Unitek Bamobil D3.2 User Manual
Manual
Bamobil D3.2
Digital Battery Drive
for EC Servo Motors
Tel.: 07195/9283 -0
Fax 07195/928329
em ail info@unitek-online.de
Http// www.unitek-online.de
Industrie Elektr onik
Version 0808-2-V3
BAMOBIL D3.2
Part 1 Manual BAMOBIL D3.2
Contents Page
1. Basic Information
Safety advice, standards and guidelines 4, 5
General information 6
Applications 7
Features 8
Technical data 9, 10
2. Mechanical installation
Important instruction 11
Dimensions - BAMOBIL D3 12
Dimensions - Control panel 13
Dimensions - Additional cooling unit 14, 15
3. Electrical installation
CE and safety advice 17
Circuit diagrams 18, 19
Connection diagram 20
EMC 21
Connectors 22
Battery connection 23
Motor connection 24
Control connections 25-28
Interfaces 29, 30
Resolver 31
Encoder TTL 32
Encoder SIN/COS 33
Rotor position Bl 34
Encoder output/input 35, 36
Displays 37-39
Options 40
4. Guarantee 41
Part 2 Manual N-Drive
Part 3 Commissioning
Part 4 CAN-BUS reference
2
1 Basic - Information
3
BAMOBIL D3.2
Safety advice - Standards and guidelines
Caution: High voltage DC 900V=.
Electric shock hazard!
Danger to life!
DC-BUS discharge - time >4min
Electronic equipment is not fault proof. This fact should be borne in mind for all
possible operating conditions.
Before installation or commissioning begins, this manual must be thoroughly read
and understood by the technical staff involved.
If any uncertainty arises, the manufacturer or dealer should be contacted.Any
incorrect installation/connection may damage the device.
BAMOBIL devices are power electric parts used for regulating energy flow.
They are designed to control EC synchronous motors (brushless dc motors) for
industrial applications.
Protection rating IP40.
Connection only to batteries.
Standards and guidelines
The device and its associated components can only be installed and switched on
where the local regulations and technical standards have been strictly adhered to:
EU Guidelines 89/392/EWG, 84/528/EWG, 86/663/EWG, 72/23/EWG
EN60204, EN50178, EN60439-1, EN60146, EN61800-3
IEC/UL EC364, IEC 664, UL508C, UL840
VDE Regulations VDE100, VDE110, VDE160
TÜV Regulations
Trade body guidelines VGB4
Control and power connections can be live even though
the drive is inoperative.
The dc bus discharge time is superior to 4min.
Measure the voltage prior to any disassembly!
4
1 Basic - Information
The user must ensure that in the event of:
- device failure
- incorrect operation
- loss of regulation or control
the axis will be safely de-activated.
It must also be ensured that the machine or equipment are fitted with device
independent monitoring and safety features.
Man as well as property must not be exposed to danger at any time.
Assembly
- should only be carried out when all voltages have been removed.
- should only be carried out by suitably trained personnel
Installation
- should only be carried out when all voltages have been removed.
- should only be carried out by suitably trained personnel
- should only be carried out in accordance with health and safety guidelines
Setting adjustments/programming
- 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
CE
After having been mounted in machines and installations the operation of the
device must not be started until the machine or the installation has been approved
of the regulations of the EC machine guideline 89/392/EWG and the EMC guideline
89/336/EWG.
Under the installation and test conditions of chapter ‘EMC advice’ the device
adheres to the following: guideline EU 89/336/EWG, EMC standards EN61000-2 and
EN61000-4.
A manufacturer’s declaration can be asked for.
The manufacturer of the machine or the installation is responsible for the
observance of the threshold values prescribed in the EMC regulations.
QS
Test results are archived with the device serial number by the manufacturer for a
period of 5 years.
Test protocols can beasked for.
Safety symbols . . . . . . . . . . . . . Important
Caution - Danger to life Attention
High voltage Warning
5
BAMOBIL D3.2
General Information
The digital 3-phase current servo amplifier BAMOBIL D3 in combination with the
brushless dc motor (synchro servo motor, CE motor) provide a drive solution free of
maintenance and with a wide dynamic control range. The drive displays the
well-known good control characteristics of dc drives without the disadvantages of
the carbon brushes’ wear and the commutation limits. The rotor moment of inertia is
notably lower and the threshold power is greater than with equally constructed
dc motors. This results in up to 5 times higher acceleration values. Compared to
asynchronous motors with frequency converters the stability, the control range and
the efficiency of the drive are considerably improved. The generated heat in
the motor only occurs in the stator, therefore, the bl-motors always have the
protection rating IP 65.
From the electrical view, the brushless dc motor is a synchro motor with a
permanent magnet rotor and a three-phase current stator.
The physical characteristics correspond to those of dc motors, i.e., the current is
proportional to the torque and the voltage is proportional to the speed. The speed
is steadily controlled up to the current limit (max. torque. In case of an overload the
speed drops and the current remains constant.
