Unitek BAMOCAR-PG-D3-400/400 User manual

M A N U A L
Digital battery - motor controller
BAMOCAR-PG-D3-400/400
BAMOCAR-PG-D3-700/250
BAMOCAR-PG-D3-700/400
for EC servo motor
for AC asynchronous servo motor
Hans-Paul-Kaysser-Straße 1
Edition / Version
71397 Leutenbach-Nellmersbach
2021/ V2
Tel: 07195 / 92 83 - 0
[e-mail]
www.unitek.eu

Basic - Information
Version: 2021 / V2
Page: 1
BAMOCAR-PG-D3-700/250, 400
Table of contents
1Basic - Information.....................................................................................................................3
1.1 History .......................................................................................................................................... 3
1.2 Other products ............................................................................................................................. 3
1.3 Project planning instructions (MANUAL) ..................................................................................... 3
1.4 Validity.......................................................................................................................................... 4
1.5 Designations and symbols used ................................................................................................... 4
1.6 General product information ....................................................................................................... 5
1.7 Application/use/design/property................................................................................................. 6
1.8 Safety regulations......................................................................................................................... 8
1.9 Commissioning ........................................................................................................................... 10
1.10 Details of the safety instructions................................................................................................ 11
1.11 Intended use............................................................................................................................... 12
1.12 Regulations and guidelines......................................................................................................... 13
1.13 Risks............................................................................................................................................ 14
1.14 Technical data ............................................................................................................................ 15
2Mechanical installation ............................................................................................................ 18
2.1 Important notes ......................................................................................................................... 18
2.2 Dimension drawings BAMOCAR-PG-D3-400/400, 700/250, 700/400 ....................................... 19
2.3 Mounting on mounting rails....................................................................................................... 21
2.4 Mounting on mounting surface.................................................................................................. 21
3Electrical installations .............................................................................................................. 22
3.1 Important notes ......................................................................................................................... 22
3.2 Block diagrams ........................................................................................................................... 23
3.3 Connection overview.................................................................................................................. 25
3.4 EMC ............................................................................................................................................ 26
3.5 Connector overview ................................................................................................................... 28
3.6 Auxiliary voltage connection...................................................................................................... 30
3.7 Power connections..................................................................................................................... 31
3.8 Battery connection..................................................................................................................... 32
3.9 Motor power connection ........................................................................................................... 33
4Control connections................................................................................................................. 34
4.1 Digital inputs............................................................................................................................... 34
4.2 Safety input RFE (rotating field - enable) / stop category 0....................................................... 35
4.3 Digital outputs (0pen emitter).................................................................................................... 36
4.4 Signalling contact Ready for operation (solid state relay) / Ready BTB / RDY........................... 37
4.5 Analogue inputs ±10 V................................................................................................................ 38
4.6 Analogue output - not available................................................................................................. 38

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Page: 2
BAMOCAR-PG-D3-700/250, 400
4.7 Serial interface RS232................................................................................................................. 39
4.8 CAN-BUS..................................................................................................................................... 40
4.9 Resolver connection................................................................................................................... 41
4.10 Encoder TTL connection............................................................................................................. 42
4.11 SIN COS 1VSS Connection........................................................................................................... 44
4.12 Rotor position sensor connection with BL tacho ....................................................................... 45
5Status information................................................................................................................... 46
5.1 Status display on the BAMOCAR ................................................................................................ 46
5.2 Status information - Error .......................................................................................................... 47
5.3 Status information - Warnings ................................................................................................... 48
6Measured values...................................................................................................................... 49
6.1 DC link DC BUS voltage, battery voltage (400 V and 700 V)....................................................... 49
6.2 Output stages - temperature ..................................................................................................... 50
7Warranty................................................................................................................................. 51

Basic - Information
Version: 2021 / V2
Page: 3
BAMOCAR-PG-D3-700/250, 400
1Basic - Information
1.1 History
Version
Change
Date
2021 / V1
Version "250" completed, pictures, graphics etc. renewed
07.04.2021
2021 / V2
Page 50 / Temperature table supplemented / renewed
27.04.2021
1.2 More products
For synchronous motors and asynchronous motors
Digital AC servo amplifier (mains up to 480V~)
UNITEK
DS series / DPC series
Digital AC servo amplifier for battery operation
UNITEK
BAMOBIL-D3 series
Analogue three-phase servo amplifier (mains 400V~)
UNITEK
TVD series
For DC motors
Analogue DC servo amplifier for battery operation
UNITEK
BAMOBIL-A2/BAMO series
Analogue DC servo amplifier (mains operation)
UNITEK
Series TV
Thyristor converter 1Q, 4Q, servo
UNITEK
Classic series
200 W to 800 kW
1.3 Project planning instructions (MANUAL)
1.
MANUAL
BAMOCAR-PG-D3-xxx
Hardware
2.
MANUAL
NDrive x
Software
Use all MANUALs for project planning, installation and commissioning!
Online as download: www.unitek.eu
Hardware MANUAL contains warnings and safety instructions, explanations of standards,
mechanical and electrical installation instructions.
The MANUAL must be made accessible to all persons working with the unit.

