E Bamocar d3

MANUAL
Digital three-phase Servo Amplifier

BAMOCAR-PG-D3
EC-synchronous-servo motors
AC-asynchronous-servo motors
Industrie Elektronik
G m b H
Hans-Paul-Kaysser-Strae 1
71397 Leutenbach Nellmersbach
Edition / Version
Tel.: 07195 / 92 83 0
Fax: 07195 / 92 83 129
09/2017 V 03
info@unitek-online.de
www.unitek-online.de
Basic information
1 Contents
2 Basic information ............................................................................................................. 3
2.1 History ................................................................................................................................ 3
2.2 Further UNITEK products ................................................................................................... 3
2.3 Engineering instructions (MANUAL) .................................................................................. 3
2.4 Validity................................................................................................................................ 4
2.5 Designations and symbols ................................................................................................. 4
2.6 General product information ............................................................................................. 5
2.7 Applications/build/features ............................................................................................... 6
2.8 Safety regulations............................................................................................................... 8
2.9 Commissioning ................................................................................................................. 10
2.10 Safety advices ................................................................................................................... 11
2.11 Intended applications....................................................................................................... 12
2.12 Regulations and guidelines .............................................................................................. 13
2.13 Risks .................................................................................................................................. 14
2.14 Technical data .................................................................................................................. 15
3 Mechanical installation .................................................................................................. 18
3.1 Important notes ............................................................................................................... 18
3.2 Dimensions BAMOCAR ..................................................................................................... 19
3.3 Mounting onto mounting rails ......................................................................................... 20
3.4 Mounting onto a mounting surface ................................................................................. 20
4 Electrical installation ...................................................................................................... 21
4.1 Important advices ............................................................................................................ 21
4.2 Circuit diagram ................................................................................................................. 22
4.3 Connection diagram ......................................................................................................... 24
4.4 EMC advice ....................................................................................................................... 25
4.5 Connectors Standard version ......................................................................................... 26
4.6 Power connections 1000 V / 400 A .................................................................................. 28
4.7 Battery connection ........................................................................................................... 29
4.8 Auxiliary voltage connection ............................................................................................ 30
4.9 Motor power connection ................................................................................................. 31
5 Control connections ....................................................................................................... 32
5.1 Digital inputs .................................................................................................................... 32
5.2 Safety input RFE (Rotating field enable) Stop class 0 ....................................................... 33
5.3 Digital outputs (open emitter) ......................................................................................... 34
5.4 Analog input +/- 10 V ....................................................................................................... 35
5.5 Serial interface RS 232...................................................................................................... 36
1 BAMOCAR-PG-D3 Version: 09/2017 - V03

Basic information
5.6 CAN-BUS ........................................................................................................................... 37

5.7 Resolver connection ......................................................................................................... 38
5.8 Encoder connection TTL ................................................................................................... 39
5.9 SIN COS 1Vss connection .................................................................................................. 41
5.10 Rotor position encoder - connection via a bl-tacho ......................................................... 42
5.11 State displays .................................................................................................................... 43
5.12 Error displays .................................................................................................................... 44
5.13 Warning signals ................................................................................................................ 45
6 Measured data ...............................................................................................................46
6.1 Bus circuit battery voltage................................................................................................ 46
7 Bus circuit dc bus voltages (battery voltage) .................................................................... 47
7.1 Bus circuit dc / bus voltages ............................................................................................. 47
8 Output stage temperature .............................................................................................. 48
8.1 Output stage temperatur ................................................................................................. 48
9 Warranty ........................................................................................................................49
9.1 Warranty .......................................................................................................................... 49
Version: 09/2017 - V03 BAMOCAR-PG-D3 2

Basic information
History
2 Basic information
2.1 History
Version Modifications Date

03/2017 V02 Capital 2 / Firmware state 10. July 2017
Capital 4 / Note for CAN-BUS
09/2017 V03 Page 4 / Article no. added 21. Sept.2017
Page 15 / Dimensions changed
Page 16 / Temperature range changed
Page 29 / item F is changed
2.2 Further UNITEK products
For synchronous and asynchronous motors

Digital AC servo amplifiers (mains up to 480V~) UNITEK DS205, DS403,
DPCxx
Digital AC servo amplifiers for battery operation UNITEK Series BAMOBIL-D3
Analog three-phase servo amplifier (mains UNITEK Series TVD
400V~)
For dc motors
Analog DC servo amplifier for battery operation Series BAMOBIL-A
Analog DC servo amplifier (operation via the UNITEK Series TV
mains)
Thyristor current converter 1Q, 4Q, servo UNITEK Classic series
200W bis 800kW
2.3 Engineering instructions (MANUAL)
1. MANUAL BAMOCAR Hardware

2. MANUAL NDrive x Software
3. MANUAL Commissioning BAMOCAR Commissioning - error detect.
Use all three MANUALS for the engineering, the installation, and the commissioning!
CD (UNITEK-DOKU-SOFT) supplied with the delivery of the units.

Online available as download version on the UNITEK website (www.unitek-online.de or
www.unitek.eu).
The hardware MANUAL comprises warning and safety advices, explanations of standards,
mechanical and electrical installation advices.
The MANUAL must be available for all persons who are concerned with the unit.

Basic information
Validity
2.4 Validity
Hardware state: TMS 2-3d, driver 1-8

Firmware state: > FW 470
2.5 Designations and symbols
Unit: BAMOCAR-PG-D3
Manufacturers or operators of machines or installations in the industrial

User:
sector (B2B, secondary environment).
Manufacturer: UNITEK Industrie Elektronik GmbH
Dealer:
Caution Danger to life!

High voltage!
Warning!
Important!
Dangerous electric fields!
Scope of delivery
BAMOCAR-PG-D3-x device, documentation, CD UNITEK DOKU-SOFT in the box.
Not included (to be ordered as accessories):
PG screw connection
Control connectors:
X1 ..( In/Out) = Article no. G435 / Binder 99-5662-15-19
X7 (Feedback) = Article no. G436 / Binder 99-5661-15-19
X9 (CAN BUS) = Article no. G437 / Binder 99-0436-14-05
Programming cable X10 = Article no. G432 / Binder 79-3464-52-06

Basic information
General product information
2.6 General product information
The digital 3-phase current servo amplifiers BAMOCAR-PG-D3xx in combination with the motor provide a
4-quadrant drive which can be used in both rotation directions for drive operations and brake operations
with energy feed-back.
According to the installed parameter components the amplifiers are suitable for EC synchronous motors, ac
asynchronous motors, or dc motors.
The individual drive versions have different advantages and disadvantages.
The EC drive (synchronous motors) has the highest efficiency and performance per weight and volume and
provides a drive solution free of maintenance and with a wide dynamic control range. However, the high
braking torque in case of motor short-circuits is a disadvantage and it is also difficult to control the field
weakening range.
From the electrical view, the EC synchronous motor (brushless dc motor) is a synchronous motor with a
permanent magnet rotor and a three-phase current stator.
The physical characteristics correspond to those of dc motors, i.e., the current is proportional to the torque
and the voltage is proportional to the speed. The speed is steadily controlled up to the current limit (max.
torque). In case of an overload the speed drops and the current remains constant.
The speed/torque characteristic is rectangular.
Current, speed, and position are precisely measured. The field frequency is not controllable, it is
automatically adjusted.
The motor voltages and the motor currents are sinusoidal.
The ac drive (asynchronous 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 rotating field frequency can be controlled in due consideration of the motor specific
parameters (field-based control). The motor voltages and motor currents are sinusoidal.
With both 3-phase current systems there will be no motor movement neither when the rotating field is
switched off nor in case of an output stage damage. Most of the heat losses are generated in the motor
stator.
The dc drive (dc motor) has the most uniform running and a wide control range. It is possible to provide an
emergency operation by directly connecting the battery voltage. The carbon brushes and the heat
development in the armature are disadvantages. The drive may run at high speed in case of an output stage
damage.
The current is proportional to the torque and the voltage is proportional to the speed.
Current, speed, and position are precisely measured. The speed is steadily controlled up to the current limit
(max. torque). In case of an overload the speed drops and the current remains constant. The speed/torque
characteristic is rectangular. Field weakening might occur with separately excited motors.
The BAMOCAR-PG-D3xx can be used as position amplifier or torque or speed amplifier.

