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Table of Contents
Related Manuals for BONFIGLIOLI Active ACT 201-05
Summary of Contents for BONFIGLIOLI Active ACT 201-05
- Page 1 ACTIVE Brief manual Frequency Inverter 230 V / 400 V 0.55 kW ... 30.0 kW...
- 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 representative of BONFIGLIOLI. The following pictograms and signal words are used in the documentation: Danger! Danger refers to an immediate threat.
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Page 4: Table Of Contents
TABLE OF CONTENTS TABLE OF CONTENTS ......................2 General Safety Instructions and Information on Use ............ 4 General Information ....................4 Purpose of the Frequency Inverters ................ 5 Transport and Storage..................... 5 Handling and Installation ..................5 Electrical Connection ....................6 Information on Use.................... - Page 5 TABLE OF CONTENTS Control Terminals ....................29 5.6.1 Relay Output ......................30 5.6.2 Control Terminals – Terminal Diagram..............31 5.6.2.1 Configuration 110 – Sensorless Control ............. 31 5.6.2.2 Configuration 410 – Sensorless Field-Oriented Control........32 Optional Components .................... 33 Control Unit KP500 ...................... 34 Actual Value Menu (VAL) ..................
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Page 6: 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 7: Purpose Of The Frequency Inverters
Purpose of the Frequency Inverters Warning! The frequency inverters are electrical drive components intended for installation 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. -
Page 8: Electrical Connection
Electrical Connection Warning! Before any assembly or connection work, discharge the frequency inverter. 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 9: Scope Of Supply
Scope of Supply Thanks to the modular hardware components, the frequency inverters can be integrated in the automation concept easily. The scope of delivery described can be supplemented by optional components and adapted to the customer-specific requirements. The plug-in type connection terminals enable a safe function and an economical assembly. -
Page 10: Frequency Inverter (18.5 To 30 Kw)
Frequency Inverter (5.5 to 15.0 kW) ACT 401 (400 V) Power range 5.5 kW to 15 kW Scope of Supply Frequency inverter Terminal strip X10 (Phoenix ZEC 1.5/3ST5.0) Plug-in terminals for the relay output Standard fixtures with fixing bolts (M4x20, M4x60) for vertical assembly Brief Instructions and manuals on CD Control terminals X210A / X210B (Wieland DST85 / RM3.5) - Page 11 Frequency Inverter (18.5 to 30.0 kW) ACT 401 (400 V) Power range 18.5 kW to 30 kW Scope of Supply Frequency inverter Terminal strip X10 (Phoenix ZEC 1.5/3ST5.0) Plug-in terminals for the relay output Standard fixtures with fixing bolts (M4x20, M4x70) for vertical assembly Brief Instructions and manuals on CD Control terminals X210A / X210B (Wieland DST85 / RM3.5)
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Page 12: Technical Data
Technical Data Frequency Inverter 230 V (0.55 to 3.0 kW) Type ACT 201 Output, motor side Recommended shaft output 0.55 0.75 4) 5) Output current 12.5 Overload current (60 s) 10.5 14.3 16.2 Overload current (1 s) 14.0 19.0 19.0 Output voltage 3 x 0 ... -
Page 13: Frequency Inverter 400 V (0.55 To 4.0 Kw)
Frequency Inverter 400 V (0.55 to 4.0 kW) Type ACT 401 Output, motor side Recommended shaft output 0.55 0.75 1.85 Output current Overload current (60 s) 11.7 13.5 Overload current (1 s) 11.6 15.6 18.0 Output voltage 3 x 0 ... mains voltage Protection Short circuit / earth fault proof Rotary field frequency... -
Page 14: Frequency Inverter 400 V (5.5 To 15.0 Kw)
Frequency Inverter 400 V (5.5 to 15.0 kW) Type ACT 401 Output, motor side Recommended shaft output 11.0 15.0 Output current Overload current (60 s) 21.0 26.3 30.3 37.5 44.5 Overload current (1 s) 28.0 33.0 33.0 50.0 64.0 Output voltage 3 x 0 ... -
Page 15: Frequency Inverter 400 V (18.5 Up To 30 Kw)
Frequency Inverter 400 V (18.5 up to 30 kW) Type ACT 401 Motor-side output Recommended motor shaft output 18.5 Output current 40.0 45.0 60.0 Overload current (60 s) 60.0 67.5 90.0 Overload current (1 s) 80.0 90.0 120.0 Output voltage 3 x 0 ... -
Page 16: Operation Diagrams
Operation diagrams The technical data of the frequency inverters refer to the nominal point which was selected to enable a wide range of applications. A functionally and efficient dimensioning (derating) of the frequency inverters is possible based on the following diagrams. -
