning safety devices!
nCheck the safety devices before starting work.
nReport faulty safety equipment.
nHave faulty safety equipment repaired.
Safety instructions
Safety devices
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4 Wireless Charger WC 3.0 - system overview
The wireless charger is a charging system with inductive energy transmis-
sion for contactless charging of batteries in AGVs.
The system is intended for industrial applications. Areas of application
include unmanned transport systems in intralogistics, mobile robot applica-
tions and other automotive applications.
4.1 Components
The charging system is divided into stationary components, which form the
primary side of the system, and mobile components, which form the secon-
dary side of the system.
MPU 3.0
Mobile Power Unit
IPS 3.0
Inductive Power Supply
IMP 3.0
Inductive Mobile Pad
ISP 3.0
Inductive Stationary Pad
Fig. 1: WC 3.0 components (schematic representation)
Stationary components:
nStationary power supply
IPS 3.0 - Inductive Power Supply
nStationary charging pad
ISP 3.0 - Inductive Stationary Pad
Mobile components:
nMobile charging pad
ISP 3.0 - Inductive Mobile Pad
nMobile power supply
MPU 3.0 - Mobile Power Unit
Wireless Charger WC 3.0 - system overview
Components
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4.2 How it works
Charging is possible as soon as the mobile and stationary pad are posi-
tioned within a tolerance range of each other.
The charging process starts:
nImmediately in the [Manual/Continuous] configuration.
nor by the battery management system
nor by the system controller
nor by the mobile control unit (e.g. vehicle control system)
The charging process ends:
nat the command of the mobile control unit
nor at the command of the battery management system
nor at the command of the system controller
nor when the charging current falls below a specified level
nor when the vehicle is removed from its charging position *
* Remove the vehicle from its charging position
If the pads are removed from each other during a charging process, the
system detects it as an error state. The charging process will be aborted
with an error message.
End-of-charge voltage
If the charging process is not terminated by the software, the charging
current is regulated down when the preset end-of-charge voltage is
reached, but it is not switched off.
Automatic positioning
The pads cannot detect their position in relation to each other. Only the
quality of the data signal is evaluated. The charging process can only be
started if the signal is sufficiently stable.
Optimal positioning must be achieved by using suitable external equip-
ment.
How it works
Wireless Charger WC 3.0 - system overview
How it works
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