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
2 Mechanical Installation
Dimensions Control tpanel
act. comm.
The control panel is connected with the control unit via the CAN BUS.
13
BAMOBIL D3.2
Dimensions - Additional cooling unit for control panel mounting
Mounting depth
without
connector:
Fixing bore hole dimensions: see basis device
Fixing screws M5x110mm
Vertical mounting position,
performance reduced by 20% if the mounting position is horizontal
14
2 Mechanical Installation
Dimensions - Additional cooling unit to be inserted
Mounting depth without connector
Enough space for the ventilation air must be provided
Control panel break through
Fixing screws M5x30mm
15
BAMOBIL D3.2
16
3 Electrical Installation
Power connections
Attention:
The order of the connections to the connector or terminal numbers is obligatory. All
further advice is non-obligatory.
The input and output conductors may be altered or supplemented in accordance
with the electrical standards and guidelines.
Adhere to:
- connection and operating instructions
- local regulations
- EU guideline 89/392/EWG
- VDE and TÜV regulations and Trade body guidelines
Electrical installation should only be carried out when all
voltages have been removed!
Ensure that the device is safely disconnected from the power
supply
- place the short-circuit bracket
- affix warning signs
The installation should only be carried out by suitably trained
personnel for electrical engineering.
- Compare the connection data with those indicated on the type plate.
- Ensure that the correct fuses have been provided for the power supply
and the auxiliary voltage.
- Power supply conductors and control lines must be routed separately from
each other.
Connection shields and grounding must be carried out in compliance
with the EMC guidelines. Use the correct line cross-sections.
Warning:
Bad or insufficiently rated cable connections between the battery and the device
may cause damage to the device! (Brake energy)
Warning:
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.
Warning:
Concerning the power supply connection and the auxiliary
voltage connection of the battery please check:
negative power supply voltage = negative auxiliary voltage
The internal connection is destroyed in case of a reverse polarity
of the auxiliary voltage.
17
BAMOBIL D3.2
18
REFERENCE
Core
3 Electrical Installation
Mains module
6x op.coup.-driver
Output stage
19
BAMOBIL D3.2
Safety circuit
emergency stop
Control
Drive enable
Analogue
com.value
Logic GND
output
stage
switch
±10V
Auxiliary voltage 24V=
Detail
page
ready
auxiliary
voltage
output
stage
switch
enable
analogue
input 1
digital GND
D1
braking
current diode
Battery voltage
Logic output
Logic input
Analogue
±10V
value 2
Digital
output
Rotating field
enable
+24V
Analogue
±10V
value 3
System-GND
Counter
input
PC
COM1/COM2
digital
inputs
digital
outputs
analogue
input 2
digital
output
rotating field
enable
digital
output
Analogue-GND
System-GND
counter pulse output
counter pulse input
Interface PC-COMx
Encoder
EC
Motor
Feedback
Encoder
D-plug with shielded conductor
shield connection in the plug
EMC mass surface-to-surface contact
Encoder
to the mounting plate
20
3 Electrical Installation
CNC/PLC
Battery voltage
double grounding
for >2m
X9
X8
CAN-
INC-
BUS
OUT
15pin connector
Shield
on the connector
housing
X1:7
X1:8
X1:9
FRG
analogue
RUN
com.value
X7 XB:2 XB:3 XB:4
RLG
bl
M
3 bl
GND
double grounding
for >2m
Motor chokes
only for a conductor length of >25m
XB:1 XB:5
Housing
Machine frame
EMC Advice
The devices adhere to the EU guidelines 89/336/EWG and the technical standards
EN 61000-2 and 61000-4 provided that the following conditions are observed:
- The device is conductively mounted on a 500x500x5 mm bright
aluminium mounting plate-
The mounting plate must be connected to -UB using a 10mm² wire.
- The motor housing must be connected to -UB using a 10mm² wire.
- The device ground X-AGND must be connected to the mounting plate
using a 1.5mm² wire.
- The housing must be connected to the mounting
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.
Battery connection:
48V dc voltage
Motor connection:
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.
A manufacturer’s declaration can be asked for.