Page 17: Mechanical Installation
Mechanical Installation The frequency inverters of degree of protection IP20 are designed, as a standard, for installation in electrical cabinets. During installation, both the installation and the safety instructions as well as the • device specifications must be complied with. To avoid serious physical injuries or major material damage, only Warning! qualified persons are allowed to work on the devices. -
Page 18: Frequency Inverter (0.55 To 4.0 Kw)
Frequency Inverter (0.55 to 4.0 kW) The frequency inverter is mounted in a vertical position on the assembly panel by means of the standard fittings. The following illustration shows the different mounting possibilities. Standard installation ≥ 100 mm Assembly is effected by inserting the long side of the fixing plate in the heat sink and screwing it to the mounting plate. -
Page 19: Frequency Inverter (5.5 To 15 Kw)
Frequency Inverter (5.5 to 15 kW) The frequency inverter is mounted in a vertical position on the assembly panel by means of the standard fittings. The following illustration shows the standard fitting. Standard installation ≥ 100 mm fixing bracket top (fixing with screws M4x20 fixing bracket bottom... -
Page 20: Frequency Inverter (18.5 To 30 Kw)
Frequency Inverter (18.5 to 30 kW) The frequency inverter is mounted in a vertical position on the assembly panel by means of the standard fittings. The following illustration shows the standard fitting. Standard installation ≥ 100 mm fixing bracket top fixing bracket bottom (fixing with screws M4x20... -
Page 21: Electrical Installation
Electrical Installation The electrical installation must be carried out by qualified staff according to the general and regional safety and installation directives. For a safe operation of the frequency inverter it is necessary that the documentation and the device specifications be complied with during installation and commissioning. In the case of special applications, you may also have to comply with further guidelines and instructions. -
Page 22: Emc Information
EMC Information The frequency inverters are designed according to the requirements and limit values of product norm EN 61800-3 with an interference immunity factor (EMI) for operation in industrial applications. Electromagnetic interference is to be avoided by expert installation and observation of the specific product information. Measures •... -
Page 23: Block Diagram
Block diagram S3OUT L2 L3 X210A +20 V / 180 mA GND 20 V S1IND S2IND S3IND U, I S4IND S5IND X210B S6IND GND 20 V S1OUT MFO1 +10 V / 4 mA MFI1 GND 10 V Relay connection S3OUT Change-over contact, response time approx. -
Page 24: Mains Connection
Mains Connection The mains fuses and cable cross-sections are to be selected according to EN 60204-1 and DIN VDE 0298 Part 4 for the nominal operating point of the frequency inverter. According to UL/CSA, approved Class 1 copper lines with a temperature range of 60/75°C and matching mains fuses are to be used for the power cables. -
Page 25: Frequency Inverter (5.5 To 15.0 Kw)
5.3.2 Frequency Inverter (5.5 to 15.0 kW) Danger! Switch off power supply before connecting or disconnecting the mains cable to terminal X1 Dangerous voltage may be present at the mains terminals and the DC terminals even after the frequency inverter has been disconnected safely from power supply. -
Page 26: Frequency Inverter (18.5 To 30 Kw)
5.3.3 Frequency Inverter (18.5 to 30 kW) Danger! Switch off power supply before connecting or disconnecting the mains cable to terminal X1 Dangerous voltage may be present at the mains terminals and the DC terminals even after the frequency inverter has been disconnected safely from power supply. -
Page 27: Frequency Inverter (0.55 To 4.0 Kw)
5.4.1 Frequency Inverter (0.55 to 4.0 kW) The connection of the motor and the brake resistor to the frequency inverter is to be done via plug-in terminal X2. Degree of protection IP20 (EN60529) is only guaranteed if terminal X2 is connected. Danger! Switch off power supply before connecting or disconnecting the keyed plug-in terminal X2. -
Page 28: Frequency Inverter (5.5 To 15 Kw)
5.4.2 Frequency Inverter (5.5 to 15 kW) The connection of the motor to the frequency inverter is to be done via terminal X2. Switch off power supply before connecting or disconnecting the Danger! motor cables to terminal X2. Dangerous voltage may be present at the motor terminals and the terminals of the brake resistor even after the frequency inverter has been disconnected safely from power supply. -
Page 29: Frequency Inverter (18.5 To 30 Kw)
