Unitek BAMOCAR-D3 Manuale utente
MANUAL
DigitalBattery-Motor-Controller
BAMOCAR-D3
for
ECServoMotors
ACInductionMotors
DC-ServoMotors
2
BAMOCARD3
Contents
Part1 Hardware
page
1 Basis-information
Safetyinstruction 4,5
General 6
Application 7
Construction 8
Technicaldata 9,10
2 Mmechanicalinstallation
Importantinstructions 11
DimensionBAMOCAR-D3 12,13
Assembly 14
3 Electricalinstallation
Importantinstructions 15
Blockdiagram 16,17
Connectiondiagram 18
EMC 19
Connectors 20-22
Batteryconnection 23
Powersupply,brake 24
Motorconnection 25
Controlsignals 27-30
Schnittstellen 31,32
Resolver 33
EncoderTTL 34
EncoderSINCOS 35
Rotorlagebl 36
Encoderout-in 37,38
LED-monitor 39-41
Options 42
Guarantee 43
part2 Software-manual
part3 Commissioning- manual
part4 Software-reference
part5 CAN-BUSreference
Contens
3
BasicInformation
4
BAMOCARD3
Electronicdevicesareneverfail-safe.
Thismanualmustbecarefullyreadandunderstoodbytheprofessionalpriortoinstallation
orstart-up.
Consultthemanufacturerorthedealerifanythingisunclear.
Faultyinstallationcanleadtodestructionofthedevices.
TheBAMOCAR-Dseriesdevicesareelectricalresources(eb)forpowerelectronics
regulatingelectriccurrents.
Theyaredesignedtocontrolecsynchronousmotors(blushlessdcmotors,bldc)in
industrialapplications.
IP65protectionstandard
Onlyconnecttobattery.
Regulationsandguidelines:
Mountandconnectthedevicesandtheirappropriatecomponentsincompliancewith
technicalregulationslocallyapplicableandrequiredbylaw:
EGguidelines 2004/108/EG,2006/95/EG,2006/42/EG
- EN60204-1,EN292,EN50178,EN60439-1,EN61800-3,ECE-R100
ISO6469,ISO26262,ISO16750,ISO20653,ISO12100
IEC/UL IEC61508,IEC364,ICE664,UL508c,UL840
Deregulations VDE100,VDE110,VDE160and
TÜVregulations
Tradeassociationregulations,.VGB4
Stvzo§§20/21
Controlandpowerconnectionscanbeliveeven
thoughthedriveisinoperative.
Thedc-busdischargetimeismorethan4minutes.
Measurethevoltagepriortodismounting
Safety instractions
Caution:highvoltageDC900V=.
Electricshockhazard!
Dangertopersonnel!
DC-busdischarge-time>4min
TechnicalData
5
Theuserhastoensure:
Thatthedrivewillbeledtoasafeoperatingcondition,
afteranequipmentfailure
-duetomalfunctionofcontrollingorregulatingunit
Machines,equipmentsandvehiclesaretobefurtherprovided
withequipmentindependentmonitoringandsafetydevices.
Un-earthedsystems(forex.vehicles)mustbeprotected
withaninsulationmonitor.
Nodangershallariseforhumansandproperty.
Assembly
-onlyinnon-energizedcondition
-bytrainedpersonnel.
Installationwork
-non-energizedcondition
-onlybytrainedelectricalpersonnel.
Safetyregulations
Observesafety-regulations
Settingup
Settingupandprogramming
-tobedonebytrainedpersonnelwithknowledgeandinelectronicdrivesandsoftware.
-observeprogramminginstructions.
Safetyregulations
Observesafetyregulations.
Installation:
Incaseofnstallationinmachines,equipmentsandvehicles,commissioningtheequipment
fortheintendedpurposeisprohibited,untilithasbeenascertained,thatthemachines,
equipmentsorvehiclescomplywiththeECguidelinesformachines2006/42/EG,theEMC
guidelines2004/108/EGandECE-R100.
TheEG-guideline2004/108/EGwithemcregulationsEN61000-2andEN61000-4
pertainingtoinstallationandtestconditionsmentionedinchapteremcinstructionsare
compliedwith.
Amanufacturer’sclarificationcanberequestedfor.
Complianceoflimitingvalues,laiddownbytheemclegislations,isthesoleresponsibility
ofvehiclemanufacturers,equipmentsormachines.
Qualityassuranceequipmentserialnumbers,alongwithdateoftestingarearchivedby
themanufacturerfor10years.Testprotocolscanberequestedfor.
Safetysymbolsttention:
Dangertolife
Warning:
highvoltage important
Safety instractions
6
BAMOCAR D3
Attention
nformation
General
TechnicalData
7
Applicationin
Machines,equipments,vehiclesofalltypesuptodrivecapacityof140kwespeciallyas
4q-servodrives
-incaseofhighlydynamicaccelerationandbrakingprocesses.
-incaseoflargecontrolareas
-incaseofhighefficiency
-incaseofsmallmotordimensions
-incaseofconstant,silentoperationfor
rpmcontrol,torquecontrolorcombinedtorque-rpmcontrolwithorwithoutsuperimposed
positioncontrol.
Constantspeeddrivesforconveyoroperation,spindledrives,pumps,longitudinaland
transversedrives.
Drivesforsynchronizedoperationofmultiplemotors.
Usedin:
Batteryoperatedvehicleslikeelectricvehicles,electricboats,lift–trucks,transport
systemsaswellasbatteryoperatedmachinesandequipmentslikeautomaticmounting
metalprocessingmachines,x-ytables,grocerymachines,robotsandhandlingsystems,
stackercranesandstoneprocessingmachinesandinmanybatteryoperatedapplications.
ThemotorsandcontrollersareconstructedwithIP65protection,
-compact,
-forharshconditions,
-forhighdynamicoverload,
-maintenancefree.
