Unitek BAMO A1 User manual

BAMO
MANUAL
Batterie - Motor-Controller
BAMO A1, A2-x-60 ... 500
for DC-Motors
Ausgabe
1108-1

2
BAMO A1, A2 60-500A
Contents
1 Basical Information Page
Safety Advice 3
General Information 4
Application 4
Construction 4
Technical Data 5
2 Mechanical Installation
Dimensions 60, 120, 240 6
Dimensions 280 7
Dimensions add. Heatsink 60 … 240 8
Dimensions add. Heatsink 280 9
3 Electrical Installation
Connection Overview 10
Power connections 11
Control connections 12
Speed-command value 13
External current limit 14
ready for operation (BTB) indication 15
Analogue maesuring outputs 15
Plug-Clamp Numbers 16
4 Device Overview
Component overview 17
Blockdiagram 18
Adjustment functions 19
5 Adjustment
Adjustment advice 20
Speed - command value 21
Speed - actual value 22
Current limitation 23
Speed controller switching 24
Adjustment without measuring instruments 24
6 Getting Started
Default setup 26
First getting started 27
7 Fault Finding
Functions errors 28
Signals 29
8 Protocol 30
9 Guarantee 31
Contents

1 Basic - Information
BAMO A1, A2 60-500 3
Electronic devices always involve the risk of failure.
This manual has to be read carefully and must be understood by experts before installing
or starting the device.
If there are any doubts call your trader or the manufacturer.
The BAMO series is designed to regulate electrical currents;
protection standard IP00.
Connection only to a battery or galvanic isolated direct voltage. (See Page 10)
Standards and Guidelines:
The device and it’s associated components can only be installed and switched on where
the local laws and technical standards have been strictly adhered to:
EU-Guidelines 89/392/EWG, 84/528/EWG, 86/663/EWG, 72/23/EWG
EN60204, EN50178, EN60439-1, EN60146, EN61800-3
- IEC/UL IEC364, IEC 664, UL508C, UL840
- VDE-regulations VDE100, VDE110, VDE160
- TÜV-regulations
- Regulations of Professional and Occupational bodies: VGB4
The user has to assure that: after
- a failure of the device
- an incorrect handling
- a failure of the control unit etc.
the drive is brought to a secure operating condition.
Machines and installations are to be provided with supervisory and safety equipment,
that is independent of the device.
Adjustment
-only by qualified personnel
- adher to safety regulations
Installation work
-only when disconnected from all power lines.
QS
The devices are archived by the manufacturer with serial number and their test
specifications.
CE
The EU-guide line 89/336/EWG with the Regulations EN61000-2 and EN61000-4 are
observed.
Caution Direct Voltage
DC 160V=
Safety advice

4
BAMO A1, A2 60-500A
General Information
The battery motor controller BAMO-Ax-xx forms together with the low voltage DC-motor a
propulsion unit distingushed by its high control range.
With a DC-motor the current is proportional to the torque and the voltage is proportional
to the speed.
Current and voltage are measured precisely.
The analogue circuits of the servo driveare simply constructed.
The speed actual value is generated from armature voltage or from the
DC-tachogenerator.
The speed and the current controller are disigned as P-I-controller.
In version BAMO-A2 (4Q) the brake energy is refeeded to the battery.
Application
for all kinds of machines or vehicles up to 40kW battery feeded drive power
especially for
- a great controller range
- a high efficiency
- small motor dimensions
- a even and smooth travel
for speed or torque regulation or
combined speed-torque regulation with or without superposed position controller.
For use in
battery powered vehicles like cleaning machines, el. boats,
fork-lift trucks, transport systems,
Solar- or wind powered installations,
and many other battery powered machines and installations.
Construction:
Cubicle-mount unit in IP00 according to the VDE- DIN- and EU- regulations.
Standard analogue regulation electronics.
Power electronics with IGBT-power semiconductors,generous dimensioning.
Characteristics:
* Battery supply or galvanicisolated direct voltage (Notice advice on page 10 !)
* Galvanic isolation between auxiliary voltage and regulation electronics
auxiliary voltage and power stage
regulation electronics and power stage
* Differential command value inputs
* Speed and torque regulation
* Static and dynamic current limit
* Measuringoutputs for speed and current
* Enable logic, quick stop
* Temperature control for motor and device
General Information