5.4.3 Frequency Inverter (18.5 to 30 kW) The connection of the motor to the frequency inverter is to be done via terminal X2. Switch off power supply before connecting or disconnecting the Danger! motor cables to terminal X2. Dangerous voltage may be present at the motor terminals and the terminals of the brake resistor even after the frequency inverter has been disconnected safely from power supply. -
Page 30: Connection Of A Brake Resistor
Connection of a Brake Resistor Connection of a brake resistor is done via terminal X2. Switch off power supply before connecting or disconnecting the brake Danger! resistor cables to terminal X2. Dangerous voltage may be present at the motor terminals and the terminals of the brake resistor even after the frequency inverter has been disconnected safely from power supply. -
Page 31: Frequency Inverter (18.5 To 30 Kw)
5.5.3 Frequency Inverter (18.5 to 30 kW) Connection of brake resistor with temperature switch Control Terminals The control and software functionality can be freely configured to ensure a reliable and economical operation. The operating instructions describe the factory settings of Configuration the standard connections in the relevant 30 as well as the software... -
Page 32: Relay Output
Control terminal X210A Ter. Description Voltage output 20 V, I =180 mA Ground / GND 20 V Digital input S1IND, U =30 V, 10 mA at 24 V, PLC compatible, response time approx. 16ms (on), 10 µs (off) Digital input EM-S2IND, U =30 V, 10 mA at 24 V, PLC compatible, response time approx. -
Page 33: Control Terminals - Terminal Diagram
5.6.2 Control Terminals – Terminal Diagram The control hardware and the software of the frequency inverter are freely configurable to a great extent. Certain functions can be assigned to the control terminals, and the internal logic of the software modules can be freely selected. In these brief instructions, the sensor-less control and the sensor-less field oriented control are described in Configuration 110 and Configuration 410, respectively 5.6.2.1... -
Page 34: Configuration 410 - Sensorless Field-Oriented Control
5.6.2.2 Configuration 410 – Sensorless Field-Oriented Control Configuration 410 contains the functions for sensorless, field-oriented control of a 3- phase machine. The current motor speed is determined from the present currents and voltages in combination with the machine parameters. Separate control of torque and flux-forming current enables high drive dynamism at a high load moment. -
Page 35: Optional Components
Optional Components Thanks to the modular hardware components, the frequency inverters can be integrated in the automation concept easily. The standard and optional modules are recognized during the initialization, and the controller functionality is adjusted automatically. For the information required for installation and handling of the optional modules, refer to the corresponding documentation. -
Page 36: Control Unit Kp500
Control Unit KP500 The optional KP500 control unit is a practical tool for controlling the frequency inverter and setting and displaying the frequency inverter parameters. The control unit is not absolutely necessary for the operation of the frequency inverter and can be plugged on when required. Keys Used for starting the drive and opening the CTRL menu. -
Page 37: Actual Value Menu (Val)
Actual Value Menu (VAL) In the VAL menu branch, the control unit displays a variety of actual values, depending on the configuration selected and the options installed. The parameters and basic software functions linked to the corresponding actual value are documented in the operating instructions. -
Page 38: Parameter Menu (Para)
Parameter Menu (PARA) The parameters to be configured during the guided commissioning were selected from common applications and can be supplemented as required by further settings in the PARA menu branch. The parameters and basic software functions linked to the corresponding actual value are documented in the operating instructions. -
Page 39: Controlling The Motor Via The Control Unit
Controlling the Motor via the Control Unit The control unit enables controlling the connected motor in accordance with the Local/Remote selected operation mode of parameter 412. In order to be able to control the drive via the control unit, the digital Note: controller input S1IND must be connected and set to "High-Signal"... - Page 40 Internal reference value int The drive is in operation, i.e. output signals are present at the frequency inverter and the current actual value is displayed. Press an arrow key to switch to the motor potentiometer function Pot. The current frequency value is taken over in the motor potentiometer function Pot.
