Table of Contents
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M A N U A L
Digital three-phase Servo Amplifier
BAMOCAR D3
EC synchronous servo motors
AC asynchronous servo motors
Industrie Elektronik
G m b H
Hans-Paul-Kaysser-Straße 1
71397 Leutenbach – Nellmersbach
Edition / Version
Tel.: 07195 / 92 83 – 0
Fax: 07195 / 92 83 – 29
01 / 2016
V 1
info@unitek-online.de
www.unitek-online.de
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Table of Contents
Related Manuals for Unitek BAMOCAR D3
Summary of Contents for Unitek BAMOCAR D3
- Page 1 M A N U A L Digital three-phase Servo Amplifier BAMOCAR D3 EC synchronous servo motors AC asynchronous servo motors Industrie Elektronik G m b H Hans-Paul-Kaysser-Straße 1 71397 Leutenbach – Nellmersbach Edition / Version Tel.: 07195 / 92 83 – 0 Fax: 07195 / 92 83 –...
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Page 2: Table Of Contents
Basic information 1 Contents Basic information ........................3 History ..........................3 Further UNITEK products ....................3 Engineering instructions (MANUAL) .................. 3 Validity ..........................4 Designations and symbols ....................4 General product information ..................... 5 Applications/build/features ....................6 Safety regulations ....................... 8 Commissioning ......................... - Page 3 Bus circuit battery voltage ....................48 Bus circuit dc bus voltages (battery voltage) ................49 Bus circuit dc / bus voltages ..................... 49 Output stage temperature ....................... 50 Output stage temperatur ....................50 Warranty ..........................51 Warranty .......................... 51 BAMOCAR D3...
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Page 4: Basic Information
MANUAL Commissioning BAMOCAR Commissioning - error detect. Use all three MANUALS for the engineering, the installation, and the commissioning! CD (UNITEK-DOKU-SOFT) supplied with the delivery of the units. Online available as download version on the UNITEK website (www.unitek-online.de www.unitek.eu). The hardware MANUAL comprises warning and safety advices, explanations of standards, mechanical and electrical installation advices. -
Page 5: Validity
Caution – Danger to life! High voltage! Warning! Important! Dangerous electric fields! Scope of delivery BAMOCAR- D3-x device, documentation, CD UNITEK DOKU-SOFT in the box. Not included (to be ordered as accessories): Power connector: Pfisterer P1 350205-101 Control connectors: X1 ..( In/Out) Binder 99-5662-15-19... -
Page 6: General Product Information
It is necessary to provide an encoder system for wide control ranges and high control dynamics. Warning/Attention: For dc, ac, or bl-servo amplifiers which are supplied via the dc mains, it must be checked that the energy is fed back into the bus during brake operation. (External ballast circuit) BAMOCAR D3... -
Page 7: Applications/Build/Features
- the distances of air gaps and leakage paths adhere to the EU standards - no internal isolation watchdog, Y2 capacitors to the housing Components: - Completely isolated IGBT power semi-conductors, comfortably over-dimensioned - Only components customary in trade and industrially standardised are used - SMD equipment BAMOCAR D3... - Page 8 If this cannot be guaranteed, a ballast circuitry must be used. Note: For non-earthed systems (vehicles, boats, machines) the isolation between parts accessible to touching and high voltages must be guaranteed and monitored by using independent isolation monitors. BAMOCAR D3...
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Page 9: Safety Regulations
Operation only allowed when the device is closed! The control and power connections can be charged with high voltage without an active operation! The minimum discharge time of the bus circuits is at least 4 minutes! Measure the voltage before any disassembly! BAMOCAR D3... - Page 10 - should only be carried out by suitably trained personnel with knowledge in electronic drives and their software - should only be carried out in accordance with the programming advice - should only be carried out in accordance with health and safety guidelines BAMOCAR D3...