The speed/torque characteristic is rectangular.
Current, speed, and position are precisely measured. The field frequency is not
controllable, it is automatically adjusted.
The motor voltages and the motor currents are sinusoidal. A maximum motor
efficiency is achieved by means of a compensating current control.
The BAMOBIL drives can be used as position control or torque or speed amplifier.
The speed actual value is generated in the encoder unit (resolver or others).
Note:
For dc, ac, or bl-servo amplifiers which are supplied by a dc mains, it must be
checked that the energy is fed back into the bus during brake operation (external
ballast circuitry).
Information:
Battery drive (analogue and digital)
Compact devices
For low power applications UNITEK series BAMO-A2/-A3 10 to 40A
UNITEK series BAMOBIL A2/D2 50 to 200A
Thyristor controllers and servo-drives (analogue and digital)
Thyristor controller UNITEK series Classic 15 to
2000AServo-drive dc UNITEK series Servo DC 5 to 75A
Servo-drive ac/EC UNITEK series Servo AC 3 to 75A
UNITEK series DS 3 to 50A
6
1 Basic - Information
Applications
Machines and installations for all types with a drive power of 7.5kW especially as
4Q-servo-drive for
- highly dynamic acceleration and braking cycles
- a wide control range
- a high efficiency
- small motor dimensions
- a uniform, accurate and smooth running
For speed or torque control or combined speed/torque control incorporated within
or independent of position control loops.
Drives with constant speed as in conveyors, spindle drives, pumps, transversal or
longitudinal pitch drives.
Synchronous multiple motor drives.
Synchro-servo-drives are more compact than other electric drives.
Particularly suitable for:
battery-driven vehicles such as electric vehicles and boats, forklifts, transportation
systems as well as battery-supplied machines and installations such as assembly
machines, metal working machines, food processing machines, robots and
handling systems, conveyors, stone working machines, and for many other
battery-supplied applications.
Motor features
- protection rating IP 65
- compact
- suitable for rough surroundings
- suitable for high dynamic overload
- free of maintenance
Note
Brushless drives are used where braking operations are
predominant, e.g. when deceleration is mainly required:
- winding machines, lifts, great centrifugal masses
The braking energy is fed to the battery.
For dc mains the braking energy must be absorbed in the
mains without the voltage exceeding the permissible value. If
this cannot be guaranteed, a ballast circuitry must be used.
Caution:
The internal regenerative resistors have only a small continuous rating. Calculate
the retarding power and use external regenerative circuit discharge resistors if
necessary or of design safety. Calculation of regenerative power. See page 24.
7
BAMOBIL D3.2
Build
- compact devices according to the VDE, DIN and EU regulations,
protection rating IP40
- for <60V no protection of the connections against contact
- splash-proof housing IP53 (option)
- standard analogue control electronics
- power electronics for 50A, 80A, 100A, 120A, 150A, 250A, 350A, and 450A
- independent 24V chopper power supply unit for the auxiliary voltages
- nominal power input range of 12 to 48V dc, (12 to 120V dc)
- additional cooling unit for air or water cooling
Galvanic isolation
- the negative battery voltage is connected with the device GND
- the housing and the heat sink are galvanically isolated from all electric parts
- the distance of air gaps and leakage paths adhere to the VDE standards
Components
- FET power semi-conductors, comfortably over-dimensioned
- only components customary in trade and industrially standardised are used
- SMD equipment
- 7-segment LED displays
Characteristics
* battery-powered or dc connection 24V= to 48V (24V= to 120V=)
* independent auxiliary voltage connection 24V=
* digital interfaces RS232, CAN BUS (further option)
* 2 analogue inputs, programmable differential inputs
* 4 digital inputs/outputs, programmable, optically de-coupled
* linear command value ramp, non-linear (s-function)
* logic for enable and the output stage switch
* BTB ready for operation, solid state relay contact
* position, speed and torque control
* resolver or incremental encoder TTL, SINCOS 1 Vss, rotor position +
bl tacho
* encoder output or 2nd encoder input
* static and dynamic current limiting
* uniform, completely digital control unit
* Protective switch-off from the motor in case of over-voltage,
under-voltage, or over-temperature
* intrinsically safe and short-circuit proof power section
* processor-independent hardware switch-off in case of short-circuits,
circuits to earth, over-voltage and over-temperature of the amplifier
8
1 Basic - Information
Technical Data
For battery voltages up to 48V=
Power supply connection
Auxiliary voltage connection
Specifikation
BAMOBIL-D3.2-62-
Supply voltage V= 24 to 48
Max. output voltage V~eff 3x14 to 3x33
Continuous current Aeff 40 60 125 175 225
Peak current max. AI o 80 120 250 350 450
Max. Power loss W 200 300 600 900 1200
Pulse frequency kHz 8
Over voltage
switching threshold
Input fuse A 80 160 250 250 500A
Weight kg 5.5 5.8 6.8 6.8 6.8
Dimensions hxwxd mm 244x194x90
Unit size 2 2 2 2 2
24V= bis 48 V=
Please indicate battery voltage on order!
