Unitek BAMOCAR-D3 User manual

MANUAL
DigitalBattery-Motor-Controller
BAMOCAR-D3
for
ECServoMotors
ACInductionMotors
DC-ServoMotors

2
BAMOCARD3
Contents
Part1 Hardware
page
1 Basis-information
Safetyinstruction 4,5
General 6
Application 7
Construction 8
Technicaldata 9,10
2 Mmechanicalinstallation
Importantinstructions 11
DimensionBAMOCAR-D3 12,13
Assembly 14
3 Electricalinstallation
Importantinstructions 15
Blockdiagram 16,17
Connectiondiagram 18
EMC 19
Connectors 20-22
Batteryconnection 23
Powersupply,brake 24
Motorconnection 25
Controlsignals 27-30
Schnittstellen 31,32
Resolver 33
EncoderTTL 34
EncoderSINCOS 35
Rotorlagebl 36
Encoderout-in 37,38
LED-monitor 39-41
Options 42
Guarantee 43
part2 Software-manual
part3 Commissioning- manual
part4 Software-reference
part5 CAN-BUSreference
Contens

3
BasicInformation

4
BAMOCARD3
Electronicdevicesareneverfail-safe.
Thismanualmustbecarefullyreadandunderstoodbytheprofessionalpriortoinstallation
orstart-up.
Consultthemanufacturerorthedealerifanythingisunclear.
Faultyinstallationcanleadtodestructionofthedevices.
TheBAMOCAR-Dseriesdevicesareelectricalresources(eb)forpowerelectronics
regulatingelectriccurrents.
Theyaredesignedtocontrolecsynchronousmotors(blushlessdcmotors,bldc)in
industrialapplications.
IP65protectionstandard
Onlyconnecttobattery.
Regulationsandguidelines:
Mountandconnectthedevicesandtheirappropriatecomponentsincompliancewith
technicalregulationslocallyapplicableandrequiredbylaw:
EGguidelines 2004/108/EG,2006/95/EG,2006/42/EG
- EN60204-1,EN292,EN50178,EN60439-1,EN61800-3,ECE-R100
ISO6469,ISO26262,ISO16750,ISO20653,ISO12100
IEC/UL IEC61508,IEC364,ICE664,UL508c,UL840
Deregulations VDE100,VDE110,VDE160and
TÜVregulations
Tradeassociationregulations,.VGB4
Stvzo§§20/21
Controlandpowerconnectionscanbeliveeven
thoughthedriveisinoperative.
Thedc-busdischargetimeismorethan4minutes.
Measurethevoltagepriortodismounting
Safety instractions
Caution:highvoltageDC900V=.
Electricshockhazard!
Dangertopersonnel!
DC-busdischarge-time>4min

TechnicalData
5
Theuserhastoensure:
Thatthedrivewillbeledtoasafeoperatingcondition,
afteranequipmentfailure
-duetomalfunctionofcontrollingorregulatingunit
Machines,equipmentsandvehiclesaretobefurtherprovided
withequipmentindependentmonitoringandsafetydevices.
Un-earthedsystems(forex.vehicles)mustbeprotected
withaninsulationmonitor.
Nodangershallariseforhumansandproperty.
Assembly
-onlyinnon-energizedcondition
-bytrainedpersonnel.
Installationwork
-non-energizedcondition
-onlybytrainedelectricalpersonnel.
Safetyregulations
Observesafety-regulations
Settingup
Settingupandprogramming
-tobedonebytrainedpersonnelwithknowledgeandinelectronicdrivesandsoftware.
-observeprogramminginstructions.
Safetyregulations
Observesafetyregulations.
Installation:
Incaseofnstallationinmachines,equipmentsandvehicles,commissioningtheequipment
fortheintendedpurposeisprohibited,untilithasbeenascertained,thatthemachines,
equipmentsorvehiclescomplywiththeECguidelinesformachines2006/42/EG,theEMC
guidelines2004/108/EGandECE-R100.
TheEG-guideline2004/108/EGwithemcregulationsEN61000-2andEN61000-4
pertainingtoinstallationandtestconditionsmentionedinchapteremcinstructionsare
compliedwith.
Amanufacturer’sclarificationcanberequestedfor.
Complianceoflimitingvalues,laiddownbytheemclegislations,isthesoleresponsibility
ofvehiclemanufacturers,equipmentsormachines.
Qualityassuranceequipmentserialnumbers,alongwithdateoftestingarearchivedby
themanufacturerfor10years.Testprotocolscanberequestedfor.
Safetysymbolsttention:
Dangertolife
Warning:
highvoltage important
Safety instractions

