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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

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Содержание BAMOCAR-D3

Страница 1: ...MANUAL Digital Battery Motor Controller BAMOCAR D3 for EC Servo Motors AC Induction Motors DC Servo Motors ...

Страница 2: ...ical 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 Soft...

Страница 3: ...3 Basic Information ...

Страница 4: ...ns 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 T...

Страница 5: ... 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 regulat...

Страница 6: ...6 BAMOCAR D3 Attention nformation General ...

Страница 7: ...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 prot...

Страница 8: ...erously 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 Referen...

Страница 9: ...ency 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 2 2 2 2 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 cur...

Страница 10: ...ower 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 D...

Страница 11: ...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 cabl...

Страница 12: ...12 BAMOCAR D3 Dimensions Screw for hex key BAMOCAR ...

Страница 13: ...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 ...

Страница 14: ...14 BAMOCAR D3 Assembly ...

Страница 15: ...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 ...

Страница 16: ...16 BAMOCAR D3 Block diagram ...

Страница 17: ...17 Electrical Installation Block diagram ...

Страница 18: ...18 BAMOCAR D3 Connection diagram ...

Страница 19: ...19 Electrical Installation EMC ...

Страница 20: ...Connectors 20 BAMOCAR D3 Connectors Connector X1 IN Output Connector X11 Brake Connector X 10 RS232 Connector X9 X9 1 CAN BUS ...

Страница 21: ...21 Electrical Installation Connectors Connector X8 Output 2 Input ENC TTL Feedback connector X7 At all connectors View the plug on solder crimp side ...

Страница 22: ...et Pfisterer p1 350 205 301 Connector plug plus Pfisterer connector straight p1 350205 002 or connector angle p1 350205 102 Connector plug minus Pfisterer connector straight p1 350205 001 or connector angle p1 350205 101 Connector plugr motor Pfisterer connector straight p1 350205 001 or connector angle p1 350205 101 22 BAMOCAR D3 Power connectors ...

Страница 23: ...upply voltage U 400 700 must not be exceeded at any time not even for short intervals Danger of damage F1 safety fuse Connection has no protection against reverse polarity If the polarity of the connection is wrong the device will be destroyed Type 125 250 25 2 160 200 400 35 1 250 Attention ...

Страница 24: ...ND 24 X 1 3 Ripple 10 Inrush current 4A Rated current in case of 12 v 1 4 A in case of 24 v 0 9 A Attention For internal power supply 1 4 A also the sum total currents of output dout has to be fed from the 12 24 V system Attention In case of Auxiliary voltage less than 10 V including during short time drop outs the internal power supply system shuts down Temporary data in ram memory are erased Dig...

Страница 25: ... M3 Motor phase U V W Connector xb 2 xb 3 xb 4 Correct wiring is essential Type BAMOCAR Dx 125 200 Cable dim mm 25 35 Cable dim AWG 2 1 Motor cables 3 wires simply shielded protective earth conductor for 600V 1000V shield capacity 150pF m Motor choke Only required upwards of a shield capacity of 5nF approx 25m motor cable Magnetic rings Against HF failures of the sensor systems Slide the rings ont...

Страница 26: ...26 BAMOCAR D3 ...

Страница 27: ...ary field release RFE the rotary field of the output stage is additionally blocked electronically second blocking channel The drive is momentum free no stop moment The 4 additional digital inputs are freely programmable Inputs lmt 1 x1 e and lmt 2 x1 f are preferred and to be used as limit switch inputs Input Plug Function Status External power supply for inputs and outputs Opto input 24for for th...

Страница 28: ...ch on Safety switch contacts closed Enable FRG RUN 0 5 seconds after RFE Safety shut down Safety switch contacts open Absence of FRG RUN signal blocks the pwm pulses in the processor through the first blocking channel Absence of FRG signal blocks the pwm pulses after the processor through the second blocking channel Restarting Reset safety switch Safety switch contacts closed The motor can start r...

Страница 29: ...on ready solid state relay ready BTB RDY Operation ready are off in case of fault indications if Auxiliary voltage is low 10 V The function of indication under voltage in DC link can be programmed BTB with or without under voltage monitoring BTB power Control signals Output voltage On level max 24V Off level 1V Output current nom 1A Output current max 2A Voltage reference 24V X1 4 ground reference...

Страница 30: ...or can be changed by reversing the polarity at the differential input by a logic input or by programming In case of digital reference value RS 232 x bus analog input Ain 1 can be programmed as external rpm limit and the Analog input Ain 2 can be programmed as external analog current limit Analog output 10 V Output Terminal Basic function Voltage Status Parameter Control signals ...

Страница 31: ...een the BAMOCAR D3 d connector X10 and the serial interface only through a null modem cable Do not use null modem link cable Cable to be plugged in only in de energized condition Select the interface baud rate in NDrive as 115200 The serial interface is galvanically coupled with the device zero GND Null modem cable Pin assignment Solder side Contact shield with the plug housing Cable length max 10...