24V= ±10% / 2A Residual ripple <10%,
regenerating fuse
Dim.
V= programmable up to max. 68V
80 120 250 350 450
For battery voltages up to 120V=
Power supply connection
Auxiliary voltage connection
Specification
BAMOBIL-D3.2-160-
Supply voltage V= 24 to 120
Max. output voltage V~eff 3x14 to 3x78
Continuous current Aeff 25 50 75
Max. peak current AI o 50 100 150
Max. Power loss W 200 300 600
Pulse frequency kHz 8
Over voltage
Switching threshold
Input fuse A 80 160 250
Weight kg 5.5 5.8 6.8
Dimensions h x w x d mm 244x194x90
Unit size 2 2 2
24V= bis 120V=
Batteriespannung bei Bestellung angeben!
24V= ±10% / 2A Residual ripple <10%,
regenerating fuse
Dim. 50 100 150
V= programmable to max. 160V
9
BAMOBIL D3.2
Control signals V A Function Connector
Analogue input 10 0.005 Differential input X1
Digital input ON
OFF
Digital output +24
Resolver, TTL, SINCOS Differential input X7
2. Encoder input >3.6V Opttically decoupled X7
Encoder output >4.7V Opttically decoupled X8
CAN-interface Logic IO X9
RS232-interface logicIO X10
Specification
Protection rating IP00 (IP20, VGB4 bei > 60V) (IPx3 Option)
Standards EN60204,
Operating temperature range -10 bis +45oC
Extended operating
temperature range
Storage temperature -30oC bis +80oC
Humidityrating Klasse F rel. humidity <85% ,no condensation !!
Site of installation 1000m a.m.s.l. 100%, >1000m with power derating 2%/100m
Ventilation Internal fan in case of additional cooling unit
Mounting position
10-30<60.010
0
1
+45oC bis +60oC
performance reduced by 2%/oC
Vertical, performance reduced by 20%
when mounted horizontally
Logic IO X1
Transitor output
open emitter
X1
Programming Version Software version
BAMOBIL-xx-RS Resolver BAMOBIL-RS
BAMOBIL-xx-IN Encoder-TTL BAMOBIL-IN
BAMOBIL-xx-SC Encoder SINCOS 1Vss BAMOBIL-SC
BAMOBIL-xx-BL Rotor posiotin+bl tacho BAMOBIL-BL
Note:
Power supply cables between the BAMOBIL 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 ELKOs would be reduced.
10
2 Mechanical Installation
Important instruction
Check the device for mechanical damage. Only perfect devices can be mounted.
Disconnect the power supply prior to any assembly.
Disconnect the positive battery pole.
The device must only mounted by suitably trained personnel.
The mounting position of the devices with ground plate and those
with additional cooling unit (air by means of fan, liquid) is arbitrary.
Devices with an additional cooling unit without a fan must be
mounted vertically.
Please note that there will be a performance reduction when they are
mounted horizontally.
Ensure that the ventilation is sufficient and that there is enough space for the discharged
ventilation air (min. 100mm). If the heat is not dissipated sufficiently the device switches off
via its temperature watchdog.
Any bore hole dimensions for the fixation of the device must be taken from the dimension
diagrams or from the drilling plan, not from the device.
The filter and the choke have to be mounted near to the device.
The line shields and the mounting plate must have surface-to-surface contact.
The power supply lines (battery line and motor line) must be routed separately from each
other. Observe the min. line cross-section.
Unshielded cable heads must be kept short.
8mm cable lugs
Use vibration-proof screw connections.
Note:
Concerning the power supply connection and the auxiliary voltage
connection of the battery pleasecheck:
negative power supply voltage = negative auxiliary voltage
The internal connection is destroyed in case of a reverse polarity of
the auxiliary voltage.
11
BAMOBIL D3.2
12
Dimensions - BAMOBIL
Mounting depth without connector: BAMOBIL up to 120A = 85mm
BAMOBIL ³150A = 95mm
Fixing screws: BAMOBIL up to 120A = M5x20
BAMOBIL ³150A = M5x30
If the mounting plate (without the additional cooling unit ) is mounted onto the rear panel of the
switch cabinet (4mm bright steel), the cooling capacity of the plate corresponds to:
- a continuous current of 35A (S1 duty) when the plate is 10mm thick
- a continuous current of 50A when the plate is 20mm thick
For currents superior to 50Aeff. (for intermittent duty S2, S3) it is necessary to provide an additional
cooling unit (air or liquid) or a heat dissipating mounting plate.
Connecting screws M8x16
max. permissible torque = 12Nm
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