The speed actual value is generated in the encoder unit (resolver or others) or internally generated (without
sensors). It is necessary to provide an encoder system for wide control ranges and high control dynamics.
Warning/Attention:
For dc, ac, or bl-servo amplifiers which are supplied via the dc mains, it must be
checked that the energy is fed back into the bus during brake operation.
(External ballast circuit)

Basic information
Applications/build/features
2.7 Applications/build/features
Application in all kinds of vehicles, boats, machines, and installations with a drive power of 140
kW under hard application conditions, especially as 4Q-servo-drive for
- highly dynamic acceleration and braking cycles
- a wide control range
- a high efficiency
- small motor dimensions
- a uniform, accurate and smooth running
- for the speed or torque control or combined speed/torque control incorporated within or
independent of position control loops. For drives with constant speed as in conveyors, spindle
drives, pumps, transversal or longitudinal pitch drives, synchronous multiple motor drives.
Particularly suitable for:

Battery-driven vehicles such as electric vehicles and boats, forklifts, transportation systems as well
as battery-supplied machines and installations such as assembly machines, metal working
machines, food 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, DIN and EC regulations,
protection rating IP65
-for rough ambient conditions and high dynamic overloads
-maintenance-free
-power connections protected against accidental contact with exposed parts
-power electronics for (S1 operation) 125 A, 200 A
-power input range nom. 12 to 700 V=
-liquid cooling (special version air cooling)
-standard digital control electronics
-Independent 12/24 V chopper power supply unit for the auxilary voltages
Galvanic isolation between:

- power connection, motor connection, and all other control connections
- auxiliary connection and all other voltages
- housing and heat sink
- the distances of air gaps and leakage paths adhere to the EU standards
- no internal isolation watchdog, Y2 capacitors to the housing
Components:
- Completely isolated IGBT power semi-conductors, comfortably over-dimensioned
- Only components customary in trade and industrially standardised are used
- SMD equipment

Basic information
Applications/build/features
Characteristics:
Battery connection 12 V= to 700 V= (dc mains, take restrictions into account)
Independent auxiliary voltage connection 24 V= or 12 V=

Digital interfaces RS232, CAN BUS (further option)
2 analogue inputs, programmable differential inputs
Digital inputs/outputs, programmable, optically de-coupled
Linear command value ramp, non-linear (s-function)
Logic for enable and the output stage switch, emergency stop function, safety
BTB ready for operation, solid state relay contact
Position, speed and torque control
Feedback encoder systems: resolver, incremental encoder, SINCOS 1 Vss, rotor position + bl
tacho
Static and dynamic current limiting
Uniform, completely digital 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 short-circuit proof power section (EN50178)
Attention: Braking energy

The braking energy is fed to the battery.
The battery must absorb the braking energy.
Note:
Pay particular attention when used with laboratory power
supplies.
For dc mains the braking energy must be absorbed in the
mains without the voltage exceeding the permissible value. If
this cannot be guaranteed, a ballast circuitry must be used.
Note:
For non-earthed systems (vehicles, boats, machines)
the isolation between parts accessible to touching and high voltages must be guaranteed and
monitored by using independent isolation monitors.

Basic information
Safety regulations
2.8 Safety regulations
In principle electronic equipment is not fault proof!
Caution - High voltage

DC 800V=
Shock hazard! / Danger to life!
Discharge time of the bus circuit >4 min.
Before installation or commissioning begins, this manual must be thoroughly read and
understood by the skilled technical staff involved. It must be ensured that the documentation
(manuals) and thus, the knowledge of the unit and especially the safety advices must be available
for all persons who are concerned with the unit
If any uncertainty arises or if any function is not or not sufficiently described in the
documentation, the manufacturer or dealer should be 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 are power electric parts used for regulating energy flow.
They are designed as components to control EC synchronous motors, ac asynchronous motors in
vehicles, machines, or installations.
For applications in residential areas additional EMC measures are necessary.
Any other type of application must be approved by the manufacturer.
The user must draw up a hazard analysis for his end product.
Protection rating IP65
Connection only to batteries
Operation only allowed when the device is closed!

The control and power connections can be charged with high
voltage without an active operation!
The minimum discharge time of the bus circuits is at least 4
minutes!
Measure the voltage before any disassembly!

Basic information
Safety regulations
The user must draw up a hazard analysis for his machine, vehicle, or installation.
The user must ensure that in the event of:
- device failure
- incorrect operation,
- loss of regulation or control
the axis will be safely de-activated.
It must also be ensured that the vehicles, machines, equipment,

or vehicles are fitted with device independent monitoring and
safety features.
The user must take appropriate measures so that man as well as
property are not exposed to danger due to incorrect or improper
movements at any time!
Im Betrieb muss das Gert geschlossen sein.

All plugged connectors must be snapped properly or secured by
screws.
The 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 units.
Assembly
- should only be carried out when all voltages have been removed and the units are secured
- should only be carried out by suitably trained personnel
Installation
- should only be carried out when all voltages have been removed and the units are secured
- should only be carried out by suitably trained personnel for electrics
- should only be carried out in accordance with health and safety guidelines
Adjustments and programming

- should only be carried out by suitably trained personnel with knowledge in electronic drives and
there software
- should only be carried out in accordance with the programming advice
- should only be carried out in accordance with health and safety guidelines

Basic information
Commissioning
2.9 Commissioning
The battery servo amplifiers BAMOBIL PG - D3 are components of the electronic drive technology.
They are functional only in connection with an electrical consumer (e.g. a motor). Their use is
limited for commercial applications.
When mounting the units into vehicles, boats, machines, and installations the proper operation of
the units 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 installation and test conditions described in the chapter 'EMV advices' it is adhered to the
EC guideline 2004/108/EG including the EMC standards EN61000-2 and EN61000-4.
A manufacturer's declaration can be requested.
The manufacturer of the machine or installation is responsible for observing the threshold values
demanded by the EMC laws.

Basic information
Safety advices
2.10 Safety advices
Machinery directive
The manufacturer of the machine or installation must draw up a hazard analysis for his product.
He must make sure that any unpredictable movements do not cause damage neither to persons
nor to property.
Skilled personnel
Hardware
The skilled qualified personnel must feature a training and instruction for an assignment in the
field of electronic drive engineering. They must have knowledge of the standards and accident
prevention regulations for drive engineering applications and they must be familiar with this field
of activity. Eventually occurring dangerous situations are realized.
The local regulations (IEC, VDE, VGB) are known to the qualified personnel and they are observed
during the works.
Software
The skilled qualified personnel for handling the software must be trained to safely program the
units in the machines and installations. Incorrect parameter settings may cause improper and
impermissible movements. Any parameter settings have to be checked for faulty operation.
Acceptance tests must be thoroughly carried out according the four-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 power supply prior to any works on electric connections. It must be ensured the
battery voltage is safely switched off.
Any voltages and residual voltages (buffer circuit) must be measured prior to any works on the
unit. Max. permissible voltage <42 V.
High temperatures (> 70C) may arise.
The working environment may be dangerous for persons having electronic medical aids or
appliances (e.g. cardiac pacemakers). Sufficient distance to these electrical parts must be
observed.
Exposure
During transport and storage the prescribed and specified climatic conditions must be adhered to.
The units must not be mechanically damaged. Warped and bent housing parts may influence or
damage the isolation distances. Damaged units must never be installed!
The units comprise parts which may be damaged by electrostatic discharge. The general
recommendations for handling electrostatic devices must be observed. Special attention should
be paid to strongly isolating plastic films and synthetic fiber.
For the operation it must be ensured that the environmental conditions in the switch cabinet are
adhered to. This applies in particular to the impermissible condensation on the units.

