Table of Contents
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Table of Contents
Summary of Contents for Unitek BAMOCAR-D3-700-100
- Page 1 M A N U A L Digital Battery Servo Amplifier BAMOCAR-D3-700-100/160 for EC servo motors for AC asynchronous servo motors Hans-Paul-Kaysser-Straße 1 Edition / Version 71397 Leutenbach-Nellmersbach 2019 - V05 Tel.: 07195 / 92 83 - 0 Fax: 07195 / 92 83 - 129 contact@unitek.eu...
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Page 2: Table Of Contents
2.14 Technical data ........................15 Mechanical installation ....................18 Important notes ....................... 18 Dimensions - BAMOCAR-D3-700-100/160 ............... 19 Dimensions -Optional cooling contact plate ..............20 Dimensions - optional air cooling unit ................20 Electrical installation ...................... 22 Important advices ......................22 Circuit diagram ......................... - Page 3 State information - error ....................46 State information - warning signals ................. 47 Measured data ....................... 48 DC bus circuit voltages, battery voltage ................48 Power-stage temperature ....................49 Current - value ........................49 Warranty ........................50 Warranty .......................... 50 BAMOCAR-D3-700-100/160 Version: 2019 / V05...
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Page 4: Basic Information
Commissioning 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. Download: www.unitek.eu The hardware MANUAL comprises warning and safety advices, explanations of standards, mechanical and electrical installation advices. -
Page 5: Validity
Dangerous electric fields! Scope of delivery/included in the packaging: - BAMOCAR-D3-700-100/160 - documentation - CD UNITEK DOKU-SOFT Not included/Cannot be ordered from UNITEK: Accessory connectors and cable glands. 35-pin connector type: Typo 776164-1 14-pin connector type: Typo 776273-1 Cable gland: M25x1.5... -
Page 6: General Product Information
Field weakening might occur with separately excited motors. The BAMOCAR-D3-700-100/160 can be used as position amplifier or torque or speed amplifier. The speed actual value is generated in the encoder unit (resolver or others) or internally generated (without sensors). -
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-D3-700-100/160 Version: 2019 / V05... - Page 8 If this cannot be guaranteed, a ballast circuitry must be used. 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. Version: 2019 / V05 BAMOCAR-D3-700-100/160...
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Page 9: Safety Regulations
Any incorrect programming may cause dangerous movements! Intended applications: The devices of the are power electric parts used for regulating energy BAMOCAR-D3-700-100/160 flow. They are designed as components to control EC synchronous motors, ac asynchronous motors in vehicles, machines, or installations. - 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 Version: 2019 / V05 BAMOCAR-D3-700-100/160...
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Page 11: Commissioning
Commissioning The battery servo amplifiers are components of the electronic drive BAMOCAR-D3-700-100/160 technology. They are functional only in connection with an electrical consumer (e.g. a motor). Their use is limited for commercial applications. When mounting the units into vehicles, boats, machines, and installations the proper operation of... -
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. Version: 2019 / V05 BAMOCAR-D3-700-100/160... -
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 - in explosive environments - in environments with acrid fumes BAMOCAR-D3-700-100/160 Version: 2019 / V05... -
Page 14: Regulations And Guidelines
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 Version: 2019 / V05 BAMOCAR-D3-700-100/160... -
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. Any designated assembly area must be indicated and labelled accordingly. BAMOCAR-D3-700-100/160 Version: 2019 / V05... -
Page 16: Technical Data
Differential input 10-30 0.010 Digital inputs Logic IO < 6 Transistor output Digital outputs open emitter Analog output ±10 Operational amplifier Resolver / TTL / SINCOS Differential input CAN interface Logic IO RS232 interface Logic IO Version: 2019 / V05 BAMOCAR-D3-700-100/160... - Page 17 IEC 60068-2-3 58 Hz to 200 Hz 1 g Shock 15 g for 11ms Environmental conditions Not permissible: oil mist, salt spray, steam Humidity class F, humidity < 85 % condensation not allowed! BAMOCAR-D3-700-100/160 Version: 2019 / V05...
- 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 Version: 2019 / V05 BAMOCAR-D3-700-100/160...
