BONFIGLIOLI ACTIVE CUBE Applications Manual
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BONFIGLIOLI ACTIVE CUBE Applications Manual

Frequency inverter
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ACTIVE CUBE
Application manual - Electronic gear
Position control and index control

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Summary of Contents for BONFIGLIOLI ACTIVE CUBE

  • Page 1 ACTIVE CUBE Application manual - Electronic gear Position control and index control...
  • Page 3 Instructions provide information on how to install and use the additional/optional components. If you need a copy of the documentation or additional information, contact your local representative of BONFIGLIOLI. The following pictograms and signal words are used in the documentation: Danger! Danger refers to an immediate threat.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS     General Safety Instructions and Information on Use ............ 3   General Information ....................3       Purpose of the Frequency Inverters ................ 4     Transport and Storage ..................... 4   Handling and Installation ..................4  ...

  • Page 5: General Safety Instructions And Information On Use

    If you require further information or if you meet with specific problems which are not dealt with in sufficient detail in the documentation, contact your local BONFIGLIOLI agent. We would also like to point out that the contents of this documentation do not form part of any previous or existing agreement, assurance or legal relationship.

  • Page 6: Purpose Of The Frequency Inverters

    Purpose of the Frequency Inverters Warning! The frequency inverters are electrical drive components intended for in- stallation in industrial plants or machines. Commissioning and start of operation is not allowed until it has been verified that the machine meets the requirements of the EC Machinery Directive 98/37/EEC and EN 60204. In accordance with the CE marking requirements, the frequency inverters also comply with the Low Voltage Directive 2006/95/EC as well as EN 50178/DIN VDE 0160 and EN 61800-2.

  • Page 7: Electrical Connection

    Electrical Connection Warning! Before any assembly or connection work, discharge the frequency inver- ter. Verify that the frequency inverter is discharged. Do not touch the terminals because the capacitors may still be charged. Comply with the information given in the operating instructions and on the frequency inverter label.

  • Page 8: Control Inputs And Outputs

    Control Inputs and Outputs The modular structure of the frequency inverters enables a wide spectrum of appli- cations on the basis of the available hardware and software functionality. The func- tionality of the control inputs and outputs described in the brief instructions and oper- ating instructions is extended in the described configurations.
  • Page 9 Configuration 116– sensorless control with electronic gear and index control X210A Control terminal X210A +20 V/180 mA X210A.1 Supply voltage +20V GND 20 V X210A.2 Ground 20 V STOA S1IND X210A.3 Safety function, digital input STOA S2IND X210A.4 Index signal Master S3IND X210A.5 Index signal Slave...
  • Page 10 Configuration 216 – field-oriented control with electronic gear and index control X210A Control terminal X210A +20 V/180 mA X210A.1 Supply voltage +20V GND 20 V X210A.2 Ground 20 V STOA S1IND X210A.3 Safety function, digital input STOA S2IND X210A.4 Index signal Master S3IND X210A.5 Index signal Slave...
  • Page 11 Configuration 515 – field-oriented control of a synchronous machine with electronic gear and position control X210A Control terminal X210A +20 V/180 mA X210A.1 Supply voltage +20V GND 20 V X210A.2 Ground 20 V STOA S1IND X210A.3 Safety function, digital input STOA S2IND X210A.4 Start of clockwise operation...

  • Page 12: Commissioning Of The Frequency Inverter

    Commissioning of the Frequency Inverter Switching on Mains Voltage After completion of the installation work, make sure to check all control and power connections again before switching on the mains voltage. If all electrical connections are correct, make sure that the frequency inverter is not enabled (control input S1IND open).
  • Page 13 Configuration 415, sensorless field-oriented control with electronic gear and position control Configuration 415 extends the sensorless field-oriented control of Configuration 410 by the functions of the electronic gear and a position controller. Configuration 515, field-oriented control of a synchronous machine with electronic gear and position control Configuration 515 includes the sensorless field-oriented control of a synchronous ma- chine and the functions of the electronic gear and a position controller.

  • Page 14: Electronic Gear

    Electronic Gear The electronic gear enables the synchronization of drives without mechanical trans- mission elements such as shafts or clutches. The reference value for the Slave is the repetition frequency determined by the Master. This value can be multiplied by a gear factor.

  • Page 15: Operation Modes Of Electronic Gear

    Operation Modes of Electronic Gear Operation Mode Via parameter 689 for the electronic gear, you can determine if the gear factor is to be set permanently or to be scaled via a signal source, e.g. an analog input signal at the Slave. The repetition frequency of the Master is multiplied by the Operation Mode gear factor.

  • Page 16: Setting A Variable Gear Factor

    4.3.2 Setting a Variable Gear Factor Analog Factor Max. Analog Factor Min. Via parameters 687 and 688 the gear factor Operation range is scaled if operation mode 2 or 3 is selected for parameter Mode Reference Percentage Source 689. The scaling is done via the 476 via which the signal sources for determining the reference value are selected.

  • Page 17: Offset Switches

    Gear Factor Denominator • Set the 686 to the required value. Operation • Set multifunction input MFI as an analog voltage input by adjusting Mode 452 to "1 – voltage Input". Reference Percentage Source • For the 476, select an operation mode which con- tains MFI1A as a reference value source, e.g.

  • Page 18: Reference Value And Actual Value Input

    Reference value and actual value input The following inputs of the slave frequency inverter can be used for reference fre- quency transmission from master to slave. The actual value input receives the actual speed from the slave speed sensor. Frequency inverter without expansion module Configuration Reference value input Actual value input...