Basic information
Intended applications
2.11 Intended applications
The devices are designed as components to control EC synchronous motors and ac asynchronous
motors in vehicles, boats, machines, or installations.
Any other type of application must be approved by the manufacturer.
Protection rating IP65.
The devices must only be mounted in vehicles, boats, machines, or installations.
The user must draw up a hazard analysis for his end product.
Power connection only to batteries. Isolation watchdogs must be installed for voltages >60V.
The capacities between clocked power modules and the housing (0.022 F Y2.capacitors). Use
external insulation measuring instruments.
The control connections (terminal X1, plugs X7, X8, X9, X10) of the unit comply with the "safe
electrical isolation SELV" acc. to EN 61800-5-1. The user must ensure that the complete control
wiring 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 connection GND). The
equalizing currents may destroy components and parts.
When measuring the isolation the units must be disconnected or the power connections must be
bridged together and the control connections must be bridged together.
Non-observance will cause damage to the semi-conductors in the unit.
Repeating circuits to earth and short circuits the values of which are all below the response
threshold for short circuits may cause damage to the output stages (conditionally short-circuit
proof acc. to standard EN 50178, EN61800-5-1).
Impermissible applications
- in life-sustaining medical devices or machines
- connection to power supply units or dc power supplies without protection circuits
- on ships
- in explosive environments
- in environments with acrid fumes

Basic information
Regulations and guidelines
2.12 Regulations and guidelines
The device and its associated components can only be installed and switched on where the local
regulations and technical standards have been strictly adhered to:
EG Guidelines 2004/108/EG, 2006/95/EG, 2006/42/EG, 2002/96/EG

EG Standards EN60204-1, EN292, EN 50178, EN60439-1, EN61800-3,
ECE-R100
International standards ISO 6469, ISO 26262, ISO 16750, ISO 20653, ISO 12100
IEC/UL IEC 61508, IEC364, IEC 664, UL508C, UL840
VDE Regulations and VDE 100, VDE 110, VDE 160
TV Regulations
Regulations of the statutory accident VGB4
insurance and prevention institution
EU standards and regulations observed for the components of the unit
Standard Description Version

EN 60146-1,-2 Semiconductor converters 2010
EN 61800-1,-2,-3 Speed-variable electrical drives 2010
EN 61800-5-1 Electric power drive systems 2010
EN 60664-1 Isolation coordinates - low 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 of the electrical equipment of vehicles
ECE-R100 Conditions for battery-driven electric vehicles

UL 508 C UL Regulations - converter 2002
UL 840 UL Regulation - clearance and creepage distances 2005
EU standards and regulations which must be observed by the user
Standard Description Version

EN 60204 Safety and electrical equipment of machines 2011
EN 50178 Equipment of power plants 1998
EN 61800-3 Speed-variable electric drives - EMC 2010
EN 60439 Low voltage switching device combinations 2011
EN 1175-1 Safety of electric industrial trucks 2011
ISO 6469 Electric road vehicles 2009

ISO 26262 Functional safety of electric road vehicles 2011
ISO 16750 Electrical components - vehicles 2010
ISO 12100 Safety of machines 2011
ISO 13849 Safety of machines and controls 2011
IEC 364 Protection against electric shocks 2010
IEC 664 Isolation coordinates - low voltage 2011

Basic information
Risks
2.13 Risks
The manufacturer aims to keep the remaining risks emanating from the unit as low as possible by
means of constructive, electrical, and software measures.
In the field of drive engineering the following known remaining risks must be considered
regarding the risks arising from machines, vehicles, and installations.
Impermissible movements
caused by:
failure of safety watchdogs or switched-off safety watchdogs during commissioning or
repair works
software errors in upstream controls, errors in bus systems
non-monitored hardware and software errors in actuating elements and connecting
cables
inverted sense of control
faults during the parameter setting and wiring
limited response time of the control features. Ramps, limits
operations not permitted in the specifications
electromagnetic interferences
electrostatic interferences, lightning strikes
failure of components
failure in the brakes
Dangerous temperatures
caused by:
faults during the installation
faulty connections, bad contacts, aging
faults in the electric safety system, incorrect types of fuses
operations not permitted in the specifications
negative climatic conditions, lightning strikes
failure of components
Dangerous voltages
caused by:
faulty earthing of the unit or motor
faulty connections, bad contacts, aging
faulty potential isolation, failure of components
conductive contamination, condensation
Dangerous fields
The units, the inductive and capacitive accessories as well as the power
wiring can generate strong electric and electromagnetic fields. These
fields may be dangerous for persons having electronic medical aids or
appliances (e.g. cardiac pacemakers). Sufficient distance to these
electrical parts must be observed.
The switch cabinet must be labeled accordingly.

Basic information
Technical data
2.14 Technical data
For three-phase current motors
Auxiliary voltage connection 12 V= to 700 V=

12 V= or 24 V= 10 % / 4 A (2 A)
Auxiliary voltage connection
residual ripple <10 %, regenerating fuse
Data BAMOCAR D3-400-(700) Dim. 125/250 200/400 125/250 200/400

Supply voltage, rated value V= 24 up to max. 400 24 up to max. 700
Max. output voltage, rated value V~eff up to 3x260 up to 3x450
Continuous current Aeff 125 200 125 200
Max. peak current Alo 250 400 250 400
Max. power loss kW 2 3 2.6 4
Pulse frequency kHz 8-24 8-16
Over-voltage
V= 440 800
switching threshold
Input fuse A 160 250 160 250
Weight kg 8.5
Dimensions h x w x d mm 355 x 230 x 135
Size 2
Control signals V A Function Connector

Analogue inputs 10 0.005 Differential input X1
ON 10-30 0.010
Digital inputs Logic IO X1
OFF <6 0
Transistor output
Digital outputs +24 1 X1
open emitter
Resolver / TTL / SINCOS Differential input X7
CAN interface Logic IO X9

RS232 interface Logic IO X10

Basic information
Technical data
Ambient conditions
Protection rating IP 65
Standards EN60204, ISO 16750 , EN61800, IEC60146
Protection class
Over-voltage +10%
Operating temperature range 0 to +45 C

Extended operating temperature from +45 C to +65C performance reduced by 2% / C
range
Storage and transport -30 C to +80 C EN60721
Installation altitude 1000m above sea level 100 %,

>1000m performance reduced by 2%/100 m
Cooling Liquid cooling unit max. 65C, 12 l/min,
pressure max. 1.3 bar
Mounting position independent
Contamination Contamination degree 2 acc. to EN 61800-5-1
Vibration 10Hz to 58Hz ampl. 0.075 mm (IEC 60068-2-3)

58 Hz to 200Hz 1 g
Shock 15 g for 11 ms
Environmental conditions Not permissible:

condensation (dew), ice formation, oil mist, salt spray,
water
Humidity class F, humidity <85 %
condensation not allowed!

Basic information
Technical data
Current reduction (torque reduction)

Only with air cooling
Permissible current limit depending on the

installation altitude
2-1 ED-Ired-Hhe-5
With air cooling

ambient temperature
With liquid cooling

temperature of the cooling agent
2-2 ID-Ired-Um-temp-5
Programmable current reduction

depending on the IGBT module temperature.
Starting temperature of the reduction
I-red-TD 0x58
Final temperature of the reduction

I-red-TE 0x4c
2-3 ED-Ired-IGBT-Temp-5
Automatic current reduction

depending on the rotation frequency
(motor speed)
2-4 ED-Ired-rot-5
Automatic current reduction

depending on the pulse frequency
2-5 ED-Ired-IGBT-takt-5

Mechanical installation
Important notes
3 Mechanical installation
3.1 Important notes
Check the device for mechanical damage.

Only devices in perfect working order can be mounted.
Disconnect the power supply prior to any assembly.

Disconnect the positive and negative battery pole and the dc
mains.
The device must only mounted by suitably trained personnel.
The mounting position of the devices with ground plate and

those with additional cooling unit (air by means of fan, liquid) is
arbitrary.
If the heat is not dissipated sufficiently the device switches off

via its temperature watchdog.
Any bore hole dimensions for the fixation of the device must be taken from the dimension
diagrams or from the drilling plan, not from the device.
The filter and the choke have to be mounted near to the device.
The line shields and the mounting plate must have surface-to-surface contact.
The power supply lines (battery line and motor line) must be routed separately from each other.
Observe the min. line cross-section.
A safe earth connection must be provided between the housing and the
mass level (vehicle chassis earth, earth of the switch cabinet)
Unshielded cable heads must be kept short.
Only use specified connectors.
Use vibration-proof screw connections.
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 capacitors would be reduced.