1 Basic - Information
BAMO A1, A2 60-500 5
Technical Data
Power Connection
Type BAMO A1, A2 36 - 60 … 360 160 - 60 … 360
Battery voltage 12, 24V 36 up to 160V
Direct voltage bus 12, 24V 36 up to 160V
Output voltage 0.8 x U B max.30V max. 150V
Auxiliary voltage 24V= ±20%, max. 0.5A, waviness <20%
Spezifications
Common specifications
Protection standard IP 00
Device layout VDE 0100 group C
VDE 0160
Humidity stress class F accordig to DIN 40040
no dewing
Set up height < 1000m above NN
Operation range 0 ... 45°C
Extended operation range up to 60°C red. 2%/°C
Bearing range -30°C up to + 80°C
Speed controller
control accuracy without actual value error ± 0,5%
Control range 1: ,000
Temperature observation 80°C
VERSIONS: BAMO A1-xx1 Quadrant-controller propeling in rotation direction
BAMO A2-xx4 Quadrant-controller propeling and breaking in both
rotation directions. Energy rear feed
CAUTION: for battery operation or direct current bus only
(see advice on page 10)
Technical data
Type BAMO A1, A2 -x-60 120 180 280 360
Steady current max. A= 60 120 180 280 360
Peek current max. (5s) A= 100 200 300 400 600
El. power max kW 7.8 15.6 23.4 36.4 46.8
Power dissipation W 300 600 900 1400 1800
External fusing A 80 160 300 500 600
Cooling See cooling advice page 8
Dimensions ( see drawings) Size 2 3
Weight Kg 6 11

6
BAMO A1, A2 60-500A
Dimensions BAMO A1,A2-x-60,120,240
Size 2
Mounting plate or
additional head sink .
(error)
Dimensions

BAMO A1, A2 60-500 7
2 Mechanical installation
Dimensions BAMO A1, A2-x-280, (500)
Size 3
Dimensions
Mounting plate or additional head sink.

8
BAMO A1, A2 60-500A
Additional heat sink type LUKUE - 3,4 (mountig on the BAMO)
Heat sink
Size 2 1x addit. heat sink LUKUE 3 (Weight + 3kg)
Size 3 1x addit. heat sink LUKUE 4
or 2x LUKUE 3 (Weight + 6kg)
Screws M10x110mm

BAMO A1, A2 60-500 9
2 Mechanical installation

10
BAMO A1, A2 60-500A
EnableEnable
Comm.value
potentiometer
PLC-
comm.value
Case
Comm.value±
Speed-act.value
Current-act.value
Current-comm.value
S1 contact 1
BTB
BTB
signal
Current limit
external
Overload-
signal
TERMINAL X3
Enable
Comm.value ±
Battery voltage
Motor connection
Case
Auxiliary voltage 24V=
X2:
X1: BAMO A1, A2
Notice:
Power connection X3:2 (-UB) , X3:10 (+UB)
Connection polarity > no protection against mixing up the contacts
when the connection is wrong the output stage can be
distroyed!
The power connection must not be devided during braking! If nessesary built in
reverse-current-protection-diode D1. On-stage current = device peek current
Connection to Direct voltage bus or Power supply unit
Make sure that the overvoltage in the buffer circuit is limitated to 20% during braking.
Small resistance of the source or ballast circuit.
If the resistance of the motor is very small the fast rising of the buffer voltage circuit can
demage the semi-conductors. In normal case the device is switched to error by the
overvoltage observation.
Auxiliary voltage connection X3:13, X3:14
Safe against mixing up the contacts. The connection can be switched seperated
from the power connection.
Notice the tolerance and the residual ripple of the voltage.
Motor connection X3:4 (M1),X3:8 (M3)
The motor connections can be exchanged.
In case of EMC-problems use chokes and shielded line.
Brakong resistor RB1 and DC-contactor K1 as resistor brake with type A1 or as battery
failure brake with type A2
Control connections see special advices.
Connection overview

BAMO A1, A2 60-500 11
3 Electrical installation
Power Connection
Caution:
The connection advices concerning the individual attachment of the connections to
the plug numbers or terminals are binding.
All further advices to this are not binding.
The input and output lines can be altered or completed in consideration of the
electrical regulations.
Notice:
- connection and operation advices
- local technical regulations
- EU-machine regulation 89/392/EWG,
84/528/EWG, 86/663/EWG
- CE-advice, EMC
Connection lines
Caution : with longer lines >>> use a one step strengther cross section !
Auxiliary voltage 24V=
Battery voltage
DC - motor
D1
brake current-
diode for A2
Connection advice
Caution:
Risk off distruction by
overvoltage in buffer circuit
Using BAMO-A2-36 the batterie
voltage (U B + X3:10 , U B - X3:2)
must be applicated to the device
10s before switching on and 10s after
switching off enable to limitate a
possible occuring brake voltage by
the battery everse current protection
diode D1 against uncontrolled
disconnecting the battery voltage
while braking.
If using a DC-Bus notice advices on
page 10.
Dimensioning at A 60 120 240 280
Battery lines (max. 2m) mm
2
10 35 95 120
Motor lines mm
2
10 35 95 120
Fuse F1 A 89 160 360 500
Auxiliary voltage line mm
2
0.5
Fuse F2 A 2A

