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

[e-mail]

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

Basic information

BAMOCAR D3 16

Technical data

Ambient conditions

Protection rating

IP 65

Standards

EN60204, ISO 16750 , EN61800, IEC60146

Protection class

Over-voltage

+10%

Operating temperature range

-10 to +45°C

Extended operating temperature
range

-30 to 65°C
from +45°C to +65°C performance reduced by 2%/°C

Storage and transport

-30°C to +80°C EN60721

Installation altitude

≤ 1000m above sea level 100 %,
>1000m performance reduced by 2%/100m

Cooling

Liquid cooling unit max. 65°C, 12 l/min,
pressure max. 1.3 bar

Mounting position

independent

Contamination

Contamination degree 2 acc. to EN 61800-5-1

Vibration

10Hz to 58Hz ampl. 0.075mm (IEC 60068-2-3)
58Hz to 200Hz 1g

Shock

15g for 11ms

Environmental conditions

Not permissible:

condensation (dew), ice formation, oil mist, salt spray,

water

Humidity

class F, humidity <85%

condensation not allowed!

17 BAMOCAR D3

Basic information

Technical data

Current reduction (torque reduction)

Only with air cooling

Permissible current limit depending on the
installation altitude

With air cooling

Permissible current limit depending on the
ambient temperature

With liquid cooling

Permissible current limit depending on the
temperature of the cooling agent

Programmable current reduction
depending on the IGBT module temperature.
Starting temperature of the reduction
I-red-TD 0x58

Final temperature of the reduction
I-red-TE 0x4c

Automatic current reduction
depending on the rotation frequency
(motor speed)

Automatic current reduction
depending on the pulse frequency

2-1 ED-Ired-Höhe-5
2-2 ID-Ired-Um-temp-5

2-3 ED-Ired-IGBT-Temp-5

2-4 ED-Ired-rot-5

2-5 ED-Ired-IGBT-takt-5

Mechanical installation

BAMOCAR D3 18

Important notes

3 Mechanical installation

3.1 Important notes

Check the device for mechanical damage.
Only devices in perfect working order can be mounted.

Disconnect the power supply prior to any assembly.

Disconnect the positive and negative battery pole and the dc
mains.
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.

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.

A safe earth connection must be provided between the housing and the
mass level (vehicle chassis earth, earth of the switch cabinet)

Unshielded cable heads must be kept short.

Only use specified connectors.

Use vibration-proof screw connections.

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.

19 BAMOCAR D3

Mechanical installation

Dimensions BAMOCAR

3.2 Dimensions BAMOCAR

Standard version (connectors partly equipped)

3-1 rh5-BAMOCAR-D3-V6-standard-oben

3-2 rh5-BAMOCAR-D3-V6-standard-seitlich

Mechanical installation

BAMOCAR D3 20

Dimensions BAMOCAR

Option connectors completely equipped

Liquid cooling

Connection
Hose connection: metal ¼-13
Input temperature: < 50°C
Flow rate: max. 12l/min
Pressure: max. 1.3 bar

3-3 rh5-BAMOCAR-D3-V6-vollbestückt-oben

3-4 rh5-BAMOCAR-D3-V6-vollbestückt-seitl

21 BAMOCAR D3

Mechanical installation

Mounting onto mounting rails

3.3 Mounting onto mounting rails

4x screw M5x20

3.4 Mounting onto a mounting surface

4x distance pipe for M5 l = 20mm
4X screw M5x40

3-5 rh5-BAMOCAR-D3-V6-standard-montage

3-6 rh5-BAMOCAR-D3-V6-standard-montagefläche

Electrical installation

BAMOCAR D3 22

Important advices

4 Electrical installation

4.1 Important advices

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 2996/42/EC

- guidelines for vehicles ECE-R100, ISO 6469, ISO 26262

- 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.

Insert external isolation monitors!

Note:

Bad or insufficiently rated cable connections between

the battery and the device may cause damage to the
device! (Brake energy)

Note:

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.

23 BAMOCAR D3

Electrical installation

Circuit diagram

4.2 Circuit diagram

4-1 BAC-blockbild-3-TMS-rund

Electrical installation

BAMOCAR D3 24

Circuit diagram

Circuit diagram

4-2 BAC-blockbild-3

25 BAMOCAR D3

Electrical installation

Connection diagram

4.3 Connection diagram

4-3 E-BAC-anschlussplan-1

Electrical installation

BAMOCAR D3 26

EMC advice

4.4 EMC advice

4-4 E-BAC-emv-3

The devices adhere to the EU guidelines 2004/108/EC and the technical standard EN 61800-3
provided that the following conditions are observed:

Mounting:

The device is conductively mounted on a 500x500x5 mm bright aluminium mounting plate.
The mounting plate must be connected to earth using a 10mm² wire.
The motor housing must be connected to earth using a 10mm² wire.
The device ground X-AGND must be connected to the mounting plate using a 1.5mm² wire.
Device PE screw X3:6 connected to the mounting plate using a 4mm² wire.