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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-D3-700-100/160 Version: 2019 / V05... -
Page 20: Dimensions - Bamocar-D3-700-100/160
Mechanical installation Dimensions - BAMOCAR-D3-700-100/160 Depth incl. connector and cable: 150 mm Liquid cooling Power connection Hose connection: Metal ¼-13 PG-cable glands metal M25x1.5 Input temperature: < 65°C with shield spring Flow rate: max. 12 l/min Recommended cable gland: Pressure: max. -
Page 21: Dimensions -Optional Cooling Contact Plate
Attention: maximum power loss 850 W Dimensions - optional air cooling unit Weight: 5.8 kg Mounting screws: M4 x 120, spacer tube 100 mm, bore 4.5 mm Voltage for fan: 24 V DC Cooling capacity 0.04 ° K / W BAMOCAR-D3-700-100/160 Version: 2019 / V05... - Page 22 Mechanical installation Blank page - for printing reasons Version: 2019 / V05 BAMOCAR-D3-700-100/160...
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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-D3-700-100/160 Version: 2019 / V05... -
Page 24: Circuit Diagram
Electrical installation Circuit diagram Version: 2019 / V05 BAMOCAR-D3-700-100/160... - Page 25 Electrical installation Circuit diagram BAMOCAR-D3-700-100/160 Version: 2019 / V05...
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Page 26: Connection Diagram
Electrical installation Connection diagram Note: 12 V variant only on request Version: 2019 / V05 BAMOCAR-D3-700-100/160... -
Page 27: Emc Advice
Connection of the control conductors: All control conductors must be shielded. Analogue signal lines must be twisted and shielded. The shield must have surface-to-surface contact with the mounting plate (earth). Battery connection: V dc voltage BAMOCAR-D3-700-100/160 Version: 2019 / V05... - Page 28 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. Potential isolation Note: 12 V variant only on request Version: 2019 / V05 BAMOCAR-D3-700-100/160...
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Page 29: Connectors The Connectors Are Not Included In The Delivery Scope
/A Temp GND GND Temp GND Temp channel /N kr-- +5 VCC +5 VCC channel /B Temp. signal Temp -Signal Temp. signal REF2 Rotor position 1 COS1 Rotor position 2 SIN2 Rotor position 3 BAMOCAR-D3-700-100/160 Version: 2019 / V05... -
Page 30: Auxiliary Voltage Connection
• 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 X1:14 = zero Version: 2019 / V05 BAMOCAR-D3-700-100/160... -
Page 31: Power Connections
PG gland. Tighten the gland of the cable lug. Connection screw: M6 x 8 (self-locking or corrugated washer, no toothed washer) max. tightening torque 7 Nm Note: The cable gland is not included in the delivery scope. BAMOCAR-D3-700-100/160 Version: 2019 / V05... -
Page 32: Battery Connection
Battery connecting line <2 m. For conductor lengths from 2 to 10m more powerful. Use an additional capacity for conductor lengths superior to 10m! Max. connector cross-section 50mm², cable lug for M10 Version: 2019 / V05 BAMOCAR-D3-700-100/160... -
Page 33: 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 shields must have multiple contacts to ground (e.g. ground terminals each 5 meter). BAMOCAR-D3-700-100/160 Version: 2019 / V05... -
Page 34: Control Connections
The enable (FRG X1:14) must not be initiated before the auxiliary voltage (24 V) and the power voltage have been switched on. External power supply for the inputs and outputs 24 V for the logic voltage GNDE logic ground Note: 12 V variant only on request Version: 2019 / V05 BAMOCAR-D3-700-100/160... -
Page 35: Safety Input Rfe (Rotating Field Enable) Stop Class 0
If the logic voltage corresponds to the supply voltage, the RFE input is bridged with +24 V. Enable FRG/RUN at least 0.5 s after the RFE signal. Note: 12 V variant only on request BAMOCAR-D3-700-100/160 Version: 2019 / V05... -
Page 36: Digital Outputs (Open Emitter)
Digital output 3 programmable Supply voltage for the logic outputs. +12..+24V for the logic voltage Always pay attention to the total current of all outputs GNDE logic ground Note: 12 V variant only on request Version: 2019 / V05 BAMOCAR-D3-700-100/160... -
Page 37: Signal Contact "Ready Btb/Rdy" (Solid State Relay)
Programming in NDrive: parameter BTB power = without (0x5a Bit 5 = 1) No BTB signal if the power voltage is missing. Programming in NDrive: parameter BTB power = with (0x5a Bit 5 = 0) (see Manual NDrive-x) BAMOCAR-D3-700-100/160 Version: 2019 / V05... -
