BONFIGLIOLI ACTIVE Applications Manual
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BONFIGLIOLI ACTIVE Applications Manual

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ACTIVE
Application manual - Crane drives
Brake control and load detection
Configurations 160, 260 and 460

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Summary of Contents for BONFIGLIOLI ACTIVE

  • Page 1 ACTIVE Application manual - Crane drives Brake control and load detection Configurations 160, 260 and 460...
  • Page 3 Instructions provide information on how to install and use the additional/optional components. The documentation and additional information can be requested via your local repre- sentation of the firm of BONFIGLIOLI. The following pictograms and signal words are used for the purposes of the present documentation: Danger! means a directly threatening danger.
  • Page 4 Caution! refers to an indirect threat. Damage to people or property can be the result. Attention! refers to a possible operational behavior or an undesired condition that can occur in accordance with the reference text. Note marks information that facilitates handling for you and supplements the corresponding part of the documentation.

  • Page 5: Table Of Contents

    Table of contents General safety and application information ..............4 General information....................4 Proper use........................ 4 Transport and storage ..................... 5 Handling and positioning..................5 Electrical connection....................5 Operation information ..................... 5 Maintenance and upkeep..................5 Technical data ........................ 6 Requirements ......................

  • Page 6: General Safety And Application Information

    General information Depending on their protection class, BONFIGLIOLI VECTRON frequency inverters can have