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:

360V dc voltage

Motor connection:

Motor lines must be shielded, and must have surface-to-surface contact

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 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.

27 BAMOCAR D3

Electrical installation

Connectors

4.5 Connectors

Standard version

Option - completely equipped

additionally installed:

X9.1 2nd CAN-Bus connector
X11 Brake connector

4-6 BAC-Steckerübersicht-voll-3

4-5 BAC-Steckerübersicht-teil-1

Electrical installation

BAMOCAR D3 28

Connectors

Connector X1 Control inputs/outputs

A brown BTB ready for operation
B red BTB
C pink GND24 auxiliary voltage 0
D yellow +24 auxiliary voltage +
E green END1/LMT1 limit switch 1
F blue END2/LMT2 limit switch 2
G violet FRG/RUN enable
H grey AIN1+ analog input 1
J white AIN1-
K black GNDE logic zero
L br-green DIN1 digital input 1
M br-yellow DIN2 digital input 2
N wh-green DOUT1 digi-output 1
O red-blue DOUT2 digi-output 2
P wh-yellow AIN2+ analog input 2
R wh-red AIN2-
S wh-grey DOUT3 digi-output 3
T wh-black RFE rotating field enable

U wh-blue +24V auxiliary voltage+

Connector X9, X9.1 CAN X9 Option X9.1

1 PE
2 Supply IN
3 CAN GND
4 CAN H
5 CAN

Connector plug Binder 99-0436-14-05 (female) Binder 99-0437-14-05 (male)

Connector X10 RS232

1 brown R2IN
2 white TxD
3 blue T2OU
4 black T2OU
5 grey RxD
6 pink GND

Option connector X11 brake

1 +24 V-Br
2 Brake +
3 Brake -
4 GND-24V-Br

connector
male device

connector

female
device

Connector plug

Binder 99-5662-15-19
connector female

connector male device

Connector plug Binder 79-3464-52-06
(connector female)

connector male device

Connector plug Binder 99-0429-15-04
(connector female)

connector male

4-7 binder-bu-14

4-11 binder-st-M12-5p
4-10 binder-bu-M12-5p

4-9 binder-st-M8-6p

4-8 binder-st-M12-4p

29 BAMOCAR D3

Electrical installation

Connectors

Feedback encoder connector X7

Connector female device

Connector plug Binder 99-5661-15-19

Connector male

Connector X7
Encoder plug Resolver

Connector X7
Encoeder plug INC-TTL

Connector X7
Encoder plus SIN/COS

Connector X7
Encoder plug bl

A A

channel A

A

channel ka+

A

MP tacho

B B

channel /N

B

channel kr+

B

C

SIN1

C

channel B

C

channel kb+

C

tacho 1

D D

supply +5V

D

supply +5V

D

supply +15V

E

COS2

E

channel N

E

channel kr+

E

tacho 2

F F

channel /B

F

channel kb-

F G

REF2

G

channel /A

G

channel ka-

G

tacho 3

H

temp signal

H

temp signal

H

temp signal

H

temp signal

J J

temp GND

J

temp GND

J

temp GND

K

REF1

K

rotor position3

K

channel kd-

K

rotor positon3

L

temp GND

L

supply GND

L

supply GND

L

supply GND

M

COS1

M

rotor position2

M

channel kc+

M

rotor position2

N N N

channel kd+

N O

SIN2

O

rotor position1

O

channel kc-

O

rotor position1

P P P Encoder plug INC

For all connectors: view at the connector onto the soldered crimp side

4-12 binder-bu-19

Electrical installation

BAMOCAR D3 30

Power connections 1000V / 400A

4.6 Power connections 1000V / 400A

Connector socket pos. pole

Pfisterer P1 (350 205-301 (-Option -302))

Connector socket neg. pole

Pfisterer P1 (350 205-301)

Motor connectors

Pfisterer P1 (350 205-301)

Connector plug pos. pole

Pfisterer plug straight P1 (350205-001..)
or plug twisted P1 (350205-101)

Connector plug neg. pole

Pfisterer Stecker straight P1 (350205-001…)
or plug twisted P1 (350205-101)

Connector plug motor

Pfisterer Stecker straight P1 (350205-001)
or plug twisted P1 (350205-101)

4-13 Pfisterer-Stecker

31 BAMOCAR D3

Electrical installation

Battery connection

4.7 Battery connection

Note:

Bus circuit capacitor C-ZW

at 400V

800µF

at 700V

320µF

Discharge resistance R-ZW 50kΩ

Series resistor
RV approx. 40 Ohm 50 W

Charging current via K2 <20A

Note:

Enable (RUN) only after the main

contactor K1 is activated.