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Page 11: Commissioning
EC guideline 2004/108/EG including the EMC standards EN61000-2 and EN61000-4. For applications in residential areas additional EMC measures are necessary. A manufacturer's declaration can be requested. The manufacturer of the machine or installation is responsible for observing the threshold values demanded by the EMC laws. BAMOCAR D3... -
Page 12: Safety Advices
For the operation it must be ensured that the environmental conditions in the switch cabinet are adhered to. This applies in particular to the impermissible condensation on the units. BAMOCAR D3... -
Page 13: Intended Applications
EN 50178, EN61800-5-1). Impermissible applications - in life-sustaining medical devices or machines - connection to power supply units or dc power supplies without protection circuits - on ships - in explosive environments - in environments with acrid fumes BAMOCAR D3... -
Page 14: Regulations And Guidelines
Functional safety of electric road vehicles 2011 ISO 16750 Electrical components - vehicles 2010 ISO 12100 Safety of machines 2011 ISO 13849 Safety of machines and controls 2011 IEC 364 Protection against electric shocks 2010 IEC 664 Isolation coordinates - low voltage 2011 BAMOCAR D3... -
Page 15: Risks
These fields may be dangerous for persons having electronic medical aids or appliances (e.g. cardiac pacemakers). Sufficient distance to these electrical parts must be observed. The switch cabinet must be labeled accordingly. BAMOCAR D3... -
Page 16: Technical Data
2.14 Technical data For three-phase current motors Auxiliary voltage connection 12V= to 700V= 12V= or 24V= ±10% / 4A (2A) Auxiliary voltage connection residual ripple <10%, regenerating fuse Data BAMOCAR D3-400-(700) Dim. 125/250 200/400 125/250 200/400 Supply voltage, rated value 24 up to max. - Page 17 Contamination degree 2 acc. to EN 61800-5-1 Vibration 10Hz to 58Hz ampl. 0.075mm (IEC 60068-2-3) 58Hz to 200Hz 1g Shock 15g for 11ms Environmental conditions Not permissible: condensation (dew), ice formation, oil mist, salt spray, water Humidity class F, humidity <85% condensation not allowed! BAMOCAR D3...
- Page 18 Starting temperature of the reduction I-red-TD 0x58 Final temperature of the reduction I-red-TE 0x4c 2-3 ED-Ired-IGBT-Temp-5 Automatic current reduction depending on the rotation frequency (motor speed) 2-4 ED-Ired-rot-5 Automatic current reduction depending on the pulse frequency 2-5 ED-Ired-IGBT-takt-5 BAMOCAR D3...
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Page 19: Mechanical Installation
Power supply cables between the BAMOCAR and the battery must be as short as possible. Long cables cause dynamic voltage drops due to the line impedance and as a consequence the service life of the installed capacitors would be reduced. BAMOCAR D3... -
Page 20: Dimensions Bamocar
Mechanical installation Dimensions BAMOCAR Standard version (connectors partly equipped) 3-1 rh5-BAMOCAR-D3-V6-standard-oben 3-2 rh5-BAMOCAR-D3-V6-standard-seitlich BAMOCAR D3... - Page 21 Mechanical installation Option connectors completely equipped 3-3 rh5-BAMOCAR-D3-V6-vollbestückt-oben 3-4 rh5-BAMOCAR-D3-V6-vollbestückt-seitl Liquid cooling Connection Hose connection: metal ¼-13 Input temperature: < 50°C Flow rate: max. 12l/min Pressure: max. 1.3 bar BAMOCAR D3...
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Page 22: Mounting Onto Mounting Rails
Mechanical installation Mounting onto mounting rails 4x screw M5x20 3-5 rh5-BAMOCAR-D3-V6-standard-montage Mounting onto a mounting surface 4x distance pipe for M5 l = 20mm 4X screw M5x40 3-6 rh5-BAMOCAR-D3-V6-standard-montagefläche BAMOCAR D3... -
Page 23: Electrical Installation
Power supply cables between the BAMOCAR-D3 and the battery must be as short as possible. Long cables cause dynamic voltage drops due to the line impedance and as a consequence the service life of the installed capacitors would be reduced. BAMOCAR D3... -
Page 24: Circuit Diagram
Electrical installation Circuit diagram 4-1 BAC-blockbild-3-TMS-rund BAMOCAR D3... - Page 25 Electrical installation Circuit diagram 4-2 BAC-blockbild-3 BAMOCAR D3...
