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M A N U A L

Digital Battery Servo Amplifier

BAMOCAR-PG-D3-700-900

for EC servo motors

for EC asynchronous servo motors

Hans-Paul-Kaysser-Straße 1

Ausgabe / Version

71397 Leutenbach-Nellmersbach

2020 / V3

Tel.: 07195 / 92 83 - 0

Preliminary release

[email protected]

www.unitek.eu

Summary of Contents for BAMOCAR-PG-D3-700-900

Page 1: ...mplifier BAMOCAR PG D3 700 900 for EC servo motors for EC asynchronous servo motors Hans Paul Kaysser Stra e 1 Ausgabe Version 71397 Leutenbach Nellmersbach 2020 V3 Tel 07195 92 83 0 Preliminary relea...

Page 2: ...data 15 2 Mechanical installation 18 2 1 Important notes 18 2 2 Dimensions BAMOCAR PG D3 700 900 19 3 Electrical installation 21 3 1 Important advices 21 3 2 Circuit diagramm 22 3 3 Connection diagra...

Page 3: ...1 SIN COS 1VSS Anschluss 42 4 12 Rotorlagegeber Anschluss mit BL Tacho 43 5 State display 44 5 1 Display of the BAMOCAR states 44 5 2 State information error 45 5 3 State information warning signals 4...

Page 4: ...g 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 80...

Page 5: ...ations 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...

Page 6: ...s 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 rot...

Page 7: ...od 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...

Page 8: ...tal 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...

Page 9: ...contacted Any incorrect installation connection may damage the device Any incorrect programming may cause dangerous movements Intended applications The devices of the BAMOCAR PG D3 700 900 are power...

Page 10: ...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...

Page 11: ...ts 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...

Page 12: ...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...

Page 13: ...ing 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 conne...

Page 14: ...ow 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...

Page 15: ...he specifications electromagnetic interferences electrostatic interferences lightning strikes failure of components failure in the brakes Dangerous temperatures caused by faults during the installatio...

Page 16: ...k power kW 480 Max power loss W 4 3 Pulse frequency kHz programmable 2 4 8 reduced torque Rotation frequency Hz 600 Over voltage switching threshold V programmable to max 800 V Input fuse A 500 Bus ci...

Page 17: ...1000m above sea level 100 1000m performance reduced by 2 100 m Cooling Liquid cooling unit 30 C to max 65 C 12 l min pressure max 6 bar 65 C performance reduced by 2 C Mounting position independent Co...

Page 18: ...air cooling Permissible current limit depending on the ambient temperature With liquid cooling Permissible current limit depending on the temperature of the cooling agent Dependence on IGBT module te...

Page 19: ...aken from the dimension diagrams or from the drilling plan Do not mark off the unit The filter and the choke have to be mounted near to the device The line shields and the mounting plate must have sur...

Page 20: ...Mechanical installation Version 2020 V3 Seite 19 BAMOCAR PG D3 700 900 2 2 Dimensions BAMOCAR PG D3 700 900...

Page 21: ...ope of delivery Liquid cooling Power connection Hose connection Metall G 13 Screws for power connections hexagon socket M10 x 20 max tightening torque 20 Nm PG cable entry metal M32 x 1 5 With screen...

Page 22: ...om the power supply place the short circuit bracket affix warning signs The installation should only be carried out by suitably trained personnel for electrical engineering Compare the connection data...

Page 23: ...Electrical installation Version 2020 V3 Seite 22 BAMOCAR PG D3 700 900 3 2 Circuit diagramm...

Page 24: ...Electrical installation Version 2020 V3 Seite 23 BAMOCAR PG D3 700 900...

Page 25: ...Electrical installation Version 2020 V3 Seite 24 BAMOCAR PG D3 700 900 3 3 Connection diagramm...

Page 26: ...ounting plate must be connected to earth using a 10 mm wire The motor housing must be connected to earth using a 10 mm wire The device ground X AGND must be connected to the mounting plate using a 1 5...

Page 27: ...been mounted in machines and installations the operation of the device must not be started until the machine or the installation has been approved of the regulations of the EC machine guideline 2006...

Page 28: ...t 1 18 DIN2 Digital input 2 19 RFE Rotor Enable 20 AR1 Analog Input 1 21 AIN1 Analog Input 1 22 AR2 Analog Input 2 23 AIN2 Analog Input 2 RS232 24 R1IN RS232 25 T1OU RS232 26 T2OU RS232 27 R2IN RS232...

Page 29: ...g connection of the power supply to earth Attention In addition to the internal supply current 1 4 A at 12 V 0 9 A at 24 V the total current of the outputs DOUT must also be supplied by the power supp...