6
BAMOCAR D3
Attention
nformation
General

TechnicalData
7
Applicationin
Machines,equipments,vehiclesofalltypesuptodrivecapacityof140kwespeciallyas
4q-servodrives
-incaseofhighlydynamicaccelerationandbrakingprocesses.
-incaseoflargecontrolareas
-incaseofhighefficiency
-incaseofsmallmotordimensions
-incaseofconstant,silentoperationfor
rpmcontrol,torquecontrolorcombinedtorque-rpmcontrolwithorwithoutsuperimposed
positioncontrol.
Constantspeeddrivesforconveyoroperation,spindledrives,pumps,longitudinaland
transversedrives.
Drivesforsynchronizedoperationofmultiplemotors.
Usedin:
Batteryoperatedvehicleslikeelectricvehicles,electricboats,lift–trucks,transport
systemsaswellasbatteryoperatedmachinesandequipmentslikeautomaticmounting
metalprocessingmachines,x-ytables,grocerymachines,robotsandhandlingsystems,
stackercranesandstoneprocessingmachinesandinmanybatteryoperatedapplications.
ThemotorsandcontrollersareconstructedwithIP65protection,
-compact,
-forharshconditions,
-forhighdynamicoverload,
-maintenancefree.
Observe:
Brakingenergywouldbefedbackintothebattery.
Thebatterymustbeabletoabsorbthebrakingenergy.
Incaseofunearthedsystems(vehicles,it–networks),the
insulationbetweenthepartswhichcomeincontactandHV-
voltagesshouldbemonitoredbyanindependentinsulation
monitoringwatchdog.
Application

8
BAMOCAR D3
Construction:
Compactequipment
Acc.toVDE-DIN-EG-standards.
IP65protectionagainstaccidentalcontactwithpowerconnections.
Powerelectronicsfor(S1operation)125A,200A,(peak250A,400A)
Inputpowerrangenom.12to700V=
Liquidcooling(specialconstructionaircooling)
Unifieddigitalcontrollerelectronics)
Independent12/24VDCchopperpowerunitforauxiliarypower.
Galvanicisolation
-Galvanicisolationbetweenpowerconnector,motorconnectorandallother
controlconnectors
-Galvanicisolationbetweenauxiliaryvoltageandallothervoltages.
-Housingandradiatorassemblyaregalvanicallyisolatedfromallelectricparts.
-TheairandcreepagedistancescomplywithVDE.
-Nointernalinsulationmonitor.Y2capacitorstohousing.
Thefollowingareused:
IGBT–powersemiconductor
- Generouslydimensioned.
- Onlycommerciallyavailablepartsinindustrystandard.
- SMD–mounting
- 7segmentledindicators(option)
Features
*Batteryconnection12v=to700volts=(dcsupply,observelimitations)
*Independentauxiliarysupply24v=or12v=
*DigitalinterfacesRS232,can-bus(additionaloption)
*2analoginputs,programmabledifferentialinputs
*4digitalin-outputs,programmable,opticallyisolated
*Referencevaluerampslinear,nonlinear(s–function)
*Releaseandlimit-switchlogic.
*BTB–operationready,solidstaterelaycontact.
*Position ,rpmandtorquecontrol
*Resolverorencoder–incrementalencoderTTL,SINCOS1Vss,
*Rotorpositon+bltacho.
*Encoderoutputor2.encoderinput.
*Staticanddynamiccurrentlimit
*Unifiedfulldigitalregulatorunit
*Safetyshutdownincaseofovervoltage,undervoltageandovertemperaturefrom
motor.
*Selfprotectedshortcircuitproofpowerpart. processorindependenthardware-shut
downincaseofshortcircuit,earthfault,overvoltageandovertemperatureof
amplifier.
Feature

TechnicalData
9
TechnicalData
DeviceforEC/AC-motors
Powersupplyvoltage 12V=to700V=
Auxiliarysupply 12V=or(24V=) !10% /4a(2a)
Ripplevoltage<10%,
self-resttable fuse
Data
BAMOCAR-D3-400-(700)- dim. 125/250 200/400 125/250 200/400
Ratedsupplyvoltage V= 24bismax.400 24bismax.700
Ratedoutputvoltage V~eff to3x260 to3x450
Continuecurrent rms A 125 200 125 200
Peakcurrent A 250 400 250 400
Dissipationmax. kW 2 3 2.6 4
Clockfrequency kHz 8-24 8-16
LevelOvervoltage V= 440 800
Externalfusing A 160 250 160 250
Weight kg 5.8 6,8 5.8 6.8
Dimension HxWxD mm 403x250x145
Size 2222
DeviceforDC-Motors
Powersupplyvoltage 12V=to400V=
Auxiliarysupply 12V=or(24V=) !10% /4a(2a)
Ripplevoltage<10%,
self-resttable fuse
Data
BAMOCAR-D2- dim. 125/250 200/400
Ratedsupplyvoltage V= 24bismax.400
Ratedoutputvoltage V= 20to360
Continuecurrentrms A= 125 200
Peakcurrent A 250 400
Dissipationmax. kW 2 3
Clockfrequency kHz 8-16
LevelOvervoltage V= programabletomax440v
Externalfusing A 160 250
Weight kg 5.8 6,8
DimensionHxWxD mm 403x250x145
Size 22
Technical Data