12
BAMO A1, A2 60-500A
Control Connection
The connecting advices are for general information and without obligation
Notice:
- Connecting- and operating instructions
- Local regulations
- EU-machine regulation
pin-No. terminal block
X1: 1 up to X1:7 and X2 : 8 up to X2 : 14
Signal lines
- Shielded and seperated from power lines.
- command values paired twisted and shielded.
Logical connections
- Relay with gold contacts or reed relays. Contact current 6mA.
Enable -internal logical voltage
- internal logical voltage X1:1 +15V/10mA
- contact chain between X1:1 and X1:2
Enable -external logical voltage
- enable voltage +10 … +30V X1:2
- GND X1:7
Switch on enable
- command value and speed controller are enabled immediately.
Switch off enable
- command value and speed controller are enabled stop
- command value >>> is switched internally immediately to 0
- after 2 seconds >>> speed controller is locked.
Caution:
Make sure that the battery voltage is connected to the device at least for 10 seconds
after switching off the enable.
Auxiliary voltage connection
- Direct voltage command 24V=
- Operating range 19V up to 54V=
- Rated current 0.5A, inrush current 2A
- Residual ripple <20%
- Fusing 2AF
Caution: when using a switching power supply for auxilary voltage.
Switch on power supply before connecting auxiliary voltage (K2).
Connection

BAMO A1, A2 60-500 13
3 Electrical installation
Command value-speed
voltage source for command values ±10V, 10mA
+10V X1:3
-10V X1:5
GND X1:7
Command value input
- command value input maximum ±10V=
- differential input
- input resistance 50 kW
- relay contacts: gold- or reed contacts
Caution
command value lines paired twisted and shielded. Screen connection one-sided.
Connection:
Command value voltage with internal supply
command value X1:4 (signal)
X1:7 (GND)
bridge X1:6 — X1:7
External command value voltage SPS/CNC
command value X1:4 (signal)
X1:6 (GND)
External command value current SPS/CNC
Resistance for command value current 0 ... ± 20mA >>> R-comm. = 500W
command value current X1:4 (signal)
X1:6 (GND)
Int.supply CNC/PLC Comm.value current
With A1(1Q) only positiove command value
leave out d2 and connection X1:5 is not coated
Caution:
do not use a command value current between 4 and 20mA
Command value

14
BAMO A1, A2 60-500A
External current limitation
voltage source for external current limit
+10V/10mA X1:13
GND X1:7
Current limit input
maximum input voltage +10V
input resistance 10 kW
internal attenuation with potentiometer I max
relay contacts: gold- or reed contacts
switch S1, contact 2 = OFF (see page 17)
Connection
current limit X2:13 (signal)
X1:7 (GND)
Adjustment range
0 … + 5V >>> 0 up to 100% device command current
0 … +10V >>> 0 up to 200% device command current
internal overcurrent control >>> max. 5sec.
Int.supply CNC/PLC Comm.value current
Caution:
case of internal current limit adjustment
switch S1 >>> contact 2 = ON
(see page 19)
Current

BAMO A1, A2 60-500 15
3 Electrical installation
Ready for operation signal BTB
Relay
signal contact X2:12 - X2:13
contact values max. 48V; 0,5A
The ready for operation signal (BTB) shows the CNC/PLC
that the drive is ready for operation.
Switch BTB- signals of several axes in one row.
delay after switching on mains >>> max. 1sec.
Function Indication BTB-Relay
Ready for operation LED bright green Contact closed
Not ready for operation LED glims green Contact open
Error LED bright red Contact open
BTB turns off with Error is
Overtemperature not stored
Overvoltage stored
Short, Line-to-earth-fault stored
Voltage error not stored
To reset store switch off/on enable
Caution:
Use BTB-contact always with CNC/PLC - control
or with emergency-stop circuit !
Self-starting possible!
Fault memory is not effective with all faults !
“Blocked” Indication
Current demand Outpu X2:14
Normal > +10V
Overload < +2V
Analogue measuring putputs
Function Motor current display Speed display
Connection X2:9 , X1:7 X2:8 , X1:7
Value peek current +5.0V
Value steady current +2.5V
Indications