Page 30: ...on to 34 38 mm Shorten shield to 10 mm Strip inner insulation Copper strand to 7 12 mm Cable lug insulation 25 mm braided sleeve or heat shrink tubing Cable lug for M10 screw Push on the PG cable glan...

Page 31: ...ERVOLTAGE F1 safety fuse Programming of an output for the pre charging The output Dout1 switches the relay K3 when the bus circuit voltage DC BUS is greater than the variable 1 Warning The power suppl...

Page 32: ...otor choke only necessary for shield capacities superior to 5 nF motor cable approx 25 m Cross section mm min 35 max 95 AWG 4 Motor choke Only necessary for a shield capacity of 5 nF approximately 25m...

Page 33: ...The inputs LMT1 X1 15 and LMT2 X1 16 are preferably to be used as inputs of the output stage switch Input Connector Function State RFE X1 19 Rotor enable fixed FRG RUN X1 14 Enable fixed END1 LMT1 X1...

Page 34: ...ce Enable input FRG RUN Rotary field enable input RFE Switching on Safety device contacts closed Release FRG RUN 0 5 s after RFE Safety switch off Safety device contacts open No FRG RUN signal blocks...

Page 35: ...age reference 24 V X1 6 Ground reference GNDE X1 7 Output Connector Function State Parameter BTB RDY X1 11 X1 12 ready for operation fixed Solid State Relais DOUT1 X1 8 Digital output 1 programmable D...

Page 36: ...ontact for max 48 V 0 5 A not short circuit proof Capacitive load max 1 F Contact resistance max 2 Ready for BTB The BTB relay contact is closed Not ready BTB relay contact is open Red LED and error m...

Page 37: ...motor can either be changed by swapping the connections at the differential input or by means of a logic input or by programming see NDrive x The analog inputs can be assigned to different functions...

Page 38: ...ed using a shielded cable Install the cable only after disconnecting the device from the mains The interface is adjusted to 115200 Baud It can also be adjusted to 9600 Baud by means of the NDrive Conn...

Page 39: ...BUS Interface complies with the standard ISO 11898 Adjustment and programming see Manual NDrive and CAN Manual CAN BUS Kabel Use a shielded bus conductor with a low shielding capacity LiYCY 3 x 0 25 s...

Page 40: ...The maximum possible speed is 50 000 rpm 10 bit The digitized signals are used for the polar wheel angle the position control the speed control and incremental output Only use motors with a 2 4 6 or 8...

Page 41: ...e device zero GND The 5 V supply voltage is provided by the servo Only use motors with TTL incremental encoders and rotor position tracks which have been approved by the manufacturer Connector X7 14 p...

Page 42: ...es which differ from 5V the voltage must be specified on order and externally be connected Checking the correct connection Rotor sequence The correct sequence of the rotor signals with a motor turning...

Page 43: ...lly set to optimum Only use motors with SIN COS encoders SC which have been approved by the manufacturer Connector X7 14 pin Tyco type connector Connecting cable 6 x 2 signal conductors twisted and sh...

Page 44: ...ho voltages X7 Connect pins 1 9 and 11 Connect speedometer center to X7 1 Only use motors with rotor position encoders bl which have been approved by the manufacturer Connector X7 14 pin Tyco type con...

Page 45: ...inherent hardware failure flashing bright dark Starting state after reset auxil voltage 24V off on The first enable stops the flashing display Drive enable Drive disabled not enabled OK 0 OK 1 ENA 1...

Page 46: ...it 12 D Bit 13 E HW_ERR Current measurement error Bit 14 F BALLAST Ballast circuit overloaded Bit 15 Note Error F is a device dependent error for BAMOBIL and BAMOCAR without function If the auxiliary...

Page 47: ...18 3 Bit 19 4 Bit 20 5 Bit 21 6 MOTORTEMP Motor temperature I red TM or 93 from M Temp Bit 22 7 DEVICETEMP Device temperature 87 of limit Bit 23 8 Vout_Sat Limit of the existing voltage output is rea...

Page 48: ...Battery voltage Measuring tolerance 2 Example for settings on the BAMOCAR DC BUS max 0xA5H for limit voltage Num 0x0B Bemerkung 144 750 V 23625 1 corresponds 5 2 V 135 700 V 22050 DC BUS min 0xA5L fo...

Page 49: ...ers I red TD 0x58 and I red TE 0x4C programmed see Manual NDrive Current actual value BAMOCAR I 100 Calibration nominal current I device Peak current DC blocked Maximum value 11Bit mV Num A eff A eff...

Page 50: ...r or a third party non observance of the manual which is included in all consignments non observance of the electrical standards and regulations improper maintenance acts of nature All further claims...

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