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Page 26: Connection Diagram
Electrical installation Connection diagram 4-3 E-BAC-anschlussplan-1 BAMOCAR D3... -
Page 27: Emc Advice
EC machine guideline 2006/42/EC and the EMC guideline 2004/108/EC, for vehicles ECE-R83 and ECE-R100. A manufacturer's declaration can be asked for. BAMOCAR D3... -
Page 28: Connectors Standard Version
Electrical installation Connectors Standard version 4-5 BAC-Steckerübersicht-teil-1 Option - completely equipped additionally installed: X9.1 2nd CAN-Bus connector Brake connector 4-6 BAC-Steckerübersicht-voll-3 BAMOCAR D3... - Page 29 Connector plug Binder 79-3464-52-06 5 grey (connector female) 6 pink Option connector X11 brake +24 V-Br connector male device Brake + Brake - Connector plug Binder 99-0429-15-04 GND-24V-Br (connector female) 4-10 binder-bu-M12-5p 4-9 binder-st-M8-6p 4-11 binder-st-M12-5p 4-8 binder-st-M12-4p BAMOCAR D3...
- Page 30 GND supply GND supply GND supply GND COS1 rotor position2 channel kc+ rotor position2 channel kd+ SIN2 rotor position1 channel kc- rotor position1 Encoder plug INC For all connectors: view at the connector onto the soldered crimp side BAMOCAR D3...
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Page 31: Power Connections 1000V / 400A
Pfisterer plug straight P1 (350205-001..) or plug twisted P1 (350205-101) Connector plug neg. pole Pfisterer Stecker straight P1 (350205-001…) or plug twisted P1 (350205-101) Connector plug motor Pfisterer Stecker straight P1 (350205-001) or plug twisted P1 (350205-101) 4-13 Pfisterer-Stecker BAMOCAR D3... -
Page 32: Battery Connection
If the polarity of the connection is wrong, the device will be destroyed! Type Battery Connector cross- Fuse AT Drive connection section contactor size mm² -125/250 -200/400 Battery connecting line <2m. For conductor lengths from 2 to 10m more powerful. Use an additional capacity for conductor lengths superior to 10m! BAMOCAR D3... -
Page 33: Auxiliary Voltage Connection
The LED signal for the state ‘OK’ is dark. Firmware download only when the power supply is switched off! The auxiliary voltage and/or power supply voltage must only be switched when the BAMOCAR is disabled. No disable. Enable input X1:G = zero BAMOCAR D3... -
Page 34: Motor Power Connection
Surface-to-surface connection to the switch cabinet inlet. Surface-to-surface connection as short as possible to the motor side. For long motor cables the motor cable shield must be connected at multiple times with the vehicle or machine frame (e.g. ground terminals every 5m). BAMOCAR D3... -
Page 35: Control Connections
Error message 5(POWERVOLTAGE). External power supply for the inputs and outputs Logic- voltage +12 – 24V for logic and Logik- X1:D auxiliary voltage +12/24 Spannung +12/24V Logic- X1:K ground GNDE logic ground GNDE Logik- Masse 5-2 ED-BAC-Logic-2 BAMOCAR D3... -
Page 36: Safety Input Rfe (Rotating Field Enable) Stop Class 0
The input RFE must be bridged with the logic voltage. If the logic voltage corresponds to the supply voltage, the RFE input is bridged Rotating Enable +12/+24 with +12/+24V. 5-5 E-BAC-RFE-4-2 Enable FRG/RUN at least 0.5s after the RFE round connector signal. BAMOCAR D3... -
Page 37: Digital Outputs (Open Emitter)
(Option)7segment-LED ‘state’ display Ready BTB opens (open BTB relay contact, (option red LED)) in case of error messages BTB with or without under-voltage monitoring (BTB-Power). The message "under-voltage in the bus circuit" can be programmed (see Manual NDrive-x) BAMOCAR D3... -
Page 38: Analog Input +/- 10V
The analog inputs can be assigned to different functions. (See NDrive-x) With a digital command value (RS232, x-bus) the analog input AIN1 can be programmed as external analog speed limit and the analog input AIN2 can be programmed as external analog current limit. (See NDrive-x) BAMOCAR D3... -
Page 39: Serial Interface Rs 232
Install the cable only after disconnecting the device from the mains. 115200Baud The interface is hard-coded to Null modem connecting cable BAMOCAR View to the soldered side Connector X10 RS232 Shield on the housing P/D (CTS) R2IN Max. cable length 10m V+ (RTS) V+ (DTR) BAMOCAR D3... -
