# Connection Overview

URL: https://irs.systems/en/docs/e-motor-emulator/connection-overview

## Connection overview

The following figure illustrates the connections which need to be established from and to EME. These are:

- connections to the overall test system (left side in the picture).
- connections to the inverter under test (right side).

![Connection overview: test system and infrastructure (automation system, safety controller, HVDC supply, cooling infrastructure) on the left, EME in the middle, DUT (inverter) with position sensor, motor phases, HV-DC and exciter output on the right](/docs/assets/e-motor-emulator/images/eme-connection-overview.png)

## Water cooling

The active motor simulation is using water cooling.

An inlet temperature of about 15°C is recommended (10…25°C). Keep cooling water clean, filters are recommended to avoid remnants in the heat exchanger which reduce the cooling capacity.

A flow limiter should be added to define the water flow. Flow rate is depending on average and peak power. Typical values are 5…30l/min. Please monitor the EME temperatures as shown in [EME internal temperatures](/en/docs/e-motor-emulator/eme-overview#eme-internal-temperatures).

Make sure that cooling water is only applied when necessary to reduce the amount of condensing water.

![Cooling water connections with flow inlet and flow return](/docs/assets/e-motor-emulator/images/eme-water-cooling.jpg)

## Test system connections

For proper operation the active motor load requires connections to the overall test system. The figure in [Connection overview](/en/docs/e-motor-emulator/connection-overview#connection-overview) illustrates the test system connections on the left side, while red marked wires contain hazardous voltages. The blue marked lines correspond to the cooling tubes.

Connections are designed with modular Harting connectors as far as possible to make sure that no wrong connections can be established. Furthermore, the same connectors may be used for different international standards. Connector counterparts are delivered together with the system.

All connections are available at the top of the cabinet.

![Connections at the top of the EME cabinet: Ethernet, HVDC input, safety and electronics supply](/docs/assets/e-motor-emulator/images/eme-test-system-connections.jpg)

**Safety + electronics supply**

### HV-DC from Power Supply

The following Harting HAN-connector is applied for connection to the HVDC power supply.

Pinout is as follows:

- Pin1 HVDC**+**
- Pin2 HVDC**-**

Both male and female connectors are protected against direct contact. This is necessary because the active load buffer capacitors may be charged even when disconnected.

The connector is rated for 200A/1kV<sub>DC</sub>. Thus, use power supply below this rating.

![Harting HAN connector for the HVDC supply](/docs/assets/e-motor-emulator/images/eme-hvdc-connector.jpg)

### Safety and electronics supply

The following Harting HAN-connector is applied for connection to the electronics supply and the safety interface. The pinout is as follows:

![Pinout of the safety and electronics supply connector: module A pins 1-3 L1 (line phase 230V), N (neutral 230V), PE (earth ground); module B pins 1-5 door and temperature switches, 6/9 discharge relay 24V (note polarity), 10/11 volt-converter DUT voltage measurement 4...20mA -> 0...1000V, 16/17 discharge feedback; photo of the connector and safety interface diagram](/docs/assets/e-motor-emulator/images/eme-safety-supply-connector.png)

On the right side the functionality of the safety interface is illustrated, both for switches and the analog output for DUT voltage measurement.

![Voltage converter between HV DC+ and HV DC- of the inverter DUT with analog output 4...20mA to the safety controller](/docs/assets/e-motor-emulator/images/eme-voltage-converter-dut.png)

### Ethernet communication

Use the Ethernet cable with RJ45 connector for communication with a Windows-PC.

### CAN communication

Currently not applied in software.

## DUT connection

After the tester internal connections are ready, the wiring to the DUT needs to be established. The figure in [Connection overview](/en/docs/e-motor-emulator/connection-overview#connection-overview) illustrates the DUT connections on the right side, while red marked wires contain hazardous voltages. The blue marked lines correspond to the cooling tubes.