The max. supply voltage (battery voltage) 450V= (780V=)
must not be exceeded at any time (not even for short intervals)!
Danger of damage! / Error message: OVERVOLTAGE / F1 = safety fuse

Block diagram of the pre-charging

Programming example:

The output Dout1 switches the relay
K3 when the bus circuit voltage (DC-

BUS) is greater than the variable 1.

Warning:

The power supply connection has no protection against reverse polarity.
If the polarity of the connection is wrong, the device will be destroyed!

Type

Battery
connection

Connector cross­section

Fuse AT

Drive

contactor size

mm²

AWG

-125/250

25 2 160 -200/400

35 1 250

Battery connecting line <2m. For conductor lengths from 2 to 10m more powerful.
Use an additional capacity for conductor lengths superior to 10m!

4-14 ED-BAC-Batt-2

4-15 ED-BAC-Vorlad-2

Electrical installation

BAMOCAR D3 32

Auxiliary voltage connection

4.8 Auxiliary voltage connection

Mains potential-free auxiliary
dc voltage +12V= (4A) to +24V= (2A) ±10%
The auxiliary voltage

-is galvanically connected with the logic voltage

-is galvanically isolated from all internal supply voltages of the device and from the housing

-internal regenerating fuse

-EMC filter

External fuse only for the line protection

Input voltage

12-24V DC

X1:4 GND24

X1:3

Residual ripple

10% Switch-on current

4A Nominal current

at 12V

1.4A at 24V

0.9A

Neg. connection of the power supply to
earth

Attention:

In addition to the internal supply current (1.4A) the sum of the output currents (DOUT) must be

provided by the mains module 12/24V.

If the auxiliary voltage is inferior to 10.5V there will be the error message ‘hardware error 1’

(power fault)

If the auxiliary voltage is inferior to 10V - even in case of short-time
voltage drop-outs - the internal mains module is switched off.
Temporary data of the RAM are deleted.
The digital speed and the command torque values are set to zero.
The LED signal for the state ‘OK’ is dark.

Firmware download only when the power supply is switched off!

The auxiliary voltage and/or power supply voltage must only be switched when the BAMOCAR is
disabled.
No disable.
Enable input X1:G = zero

33 BAMOCAR D3

Electrical installation

Motor power connection

4.9 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 the
manufacturer prior to any use.

Sequence of connection

Cable

M1

M2

M3

Motor cable

3 cores + protective conductor
single-shielded, for 1000V=
shield capacity 150pF/m
min. cross-section see table

Motor phase

U V W Connecting bolt

XB:2

XB:3

XB:4

Only one correct connecting sequence is possible!

Min. cable cross-section

Type BAMOBIL D3-xx

-125

-200

Motor choke,

only necessary for shield capacities
superior to >5nF.

motor cable approx. 25m

Cross-section mm²

25

35

AWG

2 1

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 inlet.
Surface-to-surface connection as short as possible to the motor side.

For long motor cables the motor cable shield must be connected at
multiple times with the vehicle or machine frame (e.g. ground terminals
every 5m).

4-16 ED-BAC-Motor-2

Control connections

BAMOCAR D3 34

Digital inputs

5 Control connections

5.1 Digital inputs

Input voltage

Level ON

+10 to
+30V

Level OFF

<+6V

Input current Max. 7,5 mA

Nominal

voltage/current

+24V/6mA
Ground reference

GNDE

(X1:K)

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 disabled
(2nd disable channel).
The drive is free of torque (no holding torque).

The remaining four digital inputs can be programmed.
The inputs LMT1 (X1:E) and LMT2 (X1:F) are preferably to be used as inputs of the output stage
switch.

Input

Connector

Function

State

FRG/RUN

X1:G

Enable

fixed

RFE

X1:T

Rotating field enable

fixed

END1/LMT1

X1:E

Output stage switch 1 /
digital input

programmable

END2/LMT2

X1:F

Output stage switch 2 /
digital input

programmable
DIN1

X1:L

Digital input 1

programmable

DIN2

X1:M

Digital input 2

programmable

The enable (FRG X1:G) must not be initiated before the auxiliary voltage (12-24V)
and the power voltage have been switched on. Error message 5(POWERVOLTAGE).