Dimensions BAMOCAR
3.2 Dimensions BAMOCAR
Standard version (connectors partly equipped)
Liquid cooling Power connection

Connection PG-cable glands M25x1.5 with
Hose connection: metal -13 shield spring
Input temperature: < 50C Recommended cable gland
Flow rate: max. 12l/min Lapp- SKINTOP- MS-x
Pressure: max. 1.3 bar Pflitsch- blueglobe TRI

Mounting onto mounting rails

3.3 Mounting onto mounting rails
4 x screw M5x20
3-1 rh5-BAMOCAR-D3-V6-standard-montage
3.4 Mounting onto a mounting surface
4 x distance pipe for M5 l = 20 mm

4 X screw M5x40

Electrical installation
Important advices
4 Electrical installation
4.1 Important advices
The order of the connections to the connector or terminal numbers is obligatory!
All further advice is non-obligatory.

The input and output conductors may be altered or supplemented in accordance with the
electrical standards and guidelines.
Adhere to:
- connection and operating instructions
- local regulations
- EU guideline 2996/42/EC
- guidelines for vehicles ECE-R100, ISO 6469, ISO 26262
- VDE and TV regulations and Trade body guidelines
Electrical installation should only be carried out when all voltages have
been removed!
Ensure that the device is safely disconnected from 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 with those indicated on the type plate.
Ensure that the correct fuses have been provided for the power supply and the auxiliary voltage.
Power supply conductors and control lines must be routed separately from each other.
Connection shields and grounding must be carried out in compliance with the EMC guidelines.
Use the correct line cross-sections.
Insert external isolation monitors!
Note: Bad or insufficiently rated cable connections between

the battery and the device may cause damage to the
device! (Brake energy)
Note: Power supply cables between the BAMOCAR-D3 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 capacitors
would be reduced.

Circuit diagram
4.2 Circuit diagram
4-1 BAC-blockbild-3-TMS-rund

Circuit diagram
Circuit diagram
4-2 BAC-blockbild-3

Connection diagram
4.3 Connection diagram
4-3 E-BAC-anschlussplan-2

EMC advice
4.4 EMC advice
4-4 E-BAC-emv4
The devices adhere to the EU guidelines 2004/108/EC and the technical standard EN 61800-3
provided that the following conditions are observed:
Mounting:
The device is conductively mounted on a 500 x 500 x 5 mm bright aluminium mounting plate.
The mounting 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 mm wire.
Device PE screw X3:6 connected to the mounting plate using a 4 mm wire.
Connection of the control conductors:

All control conductors must be shielded. Analogue signal lines must be twisted and shielded. The
shield must have surface-to-surface contact with the mounting plate (earth).
Battery connection:
360V dc voltage
Motor connection:
Motor lines must be shielded, and must have surface-to-surface contact
After having 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 2006/42/EC and the EMC guideline 2004/108/EC, for vehicles
ECE-R83 and ECE-R100.
A manufacturer's declaration can be asked for.

Connectors
4.5 Connectors
Standard version
Membrane X9 CAN X1 Control X10 RS232 X7 Feedback Monitor

Ventil BUS In-Output Parameter Sensor Status-error
Connector X1 Control inputs/outputs

A brown BTB ready for operation
B red BTB
C pink GND24 auxiliary voltage 0
D yellow +24 auxiliary voltage +
E green END1/LMT1 limit switch 1
F blue END2/LMT2 limit switch 2
G violet FRG/RUN enable
H grey AIN1+ analog input 1
J white AIN1-
K black GNDE logic zero
L br-green DIN1 digital input 1
M br-yellow DIN2 digital input 2
N wh-green DOUT1 digi-output 1
O red-blue DOUT2 digi-output 2 Connector plug
P wh-yellow AIN2+ analog input 2
R wh-red AIN2- connector female
S wh-grey DOUT3 digi-output 3 Binder 99-5662-15-19
T wh-black RFE rotating field enable
U wh-blue +24V auxiliary voltage+
Stecker X9 CAN
1 PE
2 Supply IN
3 CAN GND
4 CAN H
5 CAN L

Connectors
Connector X10 RS232

1 brown R2IN
2 white TxD
3 blue T2OU Connector plug Binder 79-3464-52-06
4 black T2OU (connector female)
5 grey RxD
6 pink GND
Option connector X11 brake

1 +24 V-Br
2 Brake + Connector plug Binder 99-0429-15-04
3 Brake - (connector female)
4 GND-24V-Br
Feedback encoder connector X7

Connector female device
Connector plug
Binder 99-5661-15-19
Connector X7 Connector X7 Connector X7 Connector X7

Encoder plug Resolver Encoeder plug INC-TTL Encoder plus SIN/COS Encoder plug bl
A A channel A A channel ka+ A MP tacho
B B channel /N B channel kr+ B
C SIN1 C channel B C channel kb+ C tacho 1
D D supply +5V D supply +5V D supply +15V
E COS2 E channel N E channel kr+ E tacho 2
F F channel /B F channel kb- F
G REF2 G channel /A G channel ka- G tacho 3
H temp signal H temp signal H temp signal H temp signal
J J temp GND J temp GND J temp GND
K REF1 K rotor position3 K channel kd- K rotor positon3
L temp GND L supply GND L supply GND L supply GND
M COS1 M rotor position2 M channel kc+ M rotor position2
N N N channel kd+ N
O SIN2 O rotor position1 O channel kc- O rotor position1
P P P
Encoder plug INC
For all connectors: connector view from the solder / crimp side

Power connections 1000 V / 400 A

4.6 Power connections 1000 V / 400 A
Cable gland metal M25x1.5
Connection- Battery plus
Connection Motor W
Connection Motor V
Connection -- Motor U
Connection- Battery minus
Cables maximal 50mm2 (AWG 1/0)
Preparation
Strip outer insulation/jacket to 38 mm
Shorten shield to 10 mm
Strip inner insulation/dielectric to 15 mm
Cut 25mm cable lug insulation from
braided sleeve or heat shrink tubing
Have a correct cable lug for M10 screw
Pre-assembly
Slip complete cable gland, including shield bruscing, onto cable
Slip the cable lug insulation onto cable
Crimp the inner conductor into the cable lug (15 mm)
Mounting
Screw gland body into device.
Loosely attach the cable lug to the internal conductor bar.
Bolt type M10x12 self-locking or with a disc washer,
toothed wasche rare prohibited .
Tighten gland cap-nut.
Tighten internal connection. Max locking torque 20Nm.
Connecting screw: M10x12

Cable gland : M25 metal with screen contact (Not in the delivery)
4-5 Pfisterer-Stecker
Battery connection
4.7 Battery connection
Note:
Bus circuit capacitor C-ZW
at 400 V 320 F
at 700 V 320 F
Discharge resistance R-ZW 50 k
Series resistor
RV approx. 40 Ohm 50 W
Charging current via K2 <20 A
Note:
4-6 ED-BAC-Batt-2 Enable (RUN) only after the main
contactor K1 is activated.
The max. supply voltage (battery voltage) 450 V= (780 V=)

must not be exceeded at any time (not even for short intervals)!
Danger of damage! / Error message: OVERVOLTAGE / F1 = safety fuse
Block diagram of the pre-charging Programming example:

The output Dout1 switches the relay K3 when the
bus circuit voltage (DC-BUS) is greater than the
variable 1.
4-7 ED-BAC-Vorlad-2
Warning:
The power supply connection has no protection against reverse polarity.
If the polarity of the connection is wrong, the device will be destroyed!
Type Battery connection

Connector cross- Fuse AT Drive contactor
section size
mm AWG
-125/250 25 2 160
-200/400 35 1 250
Battery connecting line <2m. For conductor lengths from 2 to 10m more powerful.
Use an additional capacity for conductor lengths superior to 10m!