  • Page 19: Position Control

    El. Gear Reference Frequency If the XPI file is loaded the parameter 125 can be ad- justed for the reference value input of the electronic gear. Practical settings for opera- tion without optional System bus are: Operation mode Function Reference value source is the speed sensor 1 80 - Freq.
  • Page 20 Amplification Position Controller Via parameter 696, the dynamism of the position controller is adjusted and the position error is assessed. Parameter Settings Description Min. Max. Fact. sett. 696 Amplification Position Controller 0.00% 200.00% 10.00% Lim. Position Deviation Via parameter 697, you can adjust the maximum angle on which the Slave drive is yet to catch up during the compensation of a position error.

  • Page 21: Index Control

    Index Control The electronic gearbox with index control is available in configurations 116, 216 and 516. Via index control, deviations from synchronous running which are due to process changes can be detected directly in the process by sensors and compensated by the index controller.
  • Page 22 Operation Mode Via parameter 598, the index controller is switched on or off perma- nently depending on the signal state at a digital input. Operation mode Function 0 - Off The index controller is switched off permanently. 1 - On The index controller is switched on permanently.

  • Page 23: Scope Sources

    Warning Limit Via parameter 597, you can monitor the phase displacement of the index signals from the Master and the Slave. A setting of e.g. 50% means that a warning is issued if the displacement between the index signals exceeds 50% of the period.

  • Page 24: Adjustment Options

    Adjustment Options The following instructions describe options for setting the electronic gear and the posi- tion controller. The settings must be adjusted to the application. For further informa- tion on the parameterization of the repetition frequency inputs and outputs, refer to the operating instructions.

  • Page 25: Frequency Inverter As Slave

    Repetition frequency Mode • Select an operation mode for parameter 555, e.g. Operation Mode "3 – Frequency Speed Sensor 1", for the Master drive with speed sensor feedback. In this operation mode, the speed of the Slave drive follows the speed of the Master drive at the highest accuracy.
  • Page 26 • If a configuration with speed sensor feedback is selected, check if the speed sen- sor monitoring is switched on. In this way, faulty speed sensor signals can be de- tected. Speed sensor monitoring is activated by default. By selecting operation Operation Mode mode "2 –...

  • Page 27: Examples Of Wiring

    4.10 Examples of wiring Example 1: Transmission of the reference frequency value without information about direction of rotation ACU Master in configuration 210 ACU Slave in configuration 215 X210A X210A +20 V/180 mA +20 V/180 mA GND 20 V GND 20 V S1IND, Safety function STOA STOA...
  • Page 28 Example 2: Transmission of the reference frequency value with information about direction of rota- tion, frequency inverter with expansion modules ACU Master in configuration 210 ACU Slave in configuration 215 X210A X210A +20 V/180 mA +20 V/180 mA GND 20 V GND 20 V STOA S1IND, Safety function...
  • Page 29 Overview of Parameter Setting Examples: Parameter Setting/Selection Master Settings Configuration 210 – speed-controlled field oriented control 420 Acceleration (Clockwise) 5 Hz/s 421 Deceleration (Clockwise) 5 Hz/s 490 Operation Mode (of speed sensor 1) 4 – Quadruple Evaluation 491 Division marks (of speed sensor 1) Division marks of the master speed sensor 546 Operation Mode Repetition Frequency 101 –...

  • Page 30: Electronic Gear Via System Bus

    Electronic gear via System bus Speed Sensor Simulation If the electronic gear is realized by means of the System Bus, the transmitted position data must be converted in a pulse-width modulated repetition frequency signal. This is done via the speed sensor simulation (remote encoder) which works as an internal Operation Mode speed sensor.

  • Page 31: Adjustment Options

    Adjustment Options The repetition frequency is transmitted via the System Bus. Note: Only the parameterization required for realizing the electronic gear are de- scribed here. For operation of the System Bus, further settings are required. These are described in the operating instructions of the expansion modules with System Bus.

  • Page 32: Slave Settings

    5.2.2 Slave Settings For the function of the electronic gear via System Bus, the following settings (exam- ples) can be made. • If not done yet after the commissioning, select one of the configurations with Configuration electronic gear for parameter 30, e.g.

  • Page 33: Position Control Via System Bus

    Position Control via System Bus Example of Position Control Settings via System Bus: Master: • Select a source for a Transmit-PDO of data type long, e.g. select signal source TxPDO1 Long1 "80 – Speed Sensor 1 via parameter 954 for transmission of the repetition frequency to the Slave.

  • Page 34: Parameter List

    Parameter List The parameter list is structured according to the menu branches of the control unit. For better clarity, the parameters have been marked with pictograms: The parameter is available in the four data sets. This parameter cannot be written in the operation of the frequency inverter. This parameter is available after loading of a configuration file, e.g.

  • Page 35: Parameter Menu (Para)

    Parameter Menu (PARA) Digital Inputs Description Unit Setting range Chapter 96 Index Controller Release Selection Electronic Gear 125 El. Gear Reference Frequency Selection Digital Inputs 132 Offset Switch 1 Selection 133 Offset Switch 2 Selection Position Controller 147 Position Reference Value Selection 148 Position Actual Value Selection...
  • Page 40 Bonfiglioli has been designing and developing innovative and reliable power transmission and control solutions for industry, mobile machinery and renewable energy applications since 1956. www.bonfiglioli.com Bonfiglioli Riduttori S.p.A. VEC 551 R1 tel: +39 051 647 3111 fax: +39 051 647 3126 Via Giovanni XXIII, 7/A bonfiglioli@bonfiglioli.com...

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