Page 38: Analog Inputs ± 10 V
-be programmed as external analog current limit (see NDrive-x). Analog outputs ±10 V Output Connector Function Voltage State Parameter DAC1 X1:29 Measured value ±10 V prog. X1:30 Signal zero fixed The analog output can be assigned to different functions. Version: 2019 / V05 BAMOCAR-D3-700-100/160... -
Page 39: Serial Interface Rs 232
There is a software description in the Manual NDrive. Note: The serial interface is galvanically connected with the device zero (GND/AGND). The BAMOCAR-D3-700-100/160 and the serial interface (COMx) of the pc must only be connected using a shielded cable. RS232 am PC Install the cable only after disconnecting the device from the mains. -
Page 40: Can-Bus
CAN-L CAN-GND CAN-GND X1:35 white Shield X1:1 CAN BUS Connection with multipleBAMOCAR-D3-700-160 Master Address xx Address xx Address xx Terminating resistor at the end of the bus line > 120 Ohm between CAN-H and CAN-L. Version: 2019 / V05 BAMOCAR-D3-700-100/160... -
Page 41: Resolver Connection
>25 m only use high-quality resolver cables with adequate shielding properties. Shield connection across connector X7 combine all shields and connect them to the housing across the motor connector connect the overall shield to the connector housing Setting parameters see software Manual NDrive BAMOCAR-D3-700-100/160 Version: 2019 / V05... -
Page 42: Encoder Connection Ttl
>25 m the cross-section of the cable used must be increased Shield connection across connector X7 connect the shield to the connector housing across the motor connector connect the shield to the connector housing Setting parameters see software Manual NDrive Version: 2019 / V05 BAMOCAR-D3-700-100/160... - Page 43 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-D3-700-100/160 Version: 2019 / V05...
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Page 44: Sin Cos 1Vss Connection
>25 m the cross-section of the cable used must be increased by one grade Shield connection across connector X7 connect the shield to the connector housing across the motor connector connect the shield to the connector housing Setting parameters see software Manual NDrive Version: 2019 / V05 BAMOCAR-D3-700-100/160... -
Page 45: Rotor Position Encoder - Connection Via A Bl-Tacho
>25 m the cross-section of the cable used must be increased by one grade Shield connection across connector X7 connect the shield to the connector housing across the motor connector connect the shield to the connector housing Setting parameters see software Manual NDrive BAMOCAR-D3-700-100/160 Version: 2019 / V05... -
Page 46: State Display
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 Version: 2019 / V05 BAMOCAR-D3-700-100/160... -
Page 47: State Information - Error
Dangerous overcurrent (causes may be currents which are too high or oscillating currents, bad controller adjustments, or hardware defects (e.g. IGBT module)) Note: Fault 5 Light display: FAULT LED rot - lighting • POWERVOLTAGE • Error No. 5 is displayed (missing power voltage) BAMOCAR-D3-700-100/160 Version: 2019 / V05... -
Page 48: State Information - Warning Signals
Warning F is a device-dependent warning (for BAMOBIL and BAMOCAR without function) Example: Warning no. 5 Light display: FAULT LED red - flashing • POWERVOLTAGE • The display swaps between the (missing power voltage) state and the warning no. 5 Version: 2019 / V05 BAMOCAR-D3-700-100/160... -
Page 49: Measured Data
750 V 23592 144 % Grange 0 to 160 % Overvoltage HW 850 V 26736 163 % fixed in Hardware The software voltage limits are programmed using DC-BUS-max (0x5aH) and DC-BUS-min (0xa5L), see manual NDrive. BAMOCAR-D3-700-100/160 Version: 2019 / V05... -
Page 50: Power-Stage Temperature
Current - value BAMOCAR-PG-D3 Calibration rated current Peak current I-device DC blocked Max. value ±11 Bit A~eff A=pk A=pk 700/100 70,7 1081 106,1 700/160 113,1 169,7 The basic set-up data are protected in the set of parameters. Version: 2019 / V05 BAMOCAR-D3-700-100/160... -
Page 51: Warranty
UNITEK makes no warranty as to the suitability of the device for a special application. 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.
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