Unitek BAMOCAR D3 User Manual
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
info@unitek-online.de
www.unitek-online.de
01 / 2016 V 1
1 BAMOCAR D3
Basic information
1 Contents
2 Basic information ....................................................................................................................... 3
2.1 History ................................................................................................................................ 3
2.2 Further UNITEK products ................................................................................................... 3
2.3 Engineering instructions (MANUAL) .................................................................................. 3
2.4 Validity ................................................................................................................................ 4
2.5 Designations and symbols ................................................................................................. 4
2.6 General product information ............................................................................................. 5
2.7 Applications/build/features ............................................................................................... 6
2.8 Safety regulations ............................................................................................................... 8
2.9 Commissioning ................................................................................................................. 10
2.10 Safety advices ................................................................................................................... 11
2.11 Intended applications ....................................................................................................... 12
2.12 Regulations and guidelines .............................................................................................. 13
2.13 Risks .................................................................................................................................. 14
2.14 Technical data .................................................................................................................. 15
3 Mechanical installation ............................................................................................................ 18
3.1 Important notes ............................................................................................................... 18
3.2 Dimensions BAMOCAR ..................................................................................................... 19
3.3 Mounting onto mounting rails ......................................................................................... 21
3.4 Mounting onto a mounting surface ................................................................................. 21
4 Electrical installation ................................................................................................................ 22
4.1 Important advices ............................................................................................................ 22
4.2 Circuit diagram ................................................................................................................. 23
4.3 Connection diagram ......................................................................................................... 25
4.4 EMC advice ....................................................................................................................... 26
4.5 Connectors Standard version ......................................................................................... 27
4.6 Power connections 1000V / 400A .................................................................................... 30
4.7 Battery connection ........................................................................................................... 31
4.8 Auxiliary voltage connection ............................................................................................ 32
4.9 Motor power connection ................................................................................................. 33
5 Control connections ................................................................................................................. 34
5.1 Digital inputs .................................................................................................................... 34
5.2 Safety input RFE (Rotating field enable) Stop class 0 ....................................................... 35
5.3 Digital outputs (open emitter) ......................................................................................... 36
5.4 Analog input +/- 10V ........................................................................................................ 37
5.5 Serial interface RS 232...................................................................................................... 38
5.6 CAN-BUS ........................................................................................................................... 39
Basic information
BAMOCAR D3 2
5.7 Resolver connection ......................................................................................................... 40
5.8 Encoder connection TTL ................................................................................................... 41
5.9 SIN COS 1Vss connection .................................................................................................. 43
5.10 Rotor position encoder - connection via a bl-tacho ......................................................... 44
5.11 Option - State displays...................................................................................................... 45
5.12 Option - Error displays ...................................................................................................... 46
5.13 Option - Warning signals .................................................................................................. 47
6 Measured data ......................................................................................................................... 48
6.1 Bus circuit battery voltage ................................................................................................ 48
7 Bus circuit dc bus voltages (battery voltage) ........................................................................... 49
7.1 Bus circuit dc / bus voltages ............................................................................................. 49
8 Output stage temperature ....................................................................................................... 50
8.1 Output stage temperatur ................................................................................................. 50
9 Warranty .................................................................................................................................. 51
9.1 Warranty .......................................................................................................................... 51
3 BAMOCAR D3
Basic information
History
2 Basic information
2.1 History
Version
Modifications
Date
01/2016 – V1
Complete revision
28.01.2016
2.2 Further UNITEK products
For synchronous and asynchronous motors
Digital AC servo amplifiers (mains up to 480V~)
UNITEK
DS205, DS403,
DPCxx
Digital AC servo amplifiers for battery operation
UNITEK
Serie BAMOBIL-D3
Analog three-phase servo amplifier (mains
400V~)
UNITEK
Serie TVD
For dc motors
Analog DC servo amplifier for battery operation
Serie BAMOBIL-A
Analog DC servo amplifier (operation via the
mains)
UNITEK
Serie TV
Thyristor current converter 1Q, 4Q, servo
UNITEK
Classic serie
200W bis 800kW
2.3 Engineering instructions (MANUAL)
1.
MANUAL
BAMOCAR
Hardware
2.
MANUAL
NDrive x
Software
3.
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 or
www.unitek.eu).
The hardware MANUAL comprises warning and safety advices, explanations of standards,
mechanical and electrical installation advices.
The MANUAL must be available for all persons who are concerned with the unit.
Basic information
BAMOCAR D3 4
Validity
2.4 Validity
Hardware state:
TMS 2-3d, driver 1-8
Firmware state:
FW 460
2.5 Designations and symbols
Unit: BAMOCAR D3
User:
Manufacturers or operators of machines or installations in the industrial
sector (B2B, secondary environment).