External power supply for the inputs and outputs

5-2 ED-BAC-Logic-2

+12/24

GNDE

Logik­Spannung

+12/24V
Logic-

ground

X1:K

X1:D

Logic­voltage

Logik­Masse

GNDE logic ground

X1:E END1/LMT1
X1:F END2/LMT2
X1:G FRG/RUN
X1:L DIN1
X1:M DIN2

VCC

PAx

3k9

470

100nF

100nF

X1:T RFE

Digital Input

Limit switch 1
Limit switch 2
Enable
Digital Input1
Digital Input2
Rotation Enable

Digital

10...30V=

Input

round connector

+12 – 24V for logic and

auxiliary voltage

5-1 E-BAC-DIN-2

35 BAMOCAR D3

Control connections

Safety input RFE (Rotating field enable)

5.2 Safety input RFE (Rotating field enable)

Stop class 0

Warning:

If the inputs 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
the BAMOCAR, the battery motor controller must be
completely disconnected from the mains power supply of the

battery.

Operation with an RFE input

5-3 E-BAC-REF1-2

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

- there is no RFE signal in the 2nd disable

channel to disable the PWM pulses at

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 +12/+24V.
Enable FRG/RUN at least 0.5s after the RFE
signal.

U

T

S

R

P

O

N

M

L

K

J

H

G

F

E

D

C

B

A

CNC/SPS

FRG / RUN

RFE

+12/24V=

GND12/24

X1

GNDE

GND12/24

+12/24V=

+12/24

GND12

12/24V-Voltage

Hardware
Enable

Enable

Enable

Logic-GNDE

Rotating

PNOZ

Safety
Device

Hardware

round connector

CNC/SPS

FRG / RUN

RFE

X1

GNDE

U

T

S

R

P

O

N

M

L

K

J

H

G

F

E

D

C

B

A

+12/24V=

GND12/24

GND12/24

Hardware
Enable

Enable

Enable

Logic-GNDE

PNOZ

Safety
Device

Hardware

Logic-voltage

round connector

Rotating

CNC/SPS

FRG / RUN

RFE

X1

GNDE

+12/24

GND12/24

+12/+24

U

T

S

R

P

O

N

M

L

K

J

H

G

F

E

D

C

B

A

+12/24V=

GND12/24

Hardware
Enable

Enable

Enable

Logic-GNDE

GND12/24

Hardware

12/24V-Voltage

round connector

Rotating

5-4 E-BAC-RFE2-2
5-5 E-BAC-RFE-4-2

Control connections

BAMOCAR D3 36

Digital outputs (open emitter)

5.3 Digital outputs (open emitter)

5-6 E-BAC-DOUT-2

Output voltage

Level ON

+12 to +24V=

Level OFF

<1V=

Output current

nom

1A

Output current

max.

2A,1s

Voltage reference

+24

(X1:D)

Ground reference

GNDE

(X1:C)
Output

Connector

Function

State

Parameter

BTB/RDY

X1:A, X1:B

ready for operation

fixed /solid state relay

DOUT1

X1:N

Digital output 1

programmable

DOUT2

X1:O

Digital output 2

programmable

DOUT3

X1:S

Digital output 3

programmable

DOUT4

X11

Brake (option) 4

programmable

Note:
The auxiliary voltage is also the supply voltage for the logic outputs.

5-7 ED-BAC-Logic-2

+12 to + 24V for logic and auxiliary voltage
Always pay attention to the total current of all
outputs

GNDE logic ground

Signal contact "Ready BTB/RDY" (Solid state relay)

Contact for

max. 48V/0,5A

(not short-circuit proof)

Capacitive load

max. 1 mF

Contact resistor

max. 2 Ohm

The contact is closed

when the device is ready
for operation.

Always install the
BTB/RDY contact in the
safety circuit!
Install a fuse 0.5Af to secure the
BTB/RDY signal path!

In case of failures the contact is open.

(Option)7segment-LED ‘state’ display

Ready BTB opens (open BTB relay contact, (option red LED))

in case of error messages
BTB with or without under-voltage monitoring (BTB-Power).
The message "under-voltage in the bus circuit" can be programmed (see Manual NDrive-x)

X1:N DOUT1
X1:O DOUT2

+24

F_AUSx

100nF

24V/1A

X1:S DOUT3

Digital Output

Digital Output1
Digital Output2
Digital Output3

Digital

24V/1A

Output

round connector

+12/24

GNDE

Logik­Spannung

+12/24V
Logic-

ground

X1:K

X1:D

Logic­voltage

Logik­Masse

BTB/RDY Solid State Relais

F_BTB

100nF

X1:A

X1:B

Sicherheits
Kreis

Rundstecker

round connector

Safety
circuit

5-8 ED-BAC-BTB-2

37 BAMOCAR D3

Control connections

Analog input +/- 10V

5.4 Analog input +/- 10V

5-9 ED-BAC-AIN-2

Input

Connector

Basic function

Voltage

State

Parameter

AIN1+, AIN1-

X1:H, X1:J

Speed command value

+/- 10V

prog.