Basic - Information
Version: 2021 / V2
Page: 4
BAMOCAR-PG-D3-700/250, 400
1.4 Validity
Hardware status:
TMS 2-3d, Driver 1-8
Firmware version:
FW 476
1.5 Designations and symbols used
Device
BAMOCAR-PG-D3-700/400, 700/250, 400/400
User:
Vehicles, boats, machinery or plant manufacturers or operators in the industrial
sector (B2B, second environment)
Manufacturer:
UNITEK Industry Electronics GmbH
Danger to life!
High voltage
Warning.
Important
Dangerous electric fields
Scope of delivery / in the shipping box:
-Unit BAMOCAR- PG-D3-x
-Hint for download "Operating Instructions / Manual“
Not included (order as accessory):
-PG screw fittings
-Control plug:
X1 (In/Out)
Order number G435 / Binder 99-5662-15-19
X7 (feedback)
Order number G436 / Binder 99-5661-15-19
X9 (CAN-BUS)
Order number G437 / Binder 99-0436-14-05
-Control cable:
X10 RS232 cable
Order number G432 / Binder 79-3464-52-06

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Version: 2021 / V2
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BAMOCAR-PG-D3-700/250, 400
1.6 General product information
The digital three-phase servo amplifier BAMOCAR-PG-D3-400/400, 700/250, 700/400 forms a 4-quadrant drive
unit together with the motor, driving and braking with energy feedback in both directions of rotation. Depending
on the installed parameter set, the amplifier is suitable for EC synchronous motors, AC asynchronous motors or DC
motors.
The drive concepts are characterised by different advantages and disadvantages.
The EC drive (synchronous motor) has the highest efficiency and the highest power per weight and volume. It is
maintenance-free and has high control dynamics. The disadvantage is the field weakening range, which is difficult
to control, and the high braking torque in the event of a motor short circuit.
The EC synchronous motor (brushless DC motor) in its electrical version is a synchronous motor with permanent
magnet rotor and three-phase stator.
The physical properties correspond to those of the DC motor, i.e. the current is proportional to the torque and the
voltage is proportional to the speed. The speed is controlled stably up to the current limit (max. torque). In case of
overload, the speed decreases at constant current.
Rectangular speed-torque characteristic.
Current, speed and position are measured exactly.
The rotating field frequency is not a controlled variable, it adjusts itself independently.
The motor voltages and motor currents are sinusoidal.
The AC drive (asynchronous motor) has the highest speed range due to the simple field weakening and it does not
generate a braking torque in the event of a motor short circuit. The disadvantage is the size and the poorer
efficiency. The controlled variable is the rotating field frequency, taking into account the motor-specific
parameters (field-oriented control). The motor voltages and motor currents are sinusoidal.
With both three-phase systems, no motor movement takes place if the rotating field is switched off or there is
power stage damage. The heat loss occurs mainly in the motor stator.
The DC drive (direct current motor) has the best synchronisation and a high control range. Emergency operation
can be achieved by directly connecting the battery voltage. Disadvantages are the carbon brushes and the heat
generation in the armature. The drive can rotate at high speed in the event of a power stage failure.
The current is proportional to the torque and the voltage is proportional to the speed.
Current, speed and position (bearing) are measured exactly. The speed is controlled stably up to the current limit
(max. torque). In case of overload, the speed decreases at constant current.
Rectangular speed-torque characteristic.
Field weakening is possible with externally excited motors.
BAMOCAR-PG-D3-xxx can be used as a position controller, torque or speed amplifier. The actual speed value is
generated from the encoder unit (resolver or other) or internally (sensorless). A large control range and high
control dynamics require an encoder system.
Warning / Caution:
For DC, AC and BL servo amplifiers fed from the DC mains, the energy feedback into the DC
link during braking operation must be taken into account.
(External ballast circuit)