21
BAMOBIL D3.2
Ready
Auxiliary voltage
Output stage switch
Drive enable
Analogue input 1
Logic - zero
Digital input
Digital output
Analogue input
Digital output
Rotating field enable
Analogue output
Analogue - zero
Channel A
Channel B
Channel N
Select IN
Supply GND
Channel N
Channel B
Channel A
Supply +5V
22
3 Electrical Installation
Connection to the battery
Battery voltage
Warning
The max. supply voltage UB +30%
(62V=) must not be exceeded at any
time
(not even for short
intervals)!
Danger of damage!
F1 = safety fuses
The power supply
connection has no protection against
reverse polarity.
If the polarity of the connection is
wrong, the device will be destroyed!
Battery connection bolt
Type
-50, 80 torque <12Nm
-100 -150 35 2
-250 70 00
-350 95 0000
-450 185 350
Battery connecting line <2m. For conductor lengths from 2 to 10m more powerful. Use an
additional capacity for conductor lengths superior to 10m!
24.48 V=
bolt M8x16
XB1 (+UB=)
XB5 (-UB=)
Connection
cross-section
mm2 AWG
16 4
Fuse A
80
160
250
350
500
Auxiliary voltage connection
Mains potential-free auxiliary dc voltage 24V= ±10%/2A
The auxiliary voltage
- is galvanically connected with the
logic voltage
- has internal regenerating fuses
- has an EMC filter
connector X4
internal
Regenerating fusses
internal
External fuse only for line protection
Input voltage 24V dc X1:4
GND24 X1:3
Residual ripple 10%
Switch-on current 2A
Nominal current 0.8A
DC/DC converter
Note: In addition to the internal supply current (0.8A) the sum of the
output currents (DOUT) must be provided by the mains module 24V.
Note: If the auxiliary voltage is inferior to 20V - even in case of
short-time voltage drop-outs - the internal mains module is switched off.
Any data of the RAM are deleted!
The speed and the position command values are set to zero and any
calibrated data are deleted.
The LED signal for the state “OK” is dark.
23
BAMOBIL D3.2
Motor power connection
Only electronically commutating synchronous motors (brushless dc motors, EC
motors) with resolver or incremental encoder must be used. These motors must be
approved of by UNITEK prior to any use.
See appendix A (Motor specific connection and parameter standards and
guidelines).
Motor connectors
or terminal cabinet
Motor choke
Incremental encoder EC
Sequence of connection
Motor cable
Cable M1 M2 M3
Motor phases U V W
Connecting bolt XB:2 XB:3 XB:4
Only one correct connecting sequence is possible !
3-core, single-shielded for
200V=,
shield capacity = 150pF/m,
min. Cross-section - see below
table
Min. cable cross-section
BAMOBIL-D3-x -50 -80 -100 -120 -150 -250 -350 -450
Cross-section mm² 4 6 6 10 16 25 70 95
AWG 10 10 10 6 4 2 000 0000
Motor choke
Only necessary for a shield capacity of >5nF. Approx. 25m motor cable
Magnetic rings
against HF failures of the sensor systems. Slide the rings onto the motor lines.
Connection of the shield
Surface-to-surface connection to the switch cabinet input.
Surface-to-surface connection as short as possible to the motor side.
24
3 Electrical Installation
Digital inputs
Digital input
10 to 30V=
Digital inputs
X1:5
Output stage switch 1
X1:6
output stage switch 2
enable
X1:7
X1:11
digital input 1
digital input 2
X1:12
rotating field-enable
X1:18
END1/LMT1
END2/LMT2
FRG/RUN
DIN1
DIN2
RFE
VCC
Opto-input
Input voltage
H-level (ON) +10V to +30V
L-level (Off) 0 to +6V
Input current max. 7.5 mA
Nominal voltage/current +24V/6mA
Referenc ground GNDE (X1:10)
DSxx/BAMO-D
The enable input (FRG/RUN) and the input for the rotating field enable (RFE) are
fixed, they cannot be programmed.
Without the enable FRG/RUN the servo-drive is electronically disabled (no PWM
pulses).
Without the rotating field enable RFE the rotating field of the output stage is
additionally electronically disabled (2nddisable channel).
The drive is free of torque (no holding torque).
The remaining four digital inputs can be programmed.
The inputs LMT1 (X1:5) and LMT2 (X1:6) are preferably to be used as inputs of the
output stage switch.