Auxiliary voltage connection

4.8 Auxiliary voltage connection
Mains potential-free auxiliary

dc voltage +12 V= (4 A) to +24 V= (2 A) 10 %
The auxiliary voltage
-is galvanically connected with the logic voltage
-is galvanically isolated from all internal supply voltages of the device and from the housing
-internal regenerating fuse
-EMC filter
External fuse only for the line protection

Input voltage 12-24 V DC X1:4
GND24 X1:3
Residual ripple 10%
Switch-on current 4A
Nominal current at 12V 1.4A
at 24V 0.9A
Neg. connection of the power supply to
earth
Attention:
In addition to the internal supply current (1.4A) the sum of the output currents (DOUT) must be
provided by the mains module 12/24 V.
If the auxiliary voltage is inferior to 10.5V there will be the error message hardware error 1
(power fault)
If the auxiliary voltage is inferior to 10 V - even in case of short-time

voltage drop-outs - the internal mains module is switched off.
Temporary data of the RAM are deleted.
The digital speed and the command torque values are set to zero.
The LED signal for the state OK is dark.
Firmware download only when the power supply is switched off!
The auxiliary voltage and/or power supply voltage must only be switched when the BAMOCAR is
disabled.
No disable.
Enable input X1:G = zero

Motor power connection
4.9 Motor power connection
Only electronically commutating synchronous motors (brushless dc motors, EC motors) with

resolver or incremental encoder must be used. These motors must be approved of by the
manufacturer prior to any use.
4-8 ED-BAC-Motor-2
Sequence of connection
Cable M1 M2 M3 Motor cable
Motor phase U V W 3 cores + protective conductor
Connecting bolt XB:2 XB:3 XB:4 single-shielded, for 1000 V=
shield capacity 150 pF/m
Only one correct connecting sequence is possible! min. cross-section see table
Min. cable cross-section

Type BAMOBIL D3-xx -125 -200 Motor choke,
Cross-section mm 25 35 only necessary for shield capacities
AWG 2 1 superior to >5 nF.
motor cable approx. 25 m
Motor choke
Only necessary for a shield capacity of >5 nF. Approx. 25m motor cable
Magnetic rings:
against HF failures of the sensor systems. Slide the rings onto the motor lines.
Connection of the shield
Surface-to-surface connection to the switch cabinet inlet.
Surface-to-surface connection as short as possible to the motor side.
For long motor cables the motor cable shield must be connected at
multiple times with the vehicle or machine frame (e.g. ground terminals
every 5 m).

Control connections
Digital inputs
5 Control connections
5.1 Digital inputs
Input voltage
Digital Input Level ON +10 to +30
X1:E Limit switch 1 END1/LMT1 V
X1:F Limit switch 2 END2/LMT2
X1:G Enable FRG/RUN Level OFF <+6 V
X1:L Digital Input1 DIN1
X1:M Digital Input2 DIN2
Input current Max. 7,5 mA
VCC
Digital
X1:T Rotation Enable RFE
Input
10...30V= 3k9
PAx
Nominal +24 V/6 mA
voltage/current
470
100nF
100nF
round connector
Ground reference GNDE (X1:K)
5-1 E-BAC-DIN-2
The enable input (FRG/RUN) and the input for the rotating field enable (RFE) are fixed, they
cannot be programmed.
Without the enable FRG/RUN the servo-drive is electronically disabled (no PWM pulses).
Without the rotating field enable RFE the rotating field of the output stage is additionally disabled
(2nd disable channel).
The drive is free of torque (no holding torque).
The remaining four digital inputs can be programmed.

The inputs LMT1 (X1:E) and LMT2 (X1:F) are preferably to be used as inputs of the output stage
switch.
Input Connector Function State

FRG/RUN X1:G Enable fixed
RFE X1:T Rotating field enable fixed
END1/LMT1 X1:E Output stage switch 1 / programmable
digital input
END2/LMT2 X1:F Output stage switch 2 / programmable
digital input
DIN1 X1:L Digital input 1 programmable
DIN2 X1:M Digital input 2 programmable
The enable (FRG X1:G) must not be initiated before the auxiliary voltage (12-24 V)
and the power voltage have been switched on. Error message 5(POWERVOLTAGE).
External power supply for the inputs and outputs
Logic-
voltage
+12 24 V for logic and
Logik- X1:D
Spannung +12/24 auxiliary voltage
+12/24V
Logic-
ground X1:K
GNDE GNDE logic ground
Logik-
Masse
5-2 ED-BAC-Logic-2

Control connections
Safety input RFE (Rotating field enable)
5.2 Safety input RFE (Rotating field enable)

Stop class 0
Warning:
If the inputs of the enable or of the rotating field enable are
switched off, the drive is free of torque. The drive could move
if there is no mechanical brake or block provided.
The motor conductors are not dead. Only the rotating field is
disabled. Prior to any work or maintenance on the motor or
the BAMOCAR, the battery motor controller must be
completely disconnected from the mains power supply of the
battery.
Operation with an RFE input 12/24V-Voltage

GND12/24 +12/24V=
Two-channel disable of the enable via a CNC/SPS

safety switching device. Hardware
Enable
Enable input FRG/RUN + +12/24V=

X1
A
Rotating field enable input RFE. Safety

GND12
B
C
Device +12/24
D
PNOZ
E
Switching-on GND12/24 FRG / RUN

Hardware
F
Contacts of the safety device closed,

Enable
H
enable FRG/RUN 0.5s after RFE.

GNDE
K
Logic-GNDE
L
M
Logic-voltage
N
GND12/24 +12/24V=
Safety switch-off
O
P
CNC/SPS
Contacts of the safety device open:
R
Hardware
S Enable
RFE
- there is no FRG/RUN signal in the 1st

T
Rotating
Enable U X1
A
disable channel to disable the PWM pulses round connector Safety

B
in the processor
Device
D
PNOZ
E
5-3 E-BAC-REF1-2
- there is no RFE signal in the 2nd disable
F
GND12/24 FRG / RUN
Hardware G
Enable
channel to disable the PWM pulses at

H
J
GNDE
the output of the processor

K
Logic-GNDE
L
12/24V-Voltage
M
GND12/24 +12/24V=
N
Restart CNC/SPS
Hardware
P
Release the safety switching device.

Enable
S
RFE
T
X1 Rotating
Contacts of the safety device closed.

Enable U
A
The motor can only move after a second

B
GND12/24
C
+12/24 round connector
disable FRG/RUN (after the rotating field
D
enable).
F
5-4 E-BAC-RFE2-2
FRG / RUN
Hardware G
Enable
H
Operation without RFE input

GNDE
K
Logic-GNDE
GND12/24
L
The input RFE must be bridged with the

M
logic voltage.
O
If the logic voltage corresponds to the

R
supply voltage, the RFE input is bridged

RFE
Rotating T
Enable
U
+12/+24
with +12/+24 V. 5-5 E-BAC-RFE-4-2
Enable FRG/RUN at least 0.5 s after the RFE round connector
signal.

Control connections
Digital outputs (open emitter)

5.3 Digital outputs (open emitter)
Output voltage
Digital Output
X1:N Digital Output1 DOUT1 Level ON +12 to +24 V=
X1:O Digital Output2 DOUT2
X1:S Digital Output3 DOUT3 Level OFF <1 V=
+24
Output current nom 1A

F_AUSx
Digital
Output current max. 2 A,1s

Output
24V/1A
100nF
round connector Voltage reference +24 (X1:D)

5-6 E-BAC-DOUT-2
Ground reference GNDE (X1:C)
Output Connector Function State Parameter

BTB/RDY X1:A, X1:B ready for operation fixed /solid state relay
DOUT1 X1:N Digital output 1 programmable
DOUT2 X1:O Digital output 2 programmable
DOUT3 X1:S Digital output 3 programmable
DOUT4 X11 Brake (option) 4 programmable
Note:
The auxiliary voltage is also the supply voltage for the logic outputs.
Logic-
voltage
Logik- X1:D
+12 to + 24 V for logic and auxiliary voltage
Always pay attention to the total current of all
Spannung +12/24
+12/24V
Logic- outputs
ground X1:K
GNDE
Logik-
Masse
GNDE logic ground
5-7 ED-BAC-Logic-2
Signal contact "Ready BTB/RDY" (Solid state relay)

Contact for max. 48 V/0,5 A
(not short-circuit proof)
BTB/RDY Solid State Relais Capacitive load max. 1 mF
Safety
X1:A
Contact resistor max. 2 Ohm
circuit
The contact is closed
Sicherheits
Kreis
when the device is ready
for operation.
X1:B
100nF Always install the

F_BTB BTB/RDY contact in the
Rundstecker safety circuit!
round connector Install a fuse 0.5 Af to secure the
5-8 ED-BAC-BTB-2 BTB/RDY signal path!
In case of failures the contact is open.
(Option)7segment-LED state display
Ready BTB opens (open BTB relay contact, (option red LED))
in case of error messages
BTB with or without under-voltage monitoring (BTB-Power).
The message "under-voltage in the bus circuit" can be programmed
(see Manual NDrive-x)

