Unitek BAMOCAR-D3-700-100, BAMOCAR-D3-700-160 User Manual
M A N U A L
Hans-Paul-Kaysser-Straße 1
Edition / Version
71397 Leutenbach-Nellmersbach
2019 - V05
Tel.: 07195 / 92 83 - 0
Fax: 07195 / 92 83 - 129
contact@unitek.eu
www.unitek.eu
Digital Battery Servo Amplifier
BAMOCAR-D3-700-100/160
for EC servo motors
for AC asynchronous servo motors
Basic information
1
Version: 2019 / V05
BAMOCAR-D3-700-100/160
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-D3-700-100/160 ....................................................................... 19
3.3 Dimensions -Optional cooling contact plate .................................................................... 20
3.4 Dimensions - optional air cooling unit ............................................................................. 20
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 The connectors are not included in the delivery scope. ............................. 28
4.6 Auxiliary voltage connection ............................................................................................ 29
4.7 Power connections .......................................................................................................... 30
4.8 Battery connection ........................................................................................................... 31
4.9 Motor power connection ................................................................................................. 32
5 Control connections ....................................................................................................... 33
5.1 Digital inputs .................................................................................................................... 33
5.2 Safety input RFE (Rotating field enable) Stop class 0 ....................................................... 34
5.3 Digital outputs (open emitter) ......................................................................................... 35
5.4 Signal contact "Ready BTB/RDY" (Solid state relay) ......................................................... 36
5.5 Analog inputs ± 10 V ......................................................................................................... 37
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5.6 Analog outputs ±10 V ....................................................................................................... 37
5.7 Serial interface RS 232 ...................................................................................................... 38
5.8 CAN-BUS ........................................................................................................................... 39
5.9 Resolver connection ......................................................................................................... 40
5.10 Encoder connection TTL ................................................................................................... 41
5.11 SIN COS 1Vss connection .................................................................................................. 43
5.12 Rotor position encoder - connection via a bl-tacho ......................................................... 44
6 State display ................................................................................................................... 45
6.1 State display ..................................................................................................................... 45
6.2 State information - error .................................................................................................. 46
6.3 State information - warning signals ................................................................................. 47
7 Measured data ............................................................................................................... 48
7.1 DC bus circuit voltages, battery voltage ........................................................................... 48
7.2 Power-stage temperature ................................................................................................ 49
7.3 Current - value .................................................................................................................. 49
8 Warranty ........................................................................................................................ 50
8.1 Warranty .......................................................................................................................... 50
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History
Version
Modifications
Date
04/2019 - V1
Revised version
31.March 2019
2019 / V02
Additional cooler / base plate 9.5 mm / power loss
18. June 2019
2019 / V03
Chapter 7 / Measurements / Graphs and Tables
03. July 2019
2019 / V04
Chapter 2.14 / continuous power / peak power
16. July 2019
2019 / V05
All 12 V auxiliary voltage references removed
09. Sep 2019
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
Series BAMOBIL-D3
Analog three-phase servo amplifier (mains
400V~)
UNITEK
Series TVD
For dc motors
Analog DC servo amplifier for battery operation
Series BAMOBIL-A
Analog DC servo amplifier (operation via the
mains)
UNITEK
Series TV
Thyristor current converter 1Q, 4Q, servo
UNITEK
Classic series
200 W to 800 kW
1.
MANUAL
BAMOCAR
Hardware
2.
MANUAL
NDrive x
Software
3.
MANUAL
Commissioning
Commissioning - error detect.
2 Basic information
2.1 History
2.2 Further UNITEK products
2.3 Engineering instructions (MANUAL)
Use all three MANUALS for the engineering, the installation and the commissioning!
CD (UNITEK-DOKU-SOFT) supplied with the delivery of the units.
Download: www.unitek.eu
The hardware MANUAL comprises warning and safety advices, explanations of standards,
mechanical and electrical installation advices.
The MANUAL must be available for all persons who are concerned with the unit.
Basic information
BAMOCAR-D3-700-100/160
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4
Validity
Hardware state:
TMS 2-3d, mBAMOCAR1-1
Firmware state:
as from FW 476
Vehicles, boats, manufacturers or operators of machines or installations in
the industrial sector (B2B, secondary environment).
2.4 Validity
2.5 Designations and symbols
Unit: BAMOCAR-D3-700-100/160
User:
Manufacturer: UNITEK Industrie Elektronik GmbH
Dealer:
Caution – Danger to life!
High voltage!