Input
Connection Function State Parameter
FRG/RUN X1:7 Enable fixed
RFE X1:18 Rotating field enable fixed
END1/LMT1 X1:5 Output stage switch 1
programmable
Digital input
END2/LMT2 X1:6 Output stage switch 2
Digital input
DIN1 X1:11 Digital input1
DIN2 X1:12 Digital input2
External power supply for the inputs and outputs
Logic
voltage
24V=
Logic
ground
X1:4
X1:10
+24V
DS400
GNDE
+24V for the logic and the auxiliary
voltage
GNDE logic ground
25
BAMOBIL D3.2
24V - voltage
Warning!
If the input of the enable or of the rotating field enable are switched off,
the drive is free of torque. The drive could move if there is no mechanical
brake or block provided.
The motor conductors are not dead. Only the rotating field is disabled.
Prior to any work or maintenance on the motor or servo-drive, the
servo-drive must be completely disconnected from the mains power
supply.
Operation with RFE input
Two-channel disable of the enable via a
safety switching device.
Enable input FRG/RUN + rotating field
enable input RFE.
Switching-on
Contacts of the safety device closed:
enable FRG/RUN 0.5s after RFE.
Safety switch-off
Contacts of the safety device open:
- there is no FRG/RUN signal in the 1st disable
channel to disable the PWM pulses
in the processor,
Safety
device
PNOZ
CNC/PLC
Hardware
Enable
Hardware
Enable
Logic-zero
Logic - voltage
Safety
device
PNOZ
CNC/PLC
CNC/PLC
Hardware
Hardware
Enable
Enable
Hardware
Enable
Logic-zero
- there is no RFE signal in the 2nddisable
channel to disable the PWM pulses at
Rotating field
the output of the processor.
Restart
Release the safety switching device.
Contacts of the safety device closed.
The motor can only move after a second disable FRG/RUN
(after the rotating field enable).
Operation without RFE input
The input RFE must be bridged with the logic voltage.
If the logic voltage corresponds to the supply voltage, the RFE
input is bridged with +24V.
Enable FRG/RUN at least 0.5s after the RFE signal.
Logic-voltage
Rotating field
Enable
CNC/PLC
Hardware
Enable
Hardware
Enable
Logic-zero
26
Rotating field
Enable
3 Electrical Installation
Digital logic outputs (open emitter)
The logic outputs 1 to 3 are rated for 24V and 1A (short-time: 2A)
Output voltage
Digital
output
24V/1A
Digital outputs:
X1:13 dig.output 1 DOUT1
X1:14 dig.output 2 DOUT2
X1:17 dig.output 3 DOUT3
On-level max. +24V
Off-level <1V
Output current nom. 1A
Output current max. 2A
Voltage reference +24V (X1:4)
ground reference GNDE(X1:10)
It is possible to program an energy saving program (clocked output).
The logic output 4 (24V, 3A) at the power section is only available with certain
devices.
Signal contact “Ready BTB/RDY” (Solid state relay)
Contact for max. 48V/0.2A
Capacitive load max. 1myF
Contact resistance max. 2 Ohm
Safety
circuit
The contact is closed when the
device is ready for operation.
State signal via seven-segment LED
display.
In case of failures the contact is
open.
BTB opens (red LED, open relay contact)
in case of error messages
in case of under-voltage of the auxiliary voltage (<20V)
The message “under-voltage in the bus circuit” can be programmed
(see Manual NDrive)
Output Connection Function State Parameter
BTB/RDY X1:1, X1:2 Ready fixed /Relay
DOUT1 X1:13 Digital output1 programmable
DOUT2 X1:14 Digital output2 programmable
DOUT3 X1:14 Digital output3 programmable
DOUT4 Xx:xx Digital output4 programmable
Logic
voltage
24V=
Logic
ground
X1:4
X1:10
+24V
DS400
GNDE
+24V for the logic and the auxiliary voltage
Observe the sum of all output currents!
GNDE logic ground
27
BAMOBIL D3.2
Analog inputs ±10V
Analog
voltage
±10V
Input Connection Basic function Voltage State Parameter
AIN1+, AIN1- X1:8, X1:9 Speed command value 10V programmable
AIN2+, AIN2- X1:15, X1:16 Current limit 10V programmable
Features
Differential input AIN1-/AIN1- AIN2+/AIN2-
Input resistance 70k
Threshold voltage 12V
Resolution 11bit + sign
The direction of rotation of the motor can either be changed by swapping
the ± connections at the differential input, or by means of a logic input or by
programming.
The analog inputs can be assigned to different functions.