10
BAMOCAR D3
Input/Outpu v A Funktion Connector
AnalogInput !10 0.005 Differentialinput x1
Digitalinput ON
OFF 10-30 <6 0.010 0Logicio(opto) x1
Digitaloutput +24 1 Transitor-output
openemitter(opto) x1
Resolverinput Differentialinput x7
Encoderinput >3.6v Opto x7
Encoderoutput >4.7v Opto x8
CAN-interface Logikio(opto) x9
RS232-interface Logikio x10
Ambientconditions
Enclosureprotection IP65
Norms EN60204,ISO16750
Ambienttemperature -10to+45 C
Maximumambient
temperature -30to+65 ab+45 Cto+65 Cwithpowerderating2%/ C
Storagetemperature -30 cto+80 c
Humidityinoperation Klasse F rel.humidity<85%,nocondensation!
Sitealtitude "1000m ü.nn100%,>1000mwithpowerderating
2%/100m
Cooling liquidcoolermax65 c,12l/min,prechermax1,3bar
Mountingposition equal
Program Type Software-version
BAMOCAR-D3(D2)-xx-rs resolver
BAMOCAR-D3-(D2)xx-in encoder-ttl
BAMOCAR-D3-(D2)xx-sc encoder-sincos1vss
BAMOCAR-D3-(D2)xx-bl rotorlage+bl-tacho
BAMOCARxx-DC dc-tacho,
armaturevoltage
Note:
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 ELKOs would be reduced.
Technical Data

11
MechanicalInstallation
Importantinstruction
Checktheequipmentformechanicaldamage
Installonlydefect-freeequipments
Assemblyonlyinnon-energizedcondition
Disconnectthepositiveandnegativeterminalsofthebattery,
disconnectDCsupply.
Assemblyonlybytrainedpersonnel
Theinstallationpositionisdiscretionaryincaseofequipmentswith
liquidcooling.
Incaseofverylowheatdissipation,theequipmentisshutdownby
itsthermalmonitoringsystem.
Equipmentfitmentholestobeobtainedfromdimensiondrawingordrillplan
nottobetracedoutfromtheequipmentitself.
Filterandchoketobemountedclosetotheequipment.
Connectcablescreenswithmountingareasoastohavesurfacecontact.
Laypowercables(batteryandmotorcables)wellseparatedfromsignalcables
observeminimumcablecross–section.
Unscreenedcableendstobeasshortaspossible.
Secureearthconnectionfromhousingtogroundplane
(vehicleground,controlpanel–earth)
Usevibrationresistantscrewjoints.
Mechanical Installation

12
BAMOCARD3
Dimensions
Screw for hex key BAMOCAR

13
MechanicalInstallation
Assembly
Liquidcooler
Connection
hoseconnection metall13mm
inlettemperature 50 gradc
flowmax 12l/min
pressuremax 1,3bar

14
BAMOCAR D3
Assembly

15
ElectricalInstallation
Importantinstructions
Theconnectioninstructionsareclassifiedaccordingtotheconnectornumbersrespectively
andaremandatory.
Allfurtherinstructionsheretoarenon-binding.
Theinputandoutputlinescanbemodifiedandsupplemented,underconsiderationof
electricalregulationsandguidelines
Regulationstobeobservedare
Connectionandoperationalinstruction
Localregulations
EC-regulationslikeecmachinerydirective2006/42/EG-
EC-regulationsforvehiclesEC-R100,ISO6469,ISO26262
VDE,TÜVandprovisionsofprofessionalassociation.
Electricalinstallationonlyinnon-energizedcondition.
Observesafeactivation.
Insertshortingbar
Putupwarningboards
Installationonlybytrainedpersonnelinelectronics
Comparedconnectedloadwithtype–identificationplatedetails.
Observecorrectinputofpowerandauxiliaryvoltage.
Laypowercableandcontrolcablespatiallyseparated.
Followemc-guidelinesforscreenconnectionandearthingprocedures.
Usecorrectcablecross-section.
Useexternalinsulationwatchdog
Attention
Poororunderdimensionedcableconnectionbetweenthebatteryand
theequipmentcanleadtoequipmentdamage.
(brakingenergy)
Attention: Powercablesfromfmciiitobatteriestobeasshortas
possible.Longcablesleadtodynamicvoltage-dropsduetotheir
impedance.
Theseburdentheinstalledcapacitorsandshortenthelifespan.
Electrical Installation

16
BAMOCAR D3
Block diagram

17
ElectricalInstallation
Block diagram

18
BAMOCAR D3
Connection diagram

19
ElectricalInstallation
EMC

Connectors
20
BAMOCAR D3
Connectors
ConnectorX1IN/Output
ConnectorX11Brake
ConnectorX10RS232
ConnectorX9,X9.1
CAN-BUS