Manufacturer: UNITEK Industrie Elektronik GmbH
Dealer:
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
X7 (Feedback) = Binder 99-5661-15-19
X9 (CAN BUS) = Binder 99-0436-14-05
Programming cable X10 = Article no. 2390 Connector Binder 79-3464-52-06
5 BAMOCAR D3
Basic information
General product information
2.6 General product information
The digital 3-phase current servo amplifiers BAMOCAR D3xx in combination with the motor provide a 4-
quadrant drive which can be used in both rotation directions for drive operations and brake operations with
energy feed-back.
According to the installed parameter components the amplifiers are suitable for EC synchronous motors, ac
asynchronous motors, or dc motors.
The individual drive versions have different advantages and disadvantages.
The EC drive (synchronous motors) has the highest efficiency and performance per weight and volume and
provides a drive solution free of maintenance and with a wide dynamic control range. However, the high
braking torque in case of motor short-circuits is a disadvantage and it is also difficult to control the field
weakening range.
From the electrical view, the EC synchronous motor (brushless dc motor) is a synchronous 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.
The ac drive (asynchronous motors) has the widest speed range due to the single field weakening and there
is no braking torque in case of a motor circuit. However, the unit size and the worse efficiency is a
disadvantage. The rotating field frequency can be controlled in due consideration of the motor specific
parameters (field-based control). The motor voltages and motor currents are sinusoidal.
With both 3-phase current systems there will be no motor movement neither when the rotating field is
switched off nor in case of an output stage damage. Most of the heat losses are generated in the motor
stator.
The dc drive (dc motor) has the most uniform running and a wide control range. It is possible to provide an
emergency operation by directly connecting the battery voltage. The carbon brushes and the heat
development in the armature are disadvantages. The drive may run at high speed in case of an output stage
damage.
The current is proportional to the torque and the voltage is proportional to the speed.
Current, speed, and position are precisely measured. 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. Field weakening might occur with separately excited motors.
The BAMOCAR D3xx 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). 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)
Basic information
BAMOCAR D3 6
Applications/build/features
2.7 Applications/build/features
Application in all kinds of vehicles, boats, machines, and installations with a drive power of
140kW under hard application conditions, 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 the speed or torque control or combined speed/torque control incorporated within or
independent of position control loops. For drives with constant speed as in conveyors, spindle
drives, pumps, transversal or longitudinal pitch drives, synchronous multiple motor 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.
Build:
-Robust unit for switch cabinet mounting according to the VDE, DIN and EC regulations,
protection rating IP65
-for rough ambient conditions and high dynamic overloads
-maintenance-free
-power connections protected against accidental contact with exposed parts
-power electronics for (S1 operation) 125A, 200A
-power input range nom. 12 to 700V=
-liquid cooling (special version air cooling)
-standard digital control electronics
-Independent 12/24V chopper power supply unit for the auxilary voltages
Galvanic isolation between:
- power connection, motor connection, and all other control connections
- auxiliary connection and all other voltages
- housing and heat sink
- 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
7 BAMOCAR D3
Basic information
Applications/build/features
Characteristics:
Battery connection 12V= to 700V= (dc mains, take restrictions into account)
Independent auxiliary voltage connection 24V= or 12V=
Digital interfaces RS232, CAN BUS (further option)
2 analogue inputs, programmable differential inputs
Digital inputs/outputs, programmable, optically de-coupled
Linear command value ramp, non-linear (s-function)
Logic for enable and the output stage switch, emergency stop function, safety
BTB ready for operation, solid state relay contact
Position, speed and torque control
Feedback encoder systems: resolver, incremental encoder, SINCOS 1 Vss, rotor position + bl
tacho
Static and dynamic current limiting
Uniform, completely digital control unit
Processor-independent hardware switch-off in case of over-voltage, under-voltage, short-
circuits, circuits to earth, and over-temperature at the amplifier or motor
Intrinsically safe and short-circuit proof power section (EN50178)
Attention: Braking energy
The braking energy is fed to the battery.
The battery must absorb the braking energy.
Note:
Pay particular attention when used with laboratory power
supplies.
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.
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.
Basic information
BAMOCAR D3 8
Safety regulations
2.8 Safety regulations
In principle electronic equipment is not fault proof!
Caution - High voltage
DC 800V=
Shock hazard! / Danger to life!
Discharge time of the bus circuit >4min.
Before installation or commissioning begins, this manual must be thoroughly read and
understood by the skilled technical staff involved. It must be ensured that the documentation
(manuals) and thus, the knowledge of the unit and especially the safety advices must be available
for all persons who are concerned with the unit
If any uncertainty arises or if any function is not or not sufficiently described in the
documentation, the manufacturer or dealer should be contacted.