Observe:
Brakingenergywouldbefedbackintothebattery.
Thebatterymustbeabletoabsorbthebrakingenergy.
Incaseofunearthedsystems(vehicles,it–networks),the
insulationbetweenthepartswhichcomeincontactandHV-
voltagesshouldbemonitoredbyanindependentinsulation
monitoringwatchdog.
Application
8
BAMOCAR D3
Construction:
Compactequipment
Acc.toVDE-DIN-EG-standards.
IP65protectionagainstaccidentalcontactwithpowerconnections.
Powerelectronicsfor(S1operation)125A,200A,(peak250A,400A)
Inputpowerrangenom.12to700V=
Liquidcooling(specialconstructionaircooling)
Unifieddigitalcontrollerelectronics)
Independent12/24VDCchopperpowerunitforauxiliarypower.
Galvanicisolation
-Galvanicisolationbetweenpowerconnector,motorconnectorandallother
controlconnectors
-Galvanicisolationbetweenauxiliaryvoltageandallothervoltages.
-Housingandradiatorassemblyaregalvanicallyisolatedfromallelectricparts.
-TheairandcreepagedistancescomplywithVDE.
-Nointernalinsulationmonitor.Y2capacitorstohousing.
Thefollowingareused:
IGBT–powersemiconductor
- Generouslydimensioned.
- Onlycommerciallyavailablepartsinindustrystandard.
- SMD–mounting
- 7segmentledindicators(option)
Features
*Batteryconnection12v=to700volts=(dcsupply,observelimitations)
*Independentauxiliarysupply24v=or12v=
*DigitalinterfacesRS232,can-bus(additionaloption)
*2analoginputs,programmabledifferentialinputs
*4digitalin-outputs,programmable,opticallyisolated
*Referencevaluerampslinear,nonlinear(s–function)
*Releaseandlimit-switchlogic.
*BTB–operationready,solidstaterelaycontact.
*Position ,rpmandtorquecontrol
*Resolverorencoder–incrementalencoderTTL,SINCOS1Vss,
*Rotorpositon+bltacho.
*Encoderoutputor2.encoderinput.
*Staticanddynamiccurrentlimit
*Unifiedfulldigitalregulatorunit
*Safetyshutdownincaseofovervoltage,undervoltageandovertemperaturefrom
motor.
*Selfprotectedshortcircuitproofpowerpart. processorindependenthardware-shut
downincaseofshortcircuit,earthfault,overvoltageandovertemperatureof
amplifier.
Feature
TechnicalData
9
TechnicalData
DeviceforEC/AC-motors
Powersupplyvoltage 12V=to700V=
Auxiliarysupply 12V=or(24V=) !10% /4a(2a)
Ripplevoltage<10%,
self-resttable fuse
Data
BAMOCAR-D3-400-(700)- dim. 125/250 200/400 125/250 200/400
Ratedsupplyvoltage V= 24bismax.400 24bismax.700
Ratedoutputvoltage V~eff to3x260 to3x450
Continuecurrent rms A 125 200 125 200
Peakcurrent A 250 400 250 400
Dissipationmax. kW 2 3 2.6 4
Clockfrequency kHz 8-24 8-16
LevelOvervoltage V= 440 800
Externalfusing A 160 250 160 250
Weight kg 5.8 6,8 5.8 6.8
Dimension HxWxD mm 403x250x145
Size 2222
DeviceforDC-Motors
Powersupplyvoltage 12V=to400V=
Auxiliarysupply 12V=or(24V=) !10% /4a(2a)
Ripplevoltage<10%,
self-resttable fuse
Data
BAMOCAR-D2- dim. 125/250 200/400
Ratedsupplyvoltage V= 24bismax.400
Ratedoutputvoltage V= 20to360
Continuecurrentrms A= 125 200
Peakcurrent A 250 400
Dissipationmax. kW 2 3
Clockfrequency kHz 8-16
LevelOvervoltage V= programabletomax440v
Externalfusing A 160 250
Weight kg 5.8 6,8
DimensionHxWxD mm 403x250x145
Size 22
Technical Data
10
BAMOCAR D3
Input/Outpu v A Funktion Connector
AnalogInput !10 0.005 Differentialinput x1
Digitalinput ON
OFF 10-30
<6 0.010
0Logicio(opto) x1
Digitaloutput +24 1 Transitor-output
openemitter(opto) x1
Resolverinput Differentialinput x7
Encoderinput >3.6v Opto x7
Encoderoutput >4.7v Opto x8
CAN-interface Logikio(opto) x9
RS232-interface Logikio x10
Ambientconditions
Enclosureprotection IP65
Norms EN60204,ISO16750
Ambienttemperature -10to+45 C
Maximumambient
temperature -30to+65
ab+45 Cto+65 Cwithpowerderating2%/ C
Storagetemperature -30 cto+80 c
Humidityinoperation Klasse F rel.humidity<85%,nocondensation!
Sitealtitude "1000m ü.nn100%,>1000mwithpowerderating
2%/100m
Cooling liquidcoolermax65 c,12l/min,prechermax1,3bar
Mountingposition equal
Program Type Software-version
BAMOCAR-D3(D2)-xx-rs resolver
BAMOCAR-D3-(D2)xx-in encoder-ttl
BAMOCAR-D3-(D2)xx-sc encoder-sincos1vss
BAMOCAR-D3-(D2)xx-bl rotorlage+bl-tacho
BAMOCARxx-DC dc-tacho,
armaturevoltage
Note:
Power supply cables between theBAMOCARandthe battery must be as short as possible.
Long cables cause dynamic voltage drops duetotheline impedance andasa
consequence the service life ofthe installed ELKOs would be reduced.
Technical Data
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