AIN2+, AIN2-

X1:P, X1:R

Current limit

+/- 10V

prog.

Features

Differential input

AIN1+ / AIN1-

AIN2+ / AIN2-

Input resistance

70kΩ

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. (See NDrive-x)

The analog inputs can be assigned to different functions. (See NDrive-x)

With a digital command value (RS232, x-bus) the analog input AIN1 can be programmed as
external analog speed limit and the analog input AIN2 can be programmed as external analog
current limit. (See NDrive-x)

Sollx

REF150

10k 100k

100k 100nF

15k

10k 100k

15k

IN+

IN-

analoge

Spannung

+/- 10V

BAMOCAR

1.5V +/- 1.36V

Analog Input

Control connections

BAMOCAR D3 38

Serial interface RS 232

5.5 Serial interface RS 232

The device is programmed and operated during commissioning via the serial pc interface RS232.
There is a software description in the Manual DS NDrive.

5-10 ED-BAC-RS232-2

The serial interface is galvanically connected
with the device zero (GND/AGND).

The controller (D-plug 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

BAMOCAR

Connector X10
1
2
3
4
5
6

RS232
P/D (CTS) R2IN
TxD
V+ (RTS)
V+ (DTR)
RxD
GND

PE am Steckergehäuse

5

2

3

T2OU

4

1
R2IN

6

RS232

RxD

TxD23

5GND

Stecker
am

PC

RxD

TxD

PE on the connector housing

Connector PC

Rundstecker

round connector

39 BAMOCAR D3

Control connections

CAN-BUS

5.6 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 NDrive and -CAN Manual.

The BUS interface is galvanically
isolated from the internal device
voltage.

The voltage is supplied via an internal,
isolated DC-DC converter.

CAN BUS cable

Use a shielded bus conductor with a low shielding capacity.
Signal plus GND (+internal supply DC/DC converter, galvanically isolated)
Circular connector M12-5p / LiYCY 4x0.25+shield

X9 Option X9.1

View on device side At the connector - view on the soldered crimp side

Terminating resistor at both ends of the bus line > 120Ohm between the CAN-H and CAN-L.

Designation

Connector no.

X9 / X9.1

CAN-BUS

Cable colour

PE 1 green-white

CAN-V+

2

brown

CAN-GND

3

white

CAN-H

4

green

CAN-L

5

yellow

2
CAN-V+

4
CANH

5
CANL

3
CANGND

CAN-BUS

CAN-V+

CANH

CANL

CANGND

CAN-VCC

CANGND

VCC

GND

DC

DC

1

PE on the connector housing

Rundstecker

round connector

PE am Steckergehäuse

5-11 ED-BAC-CAN-2

Control connections

BAMOCAR D3 40

Resolver connection

5.7 Resolver connection

Only with BAMOCAR 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.

Connector X2

Encoder connector resolver

A

B

C

SIN1

D

E

COS2

F

G

REF2 H Temperature signal

J K

REF1

L

Temperature GND

M

COS1

N

O

SIN2

P

Only use motors with a 2-, 4-, 6-, or 8-pole resolver which have been approved by the
manufacturer. Observe the motor specific connection data sheet (RS)!

Connector

X7

Connecting cable
4 x 2 cores, twisted in pairs and shielded, additional overall shield.
For link chains use appropriate cables!

Min. cross-section 0.25 mm

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 connector

connect the overall shield to the
connector housing

Setting parameters

see software Manual NDrive

AD2S

REF1

REF2

K

G

C

O

M

E

COS2

COS1

SIN1

SIN2

REF1

REF2

10nF

10nF

2x2u2

2x2u2

100nF

47

47

Stecker X7

PE am Steckergehäuse

TEMP

Motor-Stecker
Resolver

H

L

Motor
Temperatur

REF1

REF2

SIN1

SIN2

COS1

COS2

R1

R2

S2

S4

S1

S3

PE am Steckergehäuse

Rundstecker

4k7

VCC +5V

PE on the connector housing

PE on the connector housing

Motor

Temperature

Motor-Connector

Connector x7

round connector

5-12 ED-BAC-Reso-2

41 BAMOCAR D3

Control connections

Encoder connection TTL

5.8 Encoder connection TTL

Only with BAMOCAR D3-IN

TTL incremental encoder (encoder) with 2

counter tracks and 1 zero track plus 3 rotor
position tracks. Counter tracks with or without
push-pull output.