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Page 41: 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 released (control input S1IND open). -
Page 42: Configuration
7.2.1 Configuration The software of the frequency inverter offers several configuration options. These differ with respect to the way in which the drive is controlled. Parameter Configuration 30 determines the assignment and basic function of the control inputs and outputs as well as the software functions. Analog and digital inputs can be combined and complemented by optional communication protocols as further reference value sources. -
Page 43: Machine Data
Operation mode Function 0 - Unknown The motor is not a standard type. 1 - Asynchronous Three-phase asynchronous motor, squirrel cage 2 - Synchronous Three-phase synchronous motor 3 - Reluctance Three-phase reluctance motor 10 - Transformer Transformer with three primary windings When the motor type is specified, the machine data must be entered. - Page 44 The warning and error messages displayed during the verification process have to be observed. If a critical condition is detected during the guided commissioning, it is displayed by the control unit. Depending on the deviation from the expected parameter value, either a warning or an error message is displayed. −...
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Page 45: Parameter Identification
7.2.6 Parameter identification In addition to the parameterized rated data, the selected configuration demands knowledge of further machine data not stated on the rating plate of the three-phase machine. In addition to entering the rated motor parameters or as an alternative, the required machine data can also be measured during the guided commissioning process. - Page 46 Warning Messages Code Measures / Remedy SA0021 The stator resistance is very high. The following causes are possible: − The motor cable cross-section is not sufficient. The motor cable is too long. − The motor cable is not connected correctly. −...
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Page 47: Application Data
7.2.7 Application data With the frequency inverter, a great variety of different drive applications can be realized. The parameter settings required for this often require the verification of other parameters. The parameters polled during the guided commissioning procedure were selected from standard applications. After completion of commissioning, further parameters can be set in the PARA menu branch. -
Page 48: Selection Of An Actual Value For Display
7.2.8 Selection of an actual value for display Actual Frequency After commissioning, the value of parameter 241 is displayed at the control unit KP500. If another actual value is to be displayed after a restart, make the following settings: • Use the arrow keys to select the actual value to be displayed as from now. -
Page 49: Basic Parameters
Basic parameters Menu branch PARA The parameters displayed in the PARA menu branch are partly set via the guided commissioning. The parameters documented in the brief instructions are complemented by the information given in the operating instructions. Control Level 28 - The brief instructions describe the parameters in control level 1. The parameters of the higher control levels 2 or 3 are described in the operating instructions and should be set up by expert operators only. - Page 50 Rated Mech. Power 376 - enter the power (in kW) indicated on the type plate of the asynchronous motor. Setting: 0.1⋅P ... 10⋅P Switching Frequency 400 - The rated operating point of the frequency inverter is defined at a switching frequency of 2 kHz. Higher switching frequencies require a reduction of the output current (see technical data).
- Page 51 Analog Operation 553 - output MFO1 supplies a pulse width modulated signal (0 V ... 10 V) which is proportional to an actual value. Maximum Frequency Setting: actual frequency, 0 Hz ... 20 - active current, 0 A ... I Rated Mech.
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Page 52: Menu Branch Val
Menu branch VAL The actual values in the VAL menu branch facilitate operation and error diagnosis. R.m.s. Current 211 - effective output current (motor current) of the frequency inverter calculated from the measurement in the three motor phases. Display: 0.0 A ... o⋅I Output Voltage 212 - output voltage of the frequency inverter modulated depending on the operating point of the motor. -
Page 53: Operational And Error Diagnosis
Operational and error diagnosis The operation of the frequency inverter and the connected load is continuously monitored. The operating and error diagnosis documented in the brief instructions are complemented by the information given in the operating instructions. Status message The green and red light-emitting diodes give information about the operating point of the frequency inverter. -
Page 54: Fault Message
Fault message Last Error The error code saved after a fault in parameter 310 facilitates troubleshooting and error diagnosis. The error code consists of the error group FXX and the code number XX. The error message is to be acknowledged via the keys of the control unit and digital input S1IND. - Page 56 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 210 R1 tel: +39 051 647 3111 fax: +39 051 647 3126 Via Giovanni XXIII, 7/A bonfiglioli@bonfiglioli.com...