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BAMOCAR-PG-D3-700/250, 400
1.7 Application/use/design/property
Application:
In vehicles, boats, machines and plants of all kinds up to a drive power of 100 kW in rough use,
especially as 4Q servo drives for:
- highly dynamic acceleration and braking processes,
- large control ranges,
- high efficiency,
- small motor dimensions,
- smooth, quiet running and
- for speed control, torque control or combined speed-torque without superimposed position control,
- conveyor drives, spindle operation, pumps, transverse and longitudinal dividing drives, multi-motor
synchronous drives.
Deployment:
In battery-powered vehicles such as electric vehicles, electric boats, forklifts, transport systems as well
as in battery-powered machines and systems such as automatic assembly machines, metalworking
machines, X-Y tables, food processing machines, robots and handling systems, rack conveyors, stone
processing machines and in many other battery-powered applications.
Structure:
- Compact unit according to VDE- DIN and EC directives / protection class IP65 (option IP69K)
- For harsh environment and high dynamic overload
- Maintenance free
- Contact protection of the power connections
- Power electronics for (S1 operation) 125 A~eff, 200 A~effA
- Power input range nom. 12... 700 V=
- Liquid cooling (special version air cooling)
- Uniform digital control electronics
- Independent 12.. 24 V chopper power supply for the auxiliary voltages
Galvanic separation between:
- Power connection, motor connection and all other control connections
- Auxiliary voltage connection and all other voltages
- Housing and cooling block.
- Clearance and creepage distances comply with EU standards
- No internal insulation monitoring, Y2 capacitors to housing
Features:
- Fully insulated IGBT power semiconductors, generously dimensioned
- Only commercially available components in industrial standard
- SMD assembly

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BAMOCAR-PG-D3-700/250, 400
Features:
Battery connection 12 V= / 700 V= (DC mains, observe restrictions).
✓Independent auxiliary voltage connection 24 V= or 12 V=
✓Digital interfaces RS232, CAN-BUS (further option)
✓Analogue inputs, programmable differential inputs
✓Digital inputs and outputs, programmable, opto-decoupled
✓Setpoint ramps linear
✓Enable and limit switch logic, emergency stop function, safety
✓BTB-ready, solid state relay
✓Position, speed and torque control
✓Feedback encoder systems: resolver, encoder incremental encoder, SINCOS 1Vpp,
Rotor position + BL tacho
✓Static and dynamic current limit
✓Uniform fully digital control unit
✓Processor-independent protective shutdown in case of overvoltage, undervoltage
Short circuit, earth fault and overtemperature of amplifier or motor
✓Intrinsically safe short-circuit-proof power section (EN50178)
Attention: Braking energy
The braking energy is fed back into the battery.
The battery must be able to absorb the braking energy.
If the battery is disconnected from the unit during braking operation
high DC link voltages can occur.
Pay special attention when operating on laboratory power supplies!
In DC networks, the network must absorb the braking energy without the voltage rising above the
permissible value. If this is not ensured, a ballast circuit must be used.
In the case of non-grounded systems (vehicles, boats, machines)
the insulation between the touchable parts and the HV voltages must be monitored with an
independent insulation monitor.

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Version: 2021 / V2
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BAMOCAR-PG-D3-700/250, 400
1.8 Safety regulations
Electronic devices are fundamentally not fail-safe!
Attention high voltage
DC > 800 V
Danger of shock! / Danger to life!
DC link discharge time > 4 min.
This MANUAL must be carefully read and understood by qualified personnel before installation or
commissioning. The knowledge and understanding of the appliance and especially of the safety
instructions must be accessible to all persons involved in the application.
If anything is unclear, or if other functions are not described or not described in sufficient detail in the
documentation, the manufacturer or dealer must be contacted.
Incorrect installation can lead to the destruction of the units! Incorrect
programming can trigger dangerous movements!
Intended use:
The devices of the BAMOCAR- PG-D3 series are electrical equipment of the power electronics for the
regulation of the energy flow.
They are intended as components for controlling EC synchronous motors and AC asynchronous motors
in vehicles, machines or systems.
When used in residential areas, additional EMC measures are necessary.
Deviating applications require the approval of the manufacturer.
The user must prepare a hazard analysis of his end product.
Protection class IP65 (option IP69K).
Connection to batteries only!
Operation only permitted with the unit closed!
Control and power connections can lead to voltages without the
drive operating!
DC link discharge time is greater than 4 minutes!
Measure voltage before disassembly!

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BAMOCAR-PG-D3-700/250, 400
The user must prepare a hazard analysis for his machine, vehicle or plant.
The user must ensure:
- that after a failure of the unit,
- in case of operating errors,
- in case of failure of the regulation and control unit, etc.
the drive is guided into a safe operating state.
Vehicles, boats, machines and installations must also be equipped
with monitoring and safety devices that are independent of the
equipment. The user must take appropriate measures to ensure
that inadmissible movements do not cause danger to people and
property!
The unit must be closed during operation.
All connectors must be securely engaged or screwed down.
The protective systems must be active.
With the unit open and/or protection systems deactivated, the user
must ensure that only qualified personnel have access to the units.
Assembly work
- Only in a secured, de-energised state
- Only by trained specialist personnel
Installation work
- Only in a secured, de-energised state
- Only by trained electricians
- Observe the safety regulations.
Setting and programming work
- Only by qualified personnel with knowledge of electronic drives and software
- Observe programming instructions
- Observe safety instructions