Unitek BAMOCAR-PG-D3-700-100/160 User manual

M A N U A L
Digital Battery Servo Amplifier
BAMOCAR-PG-D3-700-100/160
for EC servo motors
for EC asynchronous servo motors
Hans-Paul-Kaysser-Straße 1
Version
71397 Leutenbach-Nellmersbach
2021 / V1
Tel.: 07195 / 92 83 - 0
[e-mail]
www.unitek.eu

Basis - Informationen
Version: 2021 / V1
Page: 1
BAMOCAR-PG-D3-700-100/160
Contents
1. Basis - Informationen.................................................................................................................3
1.1 History .......................................................................................................................................... 3
1.2 Further UNITEK products.............................................................................................................. 3
1.3 Engineering instructions (MANUAL)............................................................................................. 3
1.4 Validity.......................................................................................................................................... 4
1.5 Designations and symbols............................................................................................................ 4
1.6 General product information ....................................................................................................... 5
1.7 Application/build/features........................................................................................................... 6
1.8 Safety regulations......................................................................................................................... 8
1.9 Commissioning ........................................................................................................................... 10
1.10 Safety advices............................................................................................................................. 11
1.11 Intended applications................................................................................................................. 12
1.12 Regulations and guidelines......................................................................................................... 13
1.13 Risks............................................................................................................................................ 14
1.14 Technische Daten ....................................................................................................................... 15
2Mechanical installation ............................................................................................................ 18
2.1 Important ................................................................................................................................... 18
2.2 Dimensions BAMOCAR-PG-D3-700-100/160 ............................................................................ 19
2.3 Dimensions optional cooling contact plate................................................................................ 21
2.4 Dimensions - optional air cooling unit ....................................................................................... 21
3Electrical installation................................................................................................................ 22
3.1 Important advices....................................................................................................................... 22
3.2 Circuit diagramm........................................................................................................................ 23
3.3 Connection diagramm................................................................................................................ 25
3.4 EMV ............................................................................................................................................ 26
3.5 Connectors ................................................................................................................................. 28
3.6 Hilfsspannungsanschluss............................................................................................................ 29
3.7 Power connections..................................................................................................................... 30
3.8 Battery connection..................................................................................................................... 31
3.9 Motor power connection ........................................................................................................... 32
4Control connections................................................................................................................. 33
4.1 Digital inputs............................................................................................................................... 33
4.2 Safety input RFE (Rotating field enable) Stopp class 0............................................................... 34
4.3 Digital outputs (open-emitter)................................................................................................... 36
4.4 Signal contact Ready (Solid State Relay) / Ready BTB / RDY..................................................... 37
4.5 Analoge inputs ± 10 V................................................................................................................. 38
4.6 Analoger Ausgang ±10 V............................................................................................................. 38

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4.7 Serial interface RS 232................................................................................................................ 39
4.8 CAN-BUS..................................................................................................................................... 40
4.9 Resolver connection................................................................................................................... 41
4.10 Encoder connection TTL ............................................................................................................. 42
4.11 SIN COS 1VSS Anschluss............................................................................................................... 44
4.12 Rotorlagegeber Anschluss mit BL-Tacho.................................................................................... 45
5State display............................................................................................................................ 46
5.1 Display of the BAMOCAR states................................................................................................. 46
5.2 State information - error............................................................................................................ 47
5.3 Statusinformation - Warnungen ................................................................................................ 48
6Measured values...................................................................................................................... 49
6.1 DC link DC BUS voltage, battery voltage (700 V)........................................................................ 49
6.2 Endstufen –Temperatur............................................................................................................ 50
7Warranty................................................................................................................................. 51

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1. Basis - Informationen
1.1 History
Version
Modifications
Date
2020 / V1
Numbering Table of contents + layout changed
1. April 2020
2020 / V2
Chapter 2.2, Table liquid cooler adapted
10. Sept. 2020
2020 / V3
Page 31 "Parallel Plus-Minus Cable" added
18. Nov. 2020
2021 / V1
Page 28 “RS232” names redefined
10. June 2021
1.2 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
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
1.3 Engineering instructions (MANUAL)
1.
MANUAL
BAMOCAR-PG-D3-700-100/160
Hardware
2.
MANUAL
NDrive x
Software
3.
MANUAL
Commissioning
Commissioning - error detect.
Use all three MANUALS for the engineering, the installation and the commissioning!
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.

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1.4 Validity
Hardware state:
TMS 2-3d, mBAMOCAR1-1
Firmware state:
ab FW 476
1.5 Designations and symbols
Unit:
BAMOCAR-PG-D3-700-100/160
User:
Vehicles, boats, 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/included in the packaging:
-BAMOCAR-PG-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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1.6 General product information
The digital 3-phase current servo amplifiers BAMOCAR-PG-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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1.7 Application/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 (option IP69K)
-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~eff, 80 A~eff
-power input range nom. 12..700 V=
-liquid cooling (special version air cooling)
-standard digital control electronics
-Independent 12..24 V chopper power supply unit for the auxiliary 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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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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1.8 Safety regulations
In principle electronic equipment is not fault proof!
Caution - High voltage
DC > 800 V=
Shock hazard! / Danger to life!
Discharge time of the bus circuit > 4 min.
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 BAMOCAR-D3-700-100/160 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 (Option IP69K)
Connection only to batteries!
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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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!
During operation, the device must be closed.
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 de-
activated, 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