Страница 32: ...ally separated The power supply is from the intern DC DC Designation Cable colour CAN BUS cable Use a shielded bus conductor with a low shielding capacity Signal plus GND supply D connector with a metal or metallized housing LiYCY 4x0 25 shield PE on the housing ...

Страница 33: ...33 Elektrical Installation Resolver connection Applicable only for BAMOCAR D3 xx RS Resolver ...

Страница 34: ...34 BAMOCAR D3 Encoder TTL Encoder TTL Anschluß only BAMOCAR D3 IN ...

Страница 35: ...35 Electrical Installation SIN COS 1Vss Anschluss only BAMOCAR D3 xx SC SIN COS 1vss ...

Страница 36: ...36 BAMOCAR D3 Rotor sensor Anschluss with bl tacho only BAMOCAR D3 xx bl Rotor sensor ...

Страница 37: ...or X8 will be operated as input or output default Output X8 pin c not used or connected with GND Input X8 pin c connected with 5 v x8 a Attention X8 as input Connect x8 C select in with x8 A 5 V within the connector X8 Encoder output input Connector X8 Output 2 Input ENC TTL ...

Страница 38: ...r pulse rate X8 as TTL Encoder input Attention X8 pin C select in must be connected to X8 pin A 5V The encoder input is potentially isolated power supply is done through the sensor cable Option internal supply from servo input signals comply with RS 485 Maximum input frequency 200 kHz Encoder input can be programmed for various functions Refer software description DS NDrive 38 BAMOCAR D3 X8 Encode...

Страница 39: ... led FAULT glows and the 7 segment indicator indicates the fault number In case of warning the red fault led blinks and the 7 segment display alternatively indicates the status and the warning number Status indication on servo Display Point segment State State of NDrive Example Motor rotating clockwise Point blinks Processor active Bottom line Drive released Right side line Motor rotates clock wis...

Страница 40: ...l bit 4 5 POWERVOLTAGE No power supply voltage bit 5 6 MOTORTEMP Motor temperature too high bit 6 7 DEVICETEMP Device temperature too high bit 7 8 OVERVOLTAGE Over voltage 1 8 x UN bit 8 9 I_PEAK Overcurrent 300 bit 9 A RACEAWAY Racing without command value incorrect polarity bit 10 B USER User s error choice bit 11 C RESERVE bit 12 D RESERVE bit 13 E CPU ERROR Software error bit 14 F BALLAST Ball...

Страница 41: ... address 0x8f 0 bit 16 1 bit 17 2 bit 18 3 bit 19 4 bit 20 5 POWERVOLTAGE power voltage too low or not present bit 21 6 MOTORTEMP motor temperature 87 bit 22 7 DEVICETEMP equipment temperature 87 bit 23 8 OVERVOLTAGE over voltage 1 5 x un bit 24 9 I_PEAK over current 200 bit 25 A bit 26 B bit 27 C I2R over load 87 bit 28 D bit 29 E bit 30 F bit 31 Example red FAULT led flashes indication toggles b...

Страница 42: ...DC link voltage 700V BOMOCAR D3 700 DC link voltage Parameter 0xa5 maximum voltage 800V 29195 battery voltage 700V 19088 over voltage shut down 750V 28462 charging voltage 680V 24813 without power voltage 0V 0 standardization 1 36 49 parameter 0xa5 36 49 x DC link voltage Current actual BAMOCAR D3 I 100 Calibration rated current i device Peak current dc blocked maximum value 11bit mv num Aeff Aa n...

Страница 43: ...0 9000 10000 11000 12000 13000 14000 Wert von 0x4b Num Luft Temperatur C o Value of 0x4b Num Air Temperature C o Measurement BAMOCAR NTC Stage Temperature C Value of 0x4a Num Wert von 0x4a Num Wert von 0x4a Num Endstufen Temperatur C Wert von 0x4a Num 26000 24000 100 22000 20000 90 20 18000 80 o 70 10 20 60 50 0 o 40 32000 30000 28000 16000 30 10 ...

Страница 44: ...44 Settings for BAMOCAR 700 400 DC BUS max 0xa5H for max voltage 750V 27367 83 for max voltage 700V 25541 78 DC BUS min 0xa5L for undervoltage 600V 20694 63 for undervoltage 500V 17245 52 Measurement 0 50 100 150 200 250 300 350 400 450 500 0 5000 10000 15000 20000 25000 30000 Wert von 0xeb Num Zwischenkreis Spannung V 100 200 300 400 500 600 700 BAMOCAR 400V BAMOCAR 700V Value of 0xeb Num DC Link...

Страница 45: ...45 Electrical Installation ...

Страница 46: ...les and regulations due to improper handling or due to natural calamities Consequential damages all further claims of conversion reduction and replacement of damages of any kind especially damages which are not caused at UNITEK equipments are ruled out Consequential damages which arise due to the malfunctions or equipment fault in the machines or installation cannot be made valid this is invalid i...

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