(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 servo­drive

.

ConnectorX7

Encoder connector INC

A

Channel A

B

Channel /N

C

Channel B

D

Supply +5V

E

Channel N

F

Channel /B

G

Channel /A

H

Temperature signal

J

Temperature GND

K

Rotor position 3

L

Supply GND

M

Rotor position 2

N

O

Rotor position 1

P

Only use motors with TTL incremental encoders which have been approved by the manufacturer.
Observe the motor specific connection data sheet (IN)!

Connector

X7

Connecting cable

10 shielded signal conductors

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

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

PE am Steckergehäuse

Temperatur

Motor

PE am Steckergehäuse

J

H

TEMP

Motor-Stecker

Stecker X7

TMS

Encoder

D
VCC +5V

AA

G

A

CB

F

B

EN

B

N

O

ROTOR1

M

ROTOR2

K

ROTOR3

TEMP

L

VCC +5V

GND

GND

4k7

VCC +5V

PE on the connector housing

PE on the connector housing

Motor-Connector

Motor
Temperature

Connector x7

Rundstecker
round connector

5-13 EC-BAC-end-2

Control connections

BAMOCAR D3 42

Encoder connection TTL

Adapter for INC encoder with A, B, N channel without push-pull signals

The device input for the incremental counter signals
requires the push-pull counter pulses for a reliable
detection.
Encoders without push-pull signals (e.g. position
encoders) with different supply voltages are used for
many simple applications. For these applications the INC
adapter must be installed.
The adapter converts the counter signals A, B, N to he
push-pull signals A, /A, B, /B, N, /N.

For supply voltages which differ from 5V the voltage
must be specified on order and externally be connected.

Checking the correct connection

Rotor sequence

The correct sequence of
the rotor signals with a
motor turning clockwise is
1, 3, 2, 6, 4, 5.

If the sequence of
numbers is different the
encoder connection of the
rotor position signals
Rotor1, Rotor2, Rotor3
(U,V,W ) is not correct.

Use the connection
diagram!

Numerical value

Turn motor clockwise for one revolution without
enable.
One motor revolution corresponds to a position value
of Num 65536. In case of different results the input of
Feedback Inc-Mot (0xa6) is incorrect.

Zero angle

Motor turning clockwise and anti-clockwise at 10%­100% speed.
The value of zero-capture must remain constant.

turning clockwise

43 BAMOCAR D3

Control connections

SIN COS 1Vss connection

5.9 SIN COS 1Vss connection

Only with BAMOCAR D3-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 servo­drive.

The resolution is automatically set to an
optimum.

Connector X7

Encoder connector SIN/COS

A

Channel ka+

B

Channel kr+

C

Channel kb+

D

Supply +5V

E

Channel kr+

F

Channel kb-

G

Channel ka-

H

Temperatur signal

J

Temperatur GND

K

Channel kd-

L

Supply GND

M

Channel kc+

N

Channel kd+

O

Channel kc-

P

Only use motors with SIN/COS encoders (SC) which have been approved by the manufacturer.
Observe the motor specific connection data sheet (SC)!

Connector

X7

Connecting cable

2x2 signal conductors, twisted and
shielded

min. cross-section 0.14 mm

3x2 signal conductors, twisted and
shielded

min. cross-section 0.14 mm
2x supply lines, 2x temp

min. cross-section 0.5 mm

Cable type

(4x(2x0.14)+(4x0.14)C+4x0.5)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

Setting parameters

see software Manual NDrive

PE am Steckergehäuse

Temperatur

Motor

100nF

PE am Steckergehäuse

J

H

T-Motor

Motor-Stecker

Stecker X7

TMS

SIN/COS 1Vss

D VCC +5V

Aka+

Gka-

TEMP

120

Ckb+

Fkb-

120

Bkr+

Ekr-

120

Mkc+

Okc-

1000

Nkd+

Kkd-

1000

4k7

VCC +5V

GND

L

VCC +5V

GND

GND

SF1
SF0
Faktor

PE on the connector housing

PE on the connector housing

Motor-Connector

Motor

Temperature

Connector x7

Rundstecker
round connector

5-14 ED-BAC-SC-2

Control connections

BAMOCAR D3 44

Rotor position encoder - connection via a bl-tacho

5.10 Rotor position encoder - connection via a bl-tacho

Only with BAMOCAR D3-bl

3 rotor position encoder signals (Hall

sensors) for the commutation; with or
without a brushless tacho.