Page 40: Can-Bus
CAN-V+ brown CAN-GND white CAN-H green CAN-L yellow View on device side At the connector - view on the soldered crimp side Terminating resistor at both ends of the bus line > 120Ohm between the CAN-H and CAN-L. BAMOCAR D3... -
Page 41: Resolver Connection
Control connections Resolver connection Only with BAMOCAR D3-RS The resolver is an absolute measuring system 5-12 ED-BAC-Reso-2 for a motor revolution. Rundstecker It is robust and not impaired by high motor Stecker X7 round connector Connector x7 temperatures. Motor-Stecker Motor-Connector Its build corresponds to a revolving transformer. -
Page 42: Encoder Connection Ttl
Control connections Encoder connection TTL Only with BAMOCAR D3-IN TTL incremental encoder (encoder) with 2 counter tracks and 1 zero track plus 3 rotor position tracks. Counter tracks with or without push-pull output. Rundstecker Stecker X7 round connector Connector x7... - Page 43 One motor revolution corresponds to a position value of Num 65536. In case of different results the input of Feedback Inc-Mot (0xa6) is incorrect. Zero angle Motor turning clockwise and anti-clockwise at 10%- 100% speed. The value of zero-capture must remain constant. BAMOCAR D3...
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Page 44: Sin Cos 1Vss Connection
Control connections SIN COS 1Vss connection Only with BAMOCAR D3-SC Incremental encoder (encoder) with 2 analog, sinusoidal counter tracks and 1 zero 5-14 ED-BAC-SC-2 track plus 2 commutating tracks. Differential Rundstecker Stecker X7 signals 1Vss round connector Connector x7 VCC +5V VCC +5V Max. -
Page 45: Rotor Position Encoder - Connection Via A Bl-Tacho
Control connections 5.10 Rotor position encoder - connection via a bl-tacho Only with BAMOCAR D3-bl 3 rotor position encoder signals (Hall sensors) for the commutation; with or without a brushless tacho. 5-15 ED-BAC-bl-2 The rotor position encoder is galvanically Anpass-... -
Page 46: Option - State Displays
Normal operation; Motor current within the current Icns = 0 limits bright for 0.1 s A new command (value) was received from the BUS or RS232. Example: Motor revolving clockwise Point flashes active processor Bottom segment drive enabled Right segment motor revolves clockwise BAMOCAR D3... -
Page 47: Option - Error Displays
FAULT LED red (missing power voltage) Error no. 5 Note: When applying the auxiliary voltage with the enable closed (FRG/RUN X1:7 active) the red LED signals an error. There is no error signal displayed in the 7-segment display. BAMOCAR D3... -
Page 48: Option - Warning Signals
Bit 29 Bit 30 BALLAST (device- Ballast circuit >87% overloaded Bit 31 dependent) Note: With BAMOCAR the warning F (BALLAST) has no function. Example: flashing red, The display swaps between the state and the warning no., Warning no. 5 BAMOCAR D3... -
Page 49: Measured Data
Measured data 6 Measured data Bus circuit battery voltage from firmware FW450 Bus circuit dc bus voltages, battery voltage (400V) BAMOCAR D3-400 Bus circuit voltage Parameter 0xeb Max. voltage 460V 25158 Battery voltage 370V 20211 Overvoltage switch-off 440V 24059 Charging voltage... -
Page 50: Bus Circuit Dc Bus Voltages (Battery Voltage)
44 % 270V 14713 Settings for BAMOCAR 700/400 DC bus max (0xa5H) for threshold voltage Num 0xeb Note 750V = 23496 = 700V = 21921 = DC bus min (0xa5L) for undervoltage 600V = 18771= 500V = 15621= BAMOCAR D3... -
Page 51: Output Stage Temperature
15000 14000 BAMOCAR-D3 13000 12000 11000 10000 9000 -35 -30 -25 -20 -15 -10 -5 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Indoor air temperature BAMOCAR D3... -
Page 52: Warranty
UNITEK undertakes no warranties for devices which have been modified for special applications. During the warranty period, UNITEK will, at its option, either repair or replace products that prove to be defective, this includes guaranteed functional attributes. UNITEK specifically disclaims the implied warranties or merchantability and fitness for a particular purpose.