Any incorrect installation/connection may damage the device!
Any incorrect programming may cause dangerous movements!
Intended applications:
The devices of the BAMOBIL-D3 are power electric parts used for regulating energy flow.
They are designed as components to control EC synchronous motors, ac asynchronous motors in
vehicles, machines, or installations.
For applications in residential areas additional EMC measures are necessary.
Any other type of application must be approved by the manufacturer.
The user must draw up a hazard analysis for his end product.
Protection rating IP65
Connection only to batteries
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!
9 BAMOCAR D3
Basic information
Safety regulations
The user must draw up a hazard analysis for his machine, vehicle, or installation.
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 vehicles, machines, equipment,
or vehicles are fitted with device independent monitoring and
safety features.
The user must take appropriate measures so that man as well as
property are not exposed to danger due to incorrect or improper
movements at any time!
Im Betrieb muss das Gerät geschlossen sein.
All plugged connectors must be snapped properly or secured by
screws.
The safety systems must be enabled.
When the device is open and/or the safety systems are deactivated, it must be ensured by the operator that only skilled
and suitably trained personnel has access to the units.
Assembly
- should only be carried out when all voltages have been removed and the units are secured
- should only be carried out by suitably trained personnel
Installation
- should only be carried out when all voltages have been removed and the units are secured
- should only be carried out by suitably trained personnel for electrics
- should only be carried out in accordance with health and safety guidelines
Adjustments and 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
Basic information
BAMOCAR D3 10
Commissioning
2.9 Commissioning
The battery servo amplifiers BAMOBIL D3 are components of the electronic drive 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
the units may not be started until it is ensured that the machine, the installation, or the vehicle
comply with the regulations of the EC machinery directive 2006/42/EG and the EMC guideline
2004/108/EG.
On the installation and test conditions described in the chapter 'EMV advices' it is adhered to the
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.
11 BAMOCAR D3
Basic information
Safety advices
2.10 Safety advices
Machinery directive
The manufacturer of the machine or installation must draw up a hazard analysis for his product.
He must make sure that any unpredictable movements do not cause damage neither to persons
nor to property.
Skilled personnel
Hardware
The skilled qualified personnel must feature a training and instruction for an assignment in the
field of electronic drive engineering. They must have knowledge of the standards and accident
prevention regulations for drive engineering applications and they must be familiar with this field
of activity. Eventually occurring dangerous situations are realized.
The local regulations (IEC, VDE, VGB) are known to the qualified personnel and they are observed
during the works.
Software
The skilled qualified personnel for handling the software must be trained to safely program the
units in the machines and installations. Incorrect parameter settings may cause improper and
impermissible movements. Any parameter settings have to be checked for faulty operation.
Acceptance tests must be thoroughly carried out according the four-eyes principle
Working environment
Incorrect handling of the units may cause damage to persons or property.
The units must be closed during operation.
Any unit covers must not be removed!
Disconnect the power supply prior to any works on electric connections. It must be ensured the
battery voltage is safely switched off.
Any voltages and residual voltages (buffer circuit) must be measured prior to any works on the
unit. Max. permissible voltage <42V.
High temperatures (> 70°C) may arise.
The working environment may be dangerous for persons having electronic medical aids or
appliances (e.g. cardiac pacemakers). Sufficient distance to these electrical parts must be
observed.
Exposure
During transport and storage the prescribed and specified climatic conditions must be adhered to.
The units must not be mechanically damaged. Warped and bent housing parts may influence or
damage the isolation distances. Damaged units must never be installed!
The units comprise parts which may be damaged by electrostatic discharge. The general
recommendations for handling electrostatic devices must be observed. Special attention should
be paid to strongly isolating plastic films and synthetic fiber.
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.
Basic information
BAMOCAR D3 12
Intended applications
2.11 Intended applications
The devices are designed as components to control EC synchronous motors and ac asynchronous
motors in vehicles, boats, machines, or installations.
Any other type of application must be approved by the manufacturer.
Protection rating IP65.
The devices must only be mounted in vehicles, boats, machines, or installations.
For applications in residential areas additional EMC measures are necessary.
The user must draw up a hazard analysis for his end product.
Power connection only to batteries. Isolation watchdogs must be installed for voltages >60V.
The capacities between clocked power modules and the housing (0.022µF Y2.capacitors). Use
external insulation measuring instruments.
The control connections (terminal X1, plugs X7, X8, X9, X10) of the unit comply with the "safe
electrical isolation SELV" acc. to EN 61800-5-1. The user must ensure that the complete control
wiring complies with the standards.
It must be paid attention to the equipotential bonding for components which are connected to
the unit and which do not have isolated inputs and outputs (equalizing connection GND). The
equalizing currents may destroy components and parts.