### Position Sensor Simulation

#### SIN/COS Simulation

| Pin | Signal | Pin | Signal |
| --- | --- | --- | --- |
| 1 | GMR_SIN_P | 7 | AMR_COS_P |
| 2 | GMR_SIN_N | 8 | AMR_COS_N |
| 3 | GMR_COS_P | 9 | -- |
| 4 | GMR_COS_N | 10 | -- |
| 5 | AMR_SIN_P | 11 | -- |
| 6 | AMR_SIN_N | 12 | GND |

![Control board with the Sin/Cos connector, pins 1 to 12](/docs/assets/e-motor-emulator/images/eme-sincos-connector.jpg)

Please refer to [SIN/COS generator](/en/docs/e-motor-emulator/eme-overview#sin-cos-generator) for functional description

#### Resolver Simulation

| Pin | Signal |
| --- | --- |
| 1 | SIN+ |
| 2 | SIN- |
| 3 | COS+ |
| 4 | COS- |
| 5 | EXC+ |
| 6 | EXC- |

![Control board with the resolver connector, pins 1 to 6](/docs/assets/e-motor-emulator/images/eme-resolver-connector.jpg)

Please refer to [Resolver simulation](/en/docs/e-motor-emulator/eme-overview#resolver-simulation) for functional description

### DUT connection of the 3 motor phases, HV-DC and optional exciter

Motor phases, HV-DC supply and exciter wires are connected according to the picture below. Preferred, the cables are marked with the following labels to make sure not to mix them up:

- **U V W**
- **DC+ DC-**

![Current bars for the DUT connection: motor phases U1, V1, W1 and HV-supply DUT HVDC 1+ and HVDC 1-](/docs/assets/e-motor-emulator/images/eme-dut-busbars.jpg)

Always apply shielding clamps and strain reliefs similar to the following picture:

![Motor phase cables with EMC shielding clamps and strain relief on the shielding rail](/docs/assets/e-motor-emulator/images/eme-shielding-clamps-strain-relief.jpg)

Since there are several wires for three DUTs, it is a good choice also to mark the wires with DUT1, DUT2, DUT3.

> **WARNING!**
> **Always make sure to establish low impedance connections:** ring lugs must lie flat on the current bars! Do NOT use washers in between ring lugs and current bars! Use an appropriate torque wrench to fix the wires with: 30Nm for the motor phases and HV-DC+/-; 15Nm for the exciter connection.

> **WARNING!**
> **Always make sure to reduce EMC noise:** The shielding of the motor phases must be properly connected to the shielding rail with EMC-shielding clamps. For this purpose, the outer isolation of the motor phase wire has to be removed in the area of the shielding clamp. The shielding clamp is pushed over the open shielding and is linked on the shielding rail. The same procedure with shielding clamps and strain relief holds for the Exciter and HV-DC connections.

Additional to the EMC-shielding clamp, a strain relief has to be mounted in the lower part of the shielding rail. The same procedure with shielding clamps and strain relief holds for the Exciter connections.

> **WARNING!**
> **Always make sure to connect all DUT connections are fitting to the dedicated pin. Otherwise, the DUT or the system may suffer damage:** Interchanged motor phases may lead to unacceptable high phase currents on single phases and may cause overload on DUT or emulator. Interchanged HV-DC-connection results in short circuit of the HV-power supply. This is clearly visible, when the HV supply is active, in current limit and the voltage remains below 10V.

### EMC issues

Since the DUT inverter may be a source of electrical noise, measures need to be taken to reduce emissions from the DUT. Most emissions are radiated over the motor phase cables. Thus, special care needs to be taken about:

- Proper Shielding of motor phase, HV-DC-, and Exciter-cables
- Proper grounding of the DUT and test system.
- Positioning of power and signal cables

When operating the system, it is crucial that all power cables are properly shielded on BOTH ends. I.e.

- At the emulator connection
- At the DUT-housing

Use shielding clamps at the emulator connections:

![EMC shielding clamps at the emulator connections](/docs/assets/e-motor-emulator/images/eme-emc-shielding-clamps.jpg)

Make sure that all power cable shields are properly connected to the DUT housing by metal bushings:

To make sure, that the DUT housing has a proper ground connection, establish an additional ground wire to a good potential earth Ground.

![Separate ground wire between DUT housing and EME ground, also connected to a good potential earth ground at EME side](/docs/assets/e-motor-emulator/images/eme-dut-ground-wire.jpg)

![Proper grounding of the DUT housing; keep distance between signal (black) and power (orange) cables](/docs/assets/e-motor-emulator/images/eme-dut-grounding-cable-routing.jpg)

And keep as much distance as possible between signal cables and power wires to reduce cross interference. If there is not enough space, avoid routing them in parallel, prefer orthogonal orientation.