Warning!
Important!
Dangerous electric fields!
Scope of delivery/included in the packaging:
- BAMOCAR-D3-700-100/160
- documentation
- CD UNITEK DOKU-SOFT
Not included/Cannot be ordered from UNITEK:
Accessory connectors and cable glands.
35-pin connector type: Typo 776164-1
14-pin connector type: Typo 776273-1
Cable gland: M25x1.5
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General product information
2.6 General product information
The digital 3-phase current servo amplifiers BAMOCAR-D3-700-100/160 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-D3-700-100/160 can be used as position amplifier or torque or speed amplifier.
The speed actual value is generated in the encoder unit (resolver or others) or internally generated (without
sensors). 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)
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Applications/build/features
2.7 Applications/build/features
Application in all kinds of vehicles, boats, machines, and installations with a drive power of
100kW 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) 50 A, 80 A
-power input range nom. 12..700 V=
-liquid cooling (special version air cooling)
-standard digital control electronics
-Independent 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
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Applications/build/features
Characteristics:
Battery connection 12 V=.. 700 V= (dc mains, take restrictions into account)
Independent auxiliary voltage connection 24 V= / (12 V variant available on request )
Digital interfaces RS232, CAN BUS (further option)
analogue inputs, programmable differential inputs
Digital inputs/outputs, programmable, optically de-coupled
Linear command value ramp
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.
If the battery is disconnected from the device during the braking
process, high bus circuit voltages might occur.
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.
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.
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Safety regulations
Caution - High voltage
Discharge time of the bus circuit > 4 min.
2.8 Safety regulations
In principle electronic equipment is not fault proof!
DC 800 V=
Shock hazard! / Danger to life!
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
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!
BAMOCAR-D3-700-100/160 are power electric parts used for regulating energy
Operation only allowed when the device is closed!
Control and power connections can carry dangerous voltages
even if the drive is inoperative!
The minimum discharge time of the bus circuits is superior to
4 minutes!
Measure the voltage before any disassembly!
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Safety regulations
The user must ensure that in the event of:
the axis will be safely de-activated.
It must also be ensured that the vehicles, machines, equipment,
movements at any time!
During operation, the device must be closed.
and suitably trained personnel has access to the units.
The user must draw up a hazard analysis for his machine, vehicle, or installation.
- device failure
- incorrect operation,
- loss of regulation or control
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
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
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
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Commissioning
2.9 Commissioning
The battery servo amplifiers BAMOCAR-D3-700-100/160 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.
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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 < 42 V.
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.
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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 with charging current limiting on the battery side. Isolation
watchdogs must be installed for voltages > 60 V.
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 (restrictedly 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
- in explosive environments
- in environments with acrid fumes
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Regulations and guidelines
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
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
ISO 26262
Functional safety of electric vehicles
2011
ECE-R100
Conditions for battery-driven electric vehicles
UL 508 C
UL Regulations - converter
2002
UL 840
UL Regulation - clearance and creepage distances
2005
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
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:
EU standards and regulations observed for the components of the unit
EU standards and regulations which must be observed by the user
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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.
Any designated assembly area must be indicated and labelled accordingly.
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Technical data
24 V = ±10 % / 2 A
( 12 V / 4 A variant only on request)
Over-voltage
switching threshold
Bus circuit capacity
µF
75
total weight 3,5 kg
(empty housing weight 1,6 kg)
Control signals
V A Function
Connector
ON
OFF
10-30
< 6
0.010
0
Transistor output
open emitter
Analog output
±10 Operational amplifier
X1
2.14 Technical data
For three-phase current motors
Data BAMOCAR-D3 Dim. 700-100 700-160
Auxiliary voltage V=
Supply voltage V= 12 to 700
Max. output voltage V~eff 3 x 7 to 3 x 480
Continuous current A~
Continuous power kW 35 50
max. peak current Alo 100 160
max. peak current A~
max. peak power kW 52 75
max. power loss W 400 850
Pulse frequency kHz Programmable 8 - 16
Input fuse A 160 250
Weight kg
Dimensions h x w x d mm 280 x 200 x 90
50 80
eff
71 113
eff
V= Programmable up to 740 V
Residual ripple < 10 % (self-healing fuse)#
Analogue inputs ±10 0.005 Differential input X1
Digital inputs
Digital outputs +24 1
Resolver / TTL / SINCOS Differential input X7
CAN interface Logic IO X1
RS232 interface Logic IO X1
Logic IO X1
X1
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