16
BAMO A1, A2 60-500A
Control connections
Control connections
Function Designation Clamp-Number
Voltage 15V/10mA Enable - supply X1:1
Enable +10 bis +30V= Enable - input X1:2
Voltage +10V/10mA Comm.value - supply + X1:3
command value + Comm.value - input + X1:4
Spannung -10V/10mA Comm.value - supply - X1:5
command value - Comm.value - input - X1:6
GND X1:7
Speed actual value Tacho connection X2:8
Current actual value Measuring output X2:9
Current command value Measuring output X2:10
BTB - contact Ready for operation X2:11
BTB - contact Ready for operation X2:12
Current limit external Current limit input X2:13
Blocked Output X2:14
Power connections
Function Designation Bolt-/Clamp-Number
Battery - -U B X3:2
Motor 1 M1 X3:4
Motor 3 M3 X3:8
Battery + +U B X3:10
Auxilary voltage connection
Clamp-Number
GND-24V X3:13
+24V= X3:14

BAMO A1, A2 60-500 17
4 Device overview
Component overview
Component overview
IxR
P-comp.
INT
U -act.value
Tacho-act.value
plugged at U -act.value
open at Tacho
A
B
Current=P
I internal
X10,X11,X4 only for IN/RS
Indication Function Clamp Function
D1 green ready for operation X1:1 +15V
D2 red Error X1:2 Enable
X1:3 +10V
Trimmer Function X1:4 comm. value + (-)
P5 I
max
X1:5 -10V
P4 I
D
X1:6 comm. value - (+)
P3 X
P
X1:7 GND
P2 n
max
P1 Offset X2:8 n-act. value
X2:9 I-act. value
X2:10 I-comm. value
X2:11-12 BTB- contact
X2:13 Ext.current limit
X2:14 blocked

18
BAMO A1, A2 60-500A
Block Diagram
X3
Enable
Speed controller
Current controller
Current limit
Driver
Driving limit
Contin.current
X2
X1

BAMO A1, A2 60-500 19
4 Device overview
Adjustment functions
Adjustment functions
Function Trimmer Switch Jumper Component
Act.value balance DC-Tacho P2 (n
max
) J1 open R3
Actual value balance
armature voltage control P2 (n
max
)J1 plugged R27
IxR-compentation R8
Internal Current limit P5 (I
max
) S1-2 ON
External Current Limit P5 (I
max
) S1-2 OFF
Steady current P4 (I
D
)
Amplification P-Component P3 (X
P
) R9
Amplification I-Component C4
Integrator R11
Null balance P1 (Offset)
Switch S1
Function Contact ON OFF
Current limit 2 internal external
Current amplification 1 P PI
LED-Indications
Function Colour Shines LED No.
Ready for operation (BTB) green bright D1
Temperature error green glim D1
Error red bright D2
Signal outputs
Function Designation Clamp-number
Speed n-actual value X2:8
Current I-actual value X2:9
Current command value I-comm.value X2:10
blocked +12V/10mA X2:14
Ready for operation -contact BTB/error X2:11 , X2:12

20
BAMO A1, A2 60-500A
Adjustment Advice
Adjustment
- only by qualified personnel
- adhered to safety regulations
- notice adjusting sequence
Presettings Adjust with
Actual value Tacho coarse adjustment R23
Internal/external current limit Switch S1, contact 2
Current regulator P- PI Switch S1, contact 1
Optimization Adjust with
Act.value adjustment n
max
adjustment
Cuirrent controller Switch S1, contact 1 (default setup = ON)
Current limit I
max
, I
D
-adjustment
Speed controller X P -adjustment, variable components
Zero point Offset adjustment
Path-/position controller in CNC\PLC
Caution:
control systems have to be optimized from inside to outside.
Sequence :
Current controller determinated by the load circuit time constants (motor circuit
inductance and motor circuit resistance)
optimized in factory, changing P/PI-amplification with S1
Speed controller determinated by the drive (inertial moment, frictional moment)
optimize to dynamic of the drive
position controller optimize in the contol (CNC\PLC)
Measuring values
Measuring value max.value Measuring point
command value ± 10V X1:4
Speed act.value before divider ± 150V X2:8
Current act.value unipolar + 5V X2:9
Current comm.value unipolar - 10V X2:10
Adjustment Advice