With a digital command value (RS232, x-bus)
- the analog input AIN1can be programmed as external analog speed limit
- and the analog input AIN2 can be programmed as external analog current limit.
Input Connection Basic function Voltage State Param.
AOUT1 X2:20 Speed actual value 10V programmable
GND X2:21 Signal zero 0V fixed
28
3 Electrical Installation
Serial interface RS 232
BAMOBIL-D3 is programmed and operated during commissioning via the serial pc
interface RS232.
There is a software description in the Manual DS NDrive.
The serial interface is galvanically
connected with the device zero
(GND/AGND).
Null modem cable
The BAMOBIL-D3 (D connector X10) and the serial interface (COMx) of the pc must
only be connected using a null modem cable.
Do not use a null modem link cable!
Install the cable only after disconnecting the device from the mains.
The interface is hard-coded to 115200Baud.
Null modem connecting cable
View to the soldered side,
Shield on the housing,
Max. cable length 10m
In case of strong interferences at
the interface a line filter should
be installed.
Notebooks with a USB-RS232
converter are usually susceptible
to interference.
29
BAMOBIL D3.2
CAN-BUS
The CAN-BUS is a digital connection to the CNC control.
Optimum conditions are achieved with CNC controls and CAN components of
LABOD electronic or CAN Open.
Programming and operation by means of the control panel via the CAN-BUS.
Interface complies with the standard ISO 11898.
Adjustment and programming see Manual DS-CAN.
The BUS interface is galvanically
isolated from the internal device
voltage.
.
The voltage is supplied via an
internal, isolated DC-DC
converter or via the BUS cable.
CAN-V+ 9 to 15V=
CAN-BUS cable
Use a shielded bus conductor with a low
shielding capacity.
Signal plus GND (+supply).
D-connector with a metal or metallized
housing. LiYCY 4x0.25+shield.
Designation
CAN-V+ 9 brown 1
CAN-GND 3 white 4 (PE)
CAN-H 7 green 3
CAN-L 2 yellow 2
Connect. no
cable
color
cable
no.
CAN-BUS connection with several BAMOBIL-D3
Master Address xx Address xx Address xx
Terminating resistor at the end of the bus line > 120Ohm between the CAN-H and
CAN-L
30
3 Electrical Installation
Resolver connection
only for BAMOBIL-D3-RS
The resolver is an absolute measuring
system for a motor revolution.
It is robust and not impaired by high
motor temperatures.
Its build corresponds to
a revolving transformer.
The rotor is supplied by the reference
(10kHz).
The stator supplies the sine and
cosine signals modulated by the
rotational frequency.
The amplitudes of these signals are
analyzed and digitalized in the
servo-drive.
The resolution is automatically set to
an optimum of 10, 12, or 14 bit.
The max. possible speed is 50000
(10bit).
The digitalized signals are used for
the polar wheel angle,
the position and speed control, and
the incremental output.
Connect.assignment
Soldered side
Use only motors with a 2-, 4-, 6-, or 8-pole resolver
which have been approved by UNITEK (Appendix
A). Observe the motor specific connection data
M, pin contact
sheet (RS)!
Connector X7 15-pole D-connector
Connecting cable 4 x 2 cores, twisted in pairs
and shielded, additional overall shield. For link chains use
appropriate cables!
Cable length for >25m 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 con. connect the overall shield to the
connector housing
Setting parameters see software Manual DS
31
BAMOBIL D3.2
Encoder TTL connection
only for BAMOBIL-D3-xx-SC
ITTL incremental encoder
(encoder) with 2 counter tracks
and 1 zero track plus 3 rotor
position tracks. Counter tracks
with or without push-pull output.
(For single connection A, B, N do
not connect the negative inputs.)
The counter input corresponds to
RS485.
Max. counting frequency 500kHz.
The incremental encoder is
galvanically connected with
the device zero (GND)
The voltage of 5V is supplied by
the servo-drive.
Connect. assignment
Solderer side
Use only motors with TTL incremental encoders
M, pin contact
and rotor position tracks which have been
approved by UNITEK (Appendix A). Observe the
motor specific connection data sheet (IN)!
Connector X7 15-pole D-connector
Connecting cable 10 signal conductors, shielded, min. cross-section 0.14mm
2 supply lines, min. cross-section 0.5mm
For link chains use appropriate cables!