Control connections
Analog input +/- 10 V
5.4 Analog input +/- 10 V
analoge IN+
15k
Spannung
10k 100k
Analog Input 1.5V +/- 1.36V
100k 100nF
+/- 10V Sollx
IN-
10k 100k REF150

15k
BAMOCAR
5-9 ED-BAC-AIN-2
Input Connector Basic function Voltage State Parameter

AIN1+, AIN1- X1:H, X1:J Speed command value +/- 10 V prog.
AIN2+, AIN2- X1:P, X1:R Current limit +/- 10 V prog.
Features
Differential input AIN1+ / AIN1- AIN2+ / AIN2-

Input resistance 70 k
Threshold voltage +/- 12 V
Resolution 11 Bit + sign
The direction of rotation of the 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. (See NDrive-x)
With a digital command value (RS232, x-bus) the analog input AIN1 can be programmed as
external analog speed limit and the analog input AIN2 can be programmed as external analog
current limit. (See NDrive-x)

Control connections
Serial interface RS 232

5.5 Serial interface RS 232
The device is programmed and operated during commissioning via the serial pc interface RS232.
There is a software description in the Manual DS NDrive.
Connector PC
5
Stecker RxD 2
am RxD
PC 2
TxD 3
TxD
3
The serial interface is galvanically connected
T2OU with the device zero (GND/AGND).
4
1
R2IN
6 RS232
GND 5
Rundstecker
PE am Steckergehuse round connector
PE on the connector housing
5-10 ED-BAC-RS232-2
The controller (D-plug X10) and the serial interface (COMx) of the pc must only be connected using
a null modem cable.
Do not use a null modem link cable!
Install the cable only after disconnecting the device from the mains.
The interface is hard-coded to 115200 Baud.
Null modem connecting cable BAMOCAR

View to the soldered side Connector X10 RS232
Shield on the housing 1 P/D (CTS) R2IN
Max. cable length 10m 2 TxD
3 V+ (RTS)
4 V+ (DTR)
5 RxD
6 GND
Colors = recommendation

Control connections
CAN-BUS
5.6 CAN-BUS
The CAN-BUS is a digital connection to the CNC control.

Optimum conditions are achieved with CNC controls and CAN components of LABOD electronic or
CAN Open.
Programming and operation by means of the control panel via the CAN-BUS.
Interface complies with the standard ISO 11898.
Adjustment and programming see Manual NDrive and -CAN Manual.
CAN-VCC DC VCC
The BUS interface is galvanically
CANGND DC GND isolated from the internal device
CAN-BUS voltage.
2
CAN-V+
CAN-V+
The voltage is supplied via an internal,
isolated DC-DC converter.
4
CANH
CANH
5
CANL
CANL
3
CANGND
CANGND
CAN-BUS isolated /
1
PE am Steckergehuse
Rundstecker
round connector CAN Gnd to common potential
5-11 ED-BAC-CAN-2
CAN BUS cable

Use a shielded bus conductor with a low shielding capacity.
Signal plus GND (+internal supply DC/DC converter, galvanically isolated)
Circular connector M12-5p / LiYCY 4 x 0.25 + shield
Designation Connector no. X9 Cable colour

CAN-BUS
PE 1 Shield
CAN-V+ 2 brown
CAN-GND 3 white
CAN-H 4 green
CAN-L 5 yellow
(Note: colors can be different)
View on device side

At the connector - view on the soldered crimp side
Terminating resistor at both ends of the bus line > 120 Ohm between the CAN-H and CAN-L.

Control connections
Resolver connection
5.7 Resolver connection
Only with BAMOCAR D3-RS

5-12 ED-BAC-Reso-2 The resolver is an absolute measuring system
Rundstecker
for a motor revolution.
Stecker X7
Connector x7 round connector It is robust and not impaired by high motor
Motor-Stecker
Motor-Connector temperatures.
Resolver
R1 K
47
Its build corresponds to a revolving transformer.
REF1 REF1 REF1
The rotor is supplied by the reference (10kHz).
R2 G The stator supplies the sine and cosine signals
REF2 REF2
47
modulated by the rotational frequency. The
REF2
amplitudes of these signals are analyzed and
S2 C digitalized in the servo-drive. The resolution is
SIN1 SIN1 AD2S automatically set to an optimum of 10, 12, or 14
bit.
10nF
S4 O
SIN2 SIN2
2x2u2 The max. possible speed is 50 000 (10 bit).
The digitalized signals are used for the polar
S1 M
wheel angle, the position and speed control,
COS1 COS1 and the incremental output.
10nF
S3 E
COS2 COS2 Connector X2 Encoder connector resolver
2x2u2
VCC +5V A
B
4k7
C SIN 1
H
Motor TEMP
D
E COS 2
Temperature
Motor 100nF
F
Temperatur
L
G REF 2
H Temperature signal
PE am Steckergehuse
PE am Steckergehuse
J
PE on the connector housing K REF 1
L Temperature GND
M COS 1
N
O SIN 2
P
Only use motors with a 2-, 4-, 6-, or 8-pole resolver which have been approved by the
manufacturer. Observe the motor specific connection data sheet (RS)!
Connector X7 19-pin round connector
Connecting cable 4 x 2 cores, twisted in pairs and shielded, additional overall shield.
For link chains use appropriate cables!
Min. cross-section 0.25 mm
Cable length for >25 m only use high-quality resolver cables with adequate shielding
properties.
Shield connection across connector X7 combine all shields and connect
them to the housing
across the motor connector connect the overall shield to the
connector housing
Setting parameters see software Manual NDrive

Control connections
Encoder connection TTL
5.8 Encoder connection TTL
Only with BAMOCAR D3-IN

TTL incremental encoder (encoder) with 2
counter tracks and 1 zero track plus 3 rotor
position tracks. Counter tracks with or without
Stecker X7 Rundstecker
push-pull output.
Connector x7 round connector
VCC +5V
(For single connection A, B, N do not connect
D
VCC +5V
A A
TMS
the negative inputs.)
A G
The counter input corresponds to RS485.

B C
Max. counting frequency 500 kHz.
The incremental encoder is galvanically

B F
Encoder
connected with the device zero (GND).

N E
The voltage of 5 V is supplied by the servo-

Motor-Connector
N B
Motor-Stecker
ROTOR1 O
drive.
ROTOR2 M
ConnectorX7 Encoder connector INC

ROTOR3 K
GND L VCC +5V A Channel A

B Channel /N
4k7
TEMP H
C Channel B
Motor TEMP D Supply +5V
Temperature
Motor
E Channel N
Temperatur
GND J
F Channel /B
G Channel /A
H Temperature signal
PE am Steckergehuse J Temperature GND
PE am Steckergehuse
K Rotor position 3
L Supply GND
M Rotor position 2
N
5-13 EC-BAC-end-2 O Rotor position 1
P
Only use motors with TTL incremental encoders which have been approved by the manufacturer.
Observe the motor specific connection data sheet (IN)!
Connecting cable 10 shielded signal conductors min. cross-section 0.14mm
2 supply lines min. cross-section 0.5mm
Cable length for >25m the cross-section of the cable used must be increased
Shield connection across connector X7 connect the shield to the
connector housing
across the motor connector connect the shield to the
connector housing

Control connections
Encoder connection TTL

Adapter for INC encoder with A, B, N channel without push-pull signals
The device input for the incremental counter signals
requires the push-pull counter pulses for a reliable
detection.
Encoders without push-pull signals (e.g. position
encoders) with different supply voltages are used for
many simple applications. For these applications the INC
adapter must be installed.
The adapter converts the counter signals A, B, N to the
push-pull signals A, /A, B, /B, N, /N.
For supply voltages 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 clockwise is
1, 3, 2, 6, 4, 5.
If the sequence of
numbers is different the
encoder connection of the
rotor position signals
Rotor1, Rotor2, Rotor3
turning clockwise (U,V,W ) is not correct.
Use the connection

diagram!
Numerical value
Turn motor clockwise for one revolution without
enable.
One motor revolution corresponds to a position value
of Num 65536. In case of different results the input of
Feedback Inc-Mot (0xa6) is incorrect.
Zero angle
Motor turning clockwise and anti-clockwise
at 10 % - 100 % speed.
The value of zero-capture must remain constant.