The rotor position encoder is galvanically
connected with the device zero (GND).
The voltage of 15V is supplied by the servo­drive.

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.

Connector X7

Encoder connector bl

A

MP-Tacho

B

C

Tacho 1

D

Supply +15V

E

Tacho 2

F

G

Tacho 3

H

Temp signal

J

Temp GND

K

Rotor position 3

L

Supply GND

M

Rotor position 2

N O

Rotor position 1

P

Only use motors with rotor position encoders (bl) which have been approved by the

manufacturer.

Observe the motor specific connection data sheet (bl)!

Connector

X7

Connecting cable
12x signal conductors, supply lines,
temp.

min. cross-section 0.25 mm
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 parameters

see software Manual NDrive

OROTOR1

MROTOR2

KROTOR3

L

PE am Steckergehäuse

Temperatur

Motor

100nF

J

H

T-Motor

Motor-Stecker

Stecker X7

TMS

D VCC +5V

CTR+

AT Mp

TEMP

100k

ETS+

A

100k

GTT+

A

100k

GND

+15V

GND

82k

82k

82k

82k

82k

82k

Tacho R

Tacho S

Tacho T

4k7

4k7

4k7

22k

22k

22k

4k7

Rotor U1

Rotor U2

Rotor U3

GND

VCC +5V

+15V

Rv

Rv

Rv

Rv

Rv

Rv

TR+

TR-

TS+

TS-

TT+

TT-

Adapter

Anpass-

13

14

15

6

5

12

10

2

1

3

9

4

11

PE on the connector housing

PE on the connector housing

Fitting­adapter

Motor-Connector Rotor + bl-Tacho

Motor
Temperature

Connector x7

Rundstecker

PE am Steckergehäuse

round connector

5-15 ED-BAC-bl-2

45 BAMOCAR D3

Control connections

Option - State displays

5.11 Option - State displays

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 BAMOCAR states

Display

Point/segment

State

State of NDrive

flashing

dark

Processor active

Auxiliary voltage missing or inherent hardware failure

flashing

bright

dark

Starting state after reset (auxil. voltage 24V off-on).

The first enable stops the flashing display.
Drive enable

Drive disabled (not enabled)

OK = 0

OK = 1, ENA = 1

OK = 1, ENA = 0

bright

Speed zero (standstill signal)

N0 = 1

bright

Drive revolves clockwise, N currently positive

N0 = 0

bright

Drive revolves anti-clockwise, N currently negative

N0 = 0

flashing

bright
dark

Motor current reduced to continuous current Icns

Motor current at max. current limit I

max

Normal operation; Motor current within the current

limits

Icns = 1

Icns = 0
Icns = 0

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

Control connections

BAMOCAR D3 46

Option - Error displays

5.12 Option - Error displays

The red LED "fault" is bright and the fault no. is indicated by the green seven-segment display.

List of errors

Error display

Description

Display

Address

NOREPLY-No RS

RS232 interface not plugged or disturbed

REGID 0x8f

BADPARAS

Damaged parameter

0

Bit 0

POWER FAULT

Output stage error

1

Bit 1

RFE FAULT

Safety circuit fault (only active with RUN)

2

Bit 2

BUS TIMEOUT

Transmission fault BUS

3

Bit 3

FEEDBACK

Encoder signal faulty

4

Bit 4

POWERVOLTAGE

Encoder signal faulty

5

Bit 5

MOTORTEMP

Motor temperature too high

6

Bit 6

DEVICETEMP

Device temperature too high

7

Bit 7

OVERVOLTAGE

Overvoltage >1.8 x UN

8

Bit 8

I_PEAK

Over-current 300%

9

Bit 9

RACEAWAY

Drive races
(without command value, wrong direction)

A

Bit 10
USER

User - choice of error

B

Bit 11

I2R

Overload

C

Bit 12

RESERVE

D Bit 13

HW_FAIL

Firmware is not compatible with the hardware

E

Bit 14

BALLAST (device­dependent)

Ballast circuit overloaded

F

Bit 15

Note: With BAMOCAR the error F (BALLAST) has no function.

Fault

Example:

POWERVOLTAGE

(missing power voltage)

FAULT LED red

Error no. 5

Note:

When applying the auxiliary voltage with the enable closed (FRG/RUN X1:7 active) the red LED
signals an error. There is no error signal displayed in the 7-segment display.