Cable length for >25m 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 parameter see software Manual DS
32
3 Electrical Installation
SIN/COS 1Vss
only for BAMOBIL-D3-xx-SC
Incremental encoder
(encoder) with 2 analog,
sinusoidal counter tracks
and 1 zero track plus 2
commutating tracks.
Differential signals 1Vss
Max. counting frequency
500kHz.
The incremental encoder is
galvanically connected with
the device zero (GND).
The voltage of 5V is supplied
by the servo-drive.
The resolution is
automatically set to an
optimum.
Connect.assignment
Soldered side
M, pin contact
Use only motors with SIN/COS encoders (SC) which have been approved by UNITEK
(Appendix A). Observe the motor specific connection data sheet (SC)!
Connector X7 15-pole D-connector
Connecting cable 4 signal conductors,
twisted and shielded, min. cross-section 0.14mm
2 signal conductors, shielded, min. cross-section 0.14mm
4 supply lines, temp., min. cross-section 0.5mm
Cable type (4 x (2 x 0.14) + (4 x 0.14)C + 4 x 0.5)C
For link chains use appropriate cables!
Cable length for >25m 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
33
BAMOBIL D3.2
Rotor position encoder - connection via a bl-tacho
only for BAMOBIL-D3-xx-bl
3 rotor position encoder
signals (Hall sensors) for the
commutation; with or
without a brushless tacho.
The rotor position encoder is
galvanically connected with
the device zero (GND).
The voltage of 15V is
supplied by the servo-drive.
Provide an adapter in case
the tacho voltage at rated
speed is superior to 10V~.
For lower tacho voltages
connect X7: pin 1, 9, and 11.
Connect the tacho center
point to X7:1.
Use only motors with rotor
Connect.assignmen
Soldered side
M, pin
position encoders (bl) which have been approved by UNITEK (Appendix A).
Observe the motor specific connection data sheet (bl)!
Connector X7 15-pole D-connector
Connecting cable 12 signal conductors, supply lines, temp., min. Cross-section
0.25mm
For link chains use appropriate cables!
Cable length for >25m 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 parameter see software Manual DS NDrive
34
3 Electrical Installation
X8 TTL encoder output or input (2)
The D-connector X8 is connected as input or output (default).
Output X8 pin 6 not connected or bridged with GND
Input X8 pin 6 bridged with +5V (X8:1)
9-pole D-connector (M, pins)
connector assignment
soldered side
Note: X8 as input
Connect X8:6 (select IN) with X8:1
(+5V) in the D-connector
35
BAMOBIL D3.2
X8 as TTL encoder output
The encoder signals supplied by the motor (feedback) are available at the output of the
D-connector X8 TTL encoder signals for the CNC control.
The encoder output is internally isolated.
The voltage is supplied via the encoder line from the CNC/PLC control.
Voltage supply +5V ±0.2V.
The output signal corresponds to RS485.
Option: Internal supply from the servo-drive (LBR1 + LBR2)
For RS and SC the resolution can be programmed. (Parameter 0 x a4, Bit1),
for IN it corresponds to the encoder no. of pulses.
Pulse signals (motor revolving clockwise)
Output level low <0.5V, high >4.5V
Slope <0.1ms
Zero pulse min. 0.2ms
Output frequency max. 200kHz
Pulse/rpm - for RS, SC programmable
- for IN encoder no. of pulses
X8 as TTL encoder input
Note: X8 pin 6 (select IN) must be bridged with X8 pin 1 (+5V)!
The encoder input is internally isolated.
The voltage is supplied via the encoder line.
Option: Internal supply from the servo-drive
The input signal correspond to RS485.
Input frequency max. 200kHz
Option: Internal supply from the servo-drive (LBR1 + LBR2)
The encoder input can be programmed for different functions.
see software Manual DS-NDrive.
36
3 Electrical Installation
Displays - BAMOBIL D3
The state “normal” is signalled by a bright green seven-segment display + decimal
point (display of the state).
The state “fault” is signalled by a bright red fault LED and the seven-segment display
indicates the error no.
The state “warning” is signalled by the flashing red fault LED and the seven-segment
display indicates alternately the state and the warning no.