Control connections
SIN COS 1Vss connection
5.9 SIN COS 1Vss connection
Only with BAMOCAR D3-SC

Incremental encoder (encoder) with 2
5-14 ED-BAC-SC-2 analog, sinusoidal counter tracks and 1 zero
Stecker X7 Rundstecker track plus 2 commutating tracks. Differential
VCC +5V
Connector x7
D VCC +5V
round connector
signals 1 Vss
TMS
ka+ A
Max. counting frequency 500kHz.
120
ka- G
SF1
kb+ C
SF0
Faktor The incremental encoder is galvanically
connected with the device zero (GND).
SIN/COS 1Vss
120
kb- F
The voltage of 5 V is supplied by the servo-

kr+ B
drive.
120
kr- E
The resolution is automatically set to an

Motor-Connector
optimum.
Motor-Stecker
kc+ M
1000
kc- O
Connector X7 Encoder connector SIN/COS

kd+ N
A Channel ka+
1000
kd- K B Channel kr+

C Channel kb+
VCC +5V
GND L
4k7 D Supply +5V
TEMP H E Channel kr+
Motor
Temperature
T-Motor
F Channel kb-
Motor
Temperatur
100nF
G Channel ka-
H Temperatur signal
GND J GND
PE am Steckergehuse J Temperatur GND

PE am Steckergehuse
K Channel kd-
L Supply GND
M Channel kc+
N Channel kd+
O Channel kc-
P
Only use motors with SIN/COS encoders (SC) which have been approved by the manufacturer.
Observe the motor specific connection data sheet (SC)!
Connecting cable 2 x 2 signal conductors, twisted and min. cross-section 0.14 mm
shielded
3 x 2 signal conductors, twisted and min. cross-section 0.14 mm
shielded
2 x supply lines, 2 x temp min. cross-section 0.5 mm
Cable type (4 x (2 x 0.14) +( 4 x 0.14) C + 4 x 0.5) C
Cable length for >25 m the cross-section of the cable used must be increased by one
grade
connector housing
connector housing

Control connections
Rotor position encoder - connection via a bl-tacho

5.10 Rotor position encoder - connection via a bl-tacho
Only with BAMOCAR D3-bl

3 rotor position encoder signals (Hall
sensors) for the commutation; with or
without a brushless tacho.
Anpass- Fitting- Stecker X7

Adapter adapter Connector x7 Rundstecker The rotor position encoder is galvanically
round connector
+15V 10 D +15V VCC +5V connected with the device zero (GND).
TR+ 2 TR+ C
TMS The voltage of 15V is supplied by the servo-
drive.
Rv 82k
Tacho R
100k
T Mp 1 TR- A
Rv 82k
Rotor + bl-Tacho
TS+
Provide an adapter in case the tacho voltage

TS+ 3 E
Rv 82k
Tacho S
100k
9 TS- A
at rated speed is superior to 10V.

Rv 82k
TT+ 4 TT+ G
Rv 82k
Tacho T
100k
11 TT- A
For lower tacho voltages connect X7: pin 1,

Rv 82k
Motor-Connector
9, and 11. Connect the tacho center point to

Motor-Stecker
4k7
4k7
4k7
ROTOR1 13 O 22k
Rotor U1
X7:1.
ROTOR2 14 M Rotor U2
22k
Connector X7 Encoder connector bl

ROTOR3 15 K Rotor U3
22k
GND 6 L
A MP-Tacho
VCC +5V B
C Tacho 1
4k7
TEMP 12 H
Motor
Temperature
Motor
T-Motor
D Supply +15V
100nF
Temperatur
GND 5 J GND
E Tacho 2
F
PE am Steckergehuse
PE am Steckergehuse G Tacho 3
H Temp signal
J Temp GND
K Rotor position 3
L Supply GND
ED-BAC-bl-2
M Rotor position 2
N
O Rotor position 1
P
Only use motors with rotor position encoders (bl) which have been approved by the
manufacturer.
Observe the motor specific connection data sheet (bl)!
Connecting cable 12 x signal conductors, supply lines, min. cross-section 0.25 mm
temp.
Cable length for >25 m the cross-section of the cable used must be increased by one
grade
connector housing
connector housing

Control connections
State displays
5.11 State displays
The state "normal" is signalled by a bright green seven-segment display + decimal point (display
of the state).
The state "fault" is signalled by a bright red fault LED and the seven-segment display indicates the
error no.
The state "warning" is signalled by the flashing red fault LED and the seven-segment display
indicates alternately the state and the warning no.
Display of the BAMOCAR states

Display Point/segment State State of NDrive
flashing Processor active
dark Auxiliary voltage missing or inherent hardware failure

flashing Starting state after reset (auxil. voltage 24V off-on). OK = 0
The first enable stops the flashing display.
bright Drive enable OK = 1, ENA = 1
dark Drive disabled (not enabled) OK = 1, ENA = 0
bright Speed zero (standstill signal) N0 = 1
bright Drive revolves clockwise, N currently positive N0 = 0
bright Drive revolves anti-clockwise, N currently negative N0 = 0
flashing Motor current reduced to continuous current Icns Icns = 1

bright Motor current at max. current limit Imax Icns = 0
dark Normal operation; Motor current within the current Icns = 0
limits
bright for 0.1 s A new command (value) was received from the BUS
or RS232.
Example: Motor revolving clockwise
Point flashes = active processor

Bottom segment = drive enabled
Right segment = motor revolves clockwise

Control connections
Error displays
5.12 Error displays
The red LED "fault" is bright and the fault no. is indicated by the green seven-segment display.
List of errors
Error display Description Display Address

NOREPLY-No RS RS232 interface not plugged or disturbed
REGID 0x8f
BADPARAS Damaged parameter 0 Bit 0
POWER FAULT Output stage error 1 Bit 1
RFE FAULT Safety circuit fault (only active with RUN) 2 Bit 2
BUS TIMEOUT Transmission fault BUS 3 Bit 3
FEEDBACK Encoder signal faulty 4 Bit 4
POWERVOLTAGE Encoder signal faulty 5 Bit 5
MOTORTEMP Motor temperature too high 6 Bit 6
DEVICETEMP Device temperature too high 7 Bit 7
OVERVOLTAGE Overvoltage >1.8 x UN 8 Bit 8
I_PEAK Over-current 300% 9 Bit 9
RACEAWAY Drive races A Bit 10
(without command value, wrong direction)
USER User - choice of error B Bit 11
2
IR Overload C Bit 12
RESERVE D Bit 13
HW_FAIL Firmware is not compatible with the hardware E Bit 14
BALLAST (device- Ballast circuit overloaded F Bit 15
dependent)
Note: With BAMOCAR the error F (BALLAST) has no function.
Example:
Fault
FAULT LED red POWERVOLTAGE

Error no. 5 (missing power voltage)
Note:
When applying the auxiliary voltage with the enable closed (FRG/RUN X1:7 active) the red LED
signals an error. There is no error signal displayed in the 7-segment display.

Control connections
Warning signals
5.13 Warning signals
The state "warning" is signaled by the flashing red fault LED and the seven-segment display
indicates alternately the state and the warning no.
List of warning signals
Error display Description Address

REGID 0x8f
WARNING_0 No device identification 0 Bit 16
ILLEGAL STATUS RUN signal, EMI 1 Bit 17
WARNING_2 RFE signal inactive, (without RUN) 2 Bit 18
3 Bit 19
4 Bit 20
POWERVOLTAGE Power voltage too small or missing 5 Bit 21
MOTORTEMP Motor temperature >87 % 6 Bit 22
DEVICETEMP Device temperature > 87% 7 Bit 23
OVERVOLTAGE Overvoltage >1.5 x UN 8 Bit 24
I_PEAK Overcurrent 200 % 9 Bit 25
A Bit 26
B Bit 27
I2R Overload >87% C Bit 28
D Bit 29
E Bit 30
BALLAST (device- Ballast circuit >87% overloaded F Bit 31
dependent)
Note: With BAMOCAR the warning F (BALLAST) has no function.