47 BAMOCAR D3

Control connections

Option - Warning signals

5.13 Option - Warning signals

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

Error display

Description

Address

REGID 0x8f

WARNING_0

No device identification

0

Bit 16

ILLEGAL STATUS

RUN signal, EMI

1

Bit 17

WARNING_2

RFE signal inactive, (without RUN)

2

Bit 18

3

Bit 19

4

Bit 20

POWERVOLTAGE

Power voltage too small or missing

5

Bit 21

MOTORTEMP

Motor temperature >87 %

6

Bit 22

DEVICETEMP

Device temperature > 87%

7

Bit 23

OVERVOLTAGE

Overvoltage >1.5 x UN

8

Bit 24

I_PEAK

Overcurrent 200 %

9

Bit 25

A

Bit 26

B

Bit 27

I2R

Overload >87%

C

Bit 28

D

Bit 29

E

Bit 30

BALLAST (device­dependent)

Ballast circuit >87% overloaded

F

Bit 31

Note: With BAMOCAR the warning F (BALLAST) has no function.

Fault

Example:

flashing red,
The display swaps between the state and the warning no.,

Warning no. 5

Measured data

BAMOCAR D3 48

Bus circuit battery voltage

6 Measured data

6.1 Bus circuit battery voltage

from firmware FW450

Bus circuit dc bus voltages, battery voltage (400V)

BAMOCAR D3-400

Bus circuit voltage

Parameter 0xeb

Max. voltage

460V

25158

Battery voltage

370V

20211

Overvoltage switch-off

440V

24059

Charging voltage

340V

18561

without power voltage

0V

0

Scaling 1 54,971

Tolerance +/-2%

Parameter 0xeb = 54.971 x bus circuit voltage (tolerance +/-2%)

Bus circuit dc bus voltages, battery voltage (700V)

BAMOCAR D3-700

Bus circuit voltage

Parameter 0xeb

Max. voltage

800V

24045

Battery voltage

700V

20883

Overvoltage switch-off

780V

23413

Charging voltage

680V

20250

without power voltage

0V

0

Scaling 1 31,499

Tolerance +/-2%

Parameter 0xeb = 31.499 x bus circuit voltage (tolerance +/-2%)

Current - actual value

BAMOCAR-D3

I 100%

Calibration rated current

I-device

Peak current

DC blocked

Max. value +/- 11Bit

mV

Num

Aeff

A=pk

Num

A=pk

250/150

520

350

125

176

506

250

400/250

785

560

200

282

808

400

In the set of parameters the basic set-up data are protected.

49 BAMOCAR D3

Bus circuit dc bus voltages (battery voltage)

Bus circuit dc / bus voltages

7 Bus circuit dc bus voltages (battery voltage)

7.1 Bus circuit dc / bus voltages

DC bus voltage , battery voltage

Measuring tolerance +/-2%
Note: For dc bus voltages <50V (at 400V) or < 100V ( at 700V) the measured values are

not linear!

Settings for BAMOCAR 400/400

DC bus max (0xa5H)

for threshold voltage

Num 0xeb

Note

72%

440V =

24059

66%

400V =

21860

DC bus min (0xa5L)

for undervoltage

52%

320V

17462

44 %

270V

14713

Settings for BAMOCAR 700/400

DC bus max (0xa5H)

for threshold voltage

Num 0xeb

Note

83%

750V =

23496 =

78%

700V =

21921 =

DC bus min (0xa5L)

for undervoltage

63%

600V =

18771=

52%

500V =

15621=

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

20000

22000

24000

26000

28000

0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900

BAMOCAR-D3-400

BAMOCAR-D3-700

Display 0xeb

Output stage temperature

BAMOCAR D3 50

Output stage temperatur

8 Output stage temperature

8.1 Output stage temperatur

IGBT – Module temperature

Parameter 0x4a

+80o C

24000 (FW>450)

IGBT temperature

Indoor air temperature

Indoor air temperature

Parameter 0x4b

+45o C

13000 (FW>450)

14000

15000

16000

17000

18000

19000

20000

21000

22000

23000

24000

25000

26000

27000

-10 0 10 20 30 40 50 60 70 80 90 100

Tigbt.BaC1.NT
C-infin

9000

10000

11000

12000

13000

14000

15000

16000

-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

BAMOCAR-D3

Display 0x4a

Display 0x4b

51 BAMOCAR D3

Warranty

Warranty

9 Warranty

9.1 Warranty

UNITEK warranties that the device is free from material and production defects. Test results are

recorded and archived with the serial number.

The warranty time begins from the time the device is shipped, and lasts two years.

UNITEK undertakes no warranties for devices which have been modified for special applications.

During the warranty period, UNITEK will, at its option, either repair or replace products that prove
to be defective, this includes guaranteed functional attributes. UNITEK specifically disclaims the
implied warranties or merchantability and fitness for a particular purpose. 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 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