Display of the servo-drive state
Display Point/
segment
flashing
dark
Flashing
Bright
dark
bright Speed zero (standstil signal) N0 = 1
bright Drive revolves clockwise, N currently positive N0 = 0
bright Drive revolves anti-clockwise, N currently negative N0 = 0
Flashing
bright
State State of NDrive
Processor active
Auxiliary voltage missing or inherent hardware failure
Starting state after reset (auxil. voltage 24V off-on).
The first enable stops the flashing display.
Drive enabled
Drive disabled (not enabled)
Motor current reduced to continuous current Icns
Motor current at max. current limit Imax
OK = 0
OK = 1 , ENA = 1
OK = 1 , ENA = 0
Icns = 1
Icns = 0
dark
Bright for
0.1s
Normal operation; Motor current within the current
limits
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
Icns = 0
37
BAMOBIL D3.2
Errordisplay - BAMOBIL D3
The red LED "fault" isbright and the falt u o. Isindicated bythe sevensegment
-display.
List of errors.
Display at the
BAMOBIL
0 BADPARAS Damaged parameter
1 POWER FAULT Output stage error
2 RFE FAULT Safety bus fault
3 BUS TIMEOUT Transmision fault BUS
4 FEEDBACK Encoder signal faulty
5 POWER VOLTAGE Power voltage missing
6 MOTOR TEMP Motor temperature too high
7 DEVICE TEMP Device temperature too high
8 OVER VOLTAGE Over voltage >1.8 x UN
9 I_PEAK Over current 300%
A RACE AWAY
B USER User - choice of error
C RESERVE
D RESERVE
E CPU-ERROR Software error
F BALLAST Ballast circuit overload
Errordisplay with
NDrive
Meaning
Drive races
(withoutcommand value, wrong direction
Decimal point
flashes
Decima point
dark
38
Processing unit active
Auxiliaryvoltage missingor inherenthardware failure
Example:
FAULT LED red
Error no. 5 POWER VOLTAGE (power voltageis missing )
3 Electrical Installation
Warning signals - BAMOBIL D3
The state “warning” is signalled by the flashing red fault LED and the seven-segment
display indicates alternately the state and the warning no.
List of warning signals
Display at the
BAMOBIL
0 MOTOR TEMP Motor temperature superior to 80%
1 DEVICE TEMP Device temperature superior to
2 I2t I2t superior to the programmed
3 BLOCK Drive disabled
4
5
6
7
8
9
A
Warning signals with
NDrive
Meaning
80%
value
B
C
D
E
F
Example:
Fault LED flashes red
The display swaps between state and warning no.
Warning no. 5 ??
39
BAMOBIL D3.2
UNITEK guarantees that the device is free from material and production defects.
Test results are recorded and archived with the serial number.
The guarantee time begins from the time the device is shipped, and lasts one year.
Unitek undertakes no guarantee 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. For warranty service or repair, this product must be returned to
a service facility designated by UNITEK.
For products returned to UNITEK for warranty service, the Buyer shall prepay shipping
charges to UNITEK and UNITEK shall pay shipping charges to return the product to
the Buyer.
However, the Buyer shall pay all shipping charges, duties, and taxes for products
returned to UNITEK from another country.
The foregoing warranty shall not apply to defects resulting from:
* improper or inadequate repairs effected by the Buyer or a third party,
* non-observance of the manual which is included in all consignments,
* non-observance of the electrical standards and regulations
* improper maintenance
* acts of nature
All further claims on transformation, diminution, and replacement of any kind of
damage, especially damage, which does not affect the UNITEK device, cannot be
considered. Follow-on damage within the machine or system, which may arise due
to malfunction or defect in the device cannot be claimed.
This limitation does not affect the product liability laws as applied in the place of
manufacture (i. e. Germany).
UNITEK reserves the right to change any information included in this MANUAL.
All connection circuitry described is meant for general information purposes and is
not mandatory.
The local legal regulations, and those of the Standards Authorities have to be
adhered to. UNITEK does not assume any liability, expressively or inherently, for the
information contained in this MANUAL, for the functioning of the device or its
suitability for any specific application.
All rights are reserved.
Copying, modifying and translations lie outside UNITEK’s liability and thus are not
prohibited. UNITEK’s products are not authorised for use as critical components in
the life support devices or systems without express written approval.
The onus is on the reader to verify that the information here is current.
40 UniTek Industrie Elektzronik GmbH, Hans-Paul-Kaysser-Str.1 D-71397 Leutenbach-Nellm. (b.Stuttgart)
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