Example:
Fault
flashing red,
The display swaps between the state and the warning no.,
Warning no. 5

Measured data
Bus circuit battery voltage

6 Measured data
6.1 Bus circuit battery voltage
from firmware FW450
Bus circuit dc bus voltages, battery voltage (400 V)
BAMOCAR D3-400 Bus circuit voltage Parameter 0xeb

Max. voltage 460 V 25158
Battery voltage 370 V 20211
Overvoltage switch-off 440 V 24059
Charging voltage 340 V 18561
without power voltage 0V 0
Scaling 1 54,971
Tolerance +/-2 %
Parameter 0xeb = 54.971 x bus circuit voltage (tolerance +/-2%)
Bus circuit dc bus voltages, battery voltage (700V)
BAMOCAR D3-700 Bus circuit voltage Parameter 0xeb

Max. voltage 800 V 24045
Battery voltage 700 V 20883
Overvoltage switch-off 780 V 23413
Charging voltage 680 V 20250
without power voltage 0V 0
Scaling 1 31,499
Tolerance +/-2 %
Parameter 0xeb = 31.499 x bus circuit voltage (tolerance +/-2%)
Current - actual value
BAMOCAR-D3 I 100 % Calibration rated current Peak current

I-device DC blocked
Max. value +/- 11Bit mV Num Aeff A=pk Num A=pk
250/150 520 350 125 176 506 250
400/250 785 560 200 282 808 400
In the set of parameters the basic set-up data are protected.

Bus circuit dc bus voltages (battery voltage)
Bus circuit dc / bus voltages
7 Bus circuit dc bus voltages (battery voltage)

7.1 Bus circuit dc / bus voltages
28000
26000
24000
22000
20000
BAMOCAR-D3-400
18000
16000
Display 0xeb
14000 BAMOCAR-D3-700
12000
10000
8000
6000
4000
2000
0
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900
DC bus voltage , battery voltage

Measuring tolerance +/-2 %
Note: For dc bus voltages <50 V (at 400 V) or < 100V ( at 700 V) the measured values
are not linear!
Settings for BAMOCAR 400/400

DC bus max (0xa5H) for threshold voltage Num 0xeb Note
72 % 440 V = 24059
66 % 400 V = 21860
DC bus min (0xa5L) for undervoltage
52 % 320 V 17462
44 % 270 V 14713
Settings for BAMOCAR 700/400

DC bus max (0xa5H) for threshold voltage Num 0xeb Note
83 % 750 V = 23496=
78 % 700 V = 21921=
DC bus min (0xa5L) for undervoltage
63 % 600 V = 18771=
52 % 500 V = 15621=

Output stage temperature
Output stage temperatur

8 Output stage temperature
8.1 Output stage temperatur
IGBT Module temperature Parameter 0x4a

+80 oC 24000 (FW>450)
27000
[C] [] [n]
-35 83131 16245
26000 -30 62115 16308
-25 46960 16387
-20 35897 16487
25000
-15 27728 16609
-10 21629 16759
24000 -5 17028 16938
0 13524 17151
5 10830 17400
23000
10 8742 17688
15 7108 18017
22000
Display 0x4a
20 5821 18387
25 4799 18797
30 3982 19247
21000 35 3324 19733
40 2790 20250
20000 45 2356 20793
Tigbt.B 50 1999 21357

55 1705 21933
19000 aC2.N
60 1461 22515
65 1258 23097
18000 70 1088 23671
75 944 24232
80 823 24775
17000 85 720 25296
90 633 25792
16000 95 558 26261

100 493 26702
-10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
IGBT temperature
Indoor air temperature Parameter 0x4b
+ 45 oC 13000 (FW>450)
16000
15000
14000
BAMOCAR-D3
13000
Display 0x4b
12000
11000
10000
9000
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Indoor air temperature

Warranty
Warranty
9 Warranty
9.1 Warranty
UNITEK warranties that the device is free from material and production defects. Test results are
recorded and archived with the serial number.
The warranty time begins from the time the device is shipped, and lasts two years.
UNITEK undertakes no warranties for devices which have been modified for special applications.
During the warranty period, UNITEK will, at its option, either repair or replace products that prove
to be defective, this includes guaranteed functional attributes. UNITEK specifically disclaims the
implied warranties or merchantability and fitness for a particular purpose. For warranty service or
repair, this product must be returned to a service facility designated by UNITEK.
For products returned to UNITEK for warranty service, the buyer shall prepay shipping charges to
UNITEK and UNITEK shall pay shipping charges to return the product to the buyer.
However, the buyer shall pay all shipping charges, duties and taxes for products returned to
UNITEK from another country.
The foregoing warranty shall not apply to defects resulting from:

- improper or inadequate repairs effected by the buyer 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 on transformation, diminution and replacement of any kind of damage,
especially damage, which does not affect the UNITEK device, cannot be considered. Follow-on
damage within the machine or system, which may arise due to malfunction or defect in the device
cannot be claimed. This limitation does not affect the product liability laws as applied in the place
of manufacture (i.e. Germany).
UNITEK reserves the right to change any information included this MANUAL.
All connection circuitry described is meant for general information purposes and is not
mandatory.
The local legal regulations, and those of the standards authorities have to be adhered to. UNITEK
does not assume any liability, expressively or inherently, for the information contained in this
MANUAL, for the functioning of the device or its suitability for any specific application.
All rights are reserved.

Copying, modifying and translations lie outside UNITEKs liability and thus are not prohibited.
UNITEKs products are not authorised for use as critical components in the life support devices or
systems without express written approval.
The onus is on the reader to verify that the information here is current

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MANUAL

Digital three-phase Servo Amplifier

1 BAMOCAR-PG-D3 Version: 09/2017 - V03

5.6 CAN-BUS ........................................................................................................................... 37

Version: 09/2017 - V03 BAMOCAR-PG-D3 2

Version Modifications Date

2.2 Further UNITEK products

For synchronous and asynchronous motors

2.3 Engineering instructions (MANUAL)

1. MANUAL BAMOCAR Hardware

CD (UNITEK-DOKU-SOFT) supplied with the delivery of the units.

3 BAMOCAR-PG-D3 Version: 09/2017 - V03

Hardware state: TMS 2-3d, driver 1-8

2.5 Designations and symbols

Manufacturers or operators of machines or installations in the industrial

Manufacturer: UNITEK Industrie Elektronik GmbH

Caution Danger to life!

Dangerous electric fields!

Not included (to be ordered as accessories):

Programming cable X10 = Article no. G432 / Binder 79-3464-52-06

Version: 09/2017 - V03 BAMOCAR-PG-D3 4

2.6 General product information

The BAMOCAR-PG-D3xx can be used as position amplifier or torque or speed amplifier.

5 BAMOCAR-PG-D3 Version: 09/2017 - V03

Particularly suitable for:

Galvanic isolation between:

Version: 09/2017 - V03 BAMOCAR-PG-D3 6

Independent auxiliary voltage connection 24 V= or 12 V=

Attention: Braking energy

7 BAMOCAR-PG-D3 Version: 09/2017 - V03

In principle electronic equipment is not fault proof!

Caution - High voltage

Protection rating IP65

Connection only to batteries

Operation only allowed when the device is closed!

Version: 09/2017 - V03 BAMOCAR-PG-D3 8

The user must ensure that in the event of:

the axis will be safely de-activated.

It must also be ensured that the vehicles, machines, equipment,

Im Betrieb muss das Gert geschlossen sein.

Adjustments and programming

9 BAMOCAR-PG-D3 Version: 09/2017 - V03

For applications in residential areas additional EMC measures are necessary.

A manufacturer's declaration can be requested.

Version: 09/2017 - V03 BAMOCAR-PG-D3 10

2.10 Safety advices

11 BAMOCAR-PG-D3 Version: 09/2017 - V03

Version: 09/2017 - V03 BAMOCAR-PG-D3 12

2.12 Regulations and guidelines

EG Guidelines 2004/108/EG, 2006/95/EG, 2006/42/EG, 2002/96/EG

EU standards and regulations observed for the components of the unit

Standard Description Version

ECE-R100 Conditions for battery-driven electric vehicles

EU standards and regulations which must be observed by the user

Standard Description Version

ISO 6469 Electric road vehicles 2009

13 BAMOCAR-PG-D3 Version: 09/2017 - V03

Version: 09/2017 - V03 BAMOCAR-PG-D3 14