When measuring the isolation the units must be disconnected or the power connections must be
bridged together and the control connections must be bridged together.
Non-observance will cause damage to the semi-conductors in the unit.
Repeating circuits to earth and short circuits the values of which are all below the response
threshold for short circuits may cause damage to the output stages (conditionally short-circuit
proof acc. to standard 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
13 BAMOCAR D3
Basic information
Regulations and guidelines
2.12 Regulations 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:
EG Guidelines
2004/108/EG, 2006/95/EG, 2006/42/EG, 2002/96/EG
EG Standards
EN60204-1, EN292, EN 50178, EN60439-1, EN61800-3,
ECE-R100
International standards
ISO 6469, ISO 26262, ISO 16750, ISO 20653, ISO 12100
IEC/UL
IEC 61508, IEC364, IEC 664, UL508C, UL840
VDE Regulations and
TÜV Regulations
VDE 100, VDE 110, VDE 160
Regulations of the statutory accident
insurance and prevention institution
VGB4
EU standards and regulations observed for the components of the unit
Standard
Description
Version
EN 60146-1,-2
Semiconductor converters
2010
EN 61800-1,-2,-3
Speed-variable electrical drives
2010
EN 61800-5-1
Electric power drive systems
2010
EN 60664-1
Isolation coordinates - low voltage
2012
EN 61010
Safety regulations - control units
2011
EN 61508-5
Functional safety of electric, electronic systems
2011
EN 60068-1,-2
Environmental influences
2011
ISO 20653
Type of protection of the electrical equipment of vehicles
ECE-R100
Conditions for battery-driven electric vehicles
UL 508 C
UL Regulations - converter
2002
UL 840
UL Regulation - clearance and creepage distances
2005
EU standards and regulations which must be observed by the user
Standard
Description
Version
EN 60204
Safety and electrical equipment of machines
2011
EN 50178
Equipment of power plants
1998
EN 61800-3
Speed-variable electric drives - EMC
2010
EN 60439
Low voltage switching device combinations
2011
EN 1175-1
Safety of electric industrial trucks
2011
ISO 6469
Electric road vehicles
2009
ISO 26262
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
Basic information
BAMOCAR D3 14
Risks
2.13 Risks
The manufacturer aims to keep the remaining risks emanating from the unit as low as possible by
means of constructive, electrical, and software measures.
In the field of drive engineering the following known remaining risks must be considered
regarding the risks arising from machines, vehicles, and installations.
Impermissible movements
caused by:
• failure of safety watchdogs or switched-off safety watchdogs during commissioning or
repair works
• software errors in upstream controls, errors in bus systems
• non-monitored hardware and software errors in actuating elements and connecting
cables
• inverted sense of control
• faults during the parameter setting and wiring
• limited response time of the control features. Ramps, limits
• operations not permitted in the specifications
• electromagnetic interferences
• electrostatic interferences, lightning strikes
• failure of components
• failure in the brakes
Dangerous temperatures
caused by:
• faults during the installation
• faulty connections, bad contacts, aging
• faults in the electric safety system, incorrect types of fuses
• operations not permitted in the specifications
• negative climatic conditions, lightning strikes
• failure of components
Dangerous voltages
caused by:
• faulty earthing of the unit or motor
• faulty connections, bad contacts, aging
• faulty potential isolation, failure of components
• conductive contamination, condensation
Dangerous fields
The units, the inductive and capacitive accessories as well as the power
wiring can generate strong electric and electromagnetic fields. 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.
15 BAMOCAR D3
Basic information
Technical data
2.14 Technical data
For three-phase current motors
Auxiliary voltage connection
12V= to 700V=
Auxiliary voltage connection
12V= or 24V= ±10% / 4A (2A)
residual ripple <10%, regenerating fuse
Data BAMOCAR D3-400-(700)
Dim.
125/250 200/400 125/250 200/400
Supply voltage, rated value
V= 24 up to max. 400 24 up to max. 700
Max. output voltage, rated value
V~eff up to 3x260 up to 3x450
Continuous current
A
eff
125 200 125 200
Max. peak current
Alo 250 400 250 400
Max. power loss
kW 2 3 2.6 4
Pulse frequency
kHz 8-24 8-16
Over-voltage
switching threshold
V= 440 800
Input fuse
A 160 250 160 250
Weight kg 8.5
Dimensions h x w x d mm 403x250x145
Size 2
Control signals V A Function Connector
Analogue inputs ± 10 0.005 Differential input X1
Digital inputs
ON
OFF
10-30
<6
0.010
0
Logic IO X1
Digital outputs +24 1
Transitor output
open emitter
X1
Resolver / TTL / SINCOS Differential input X7
CAN interface Logic IO X9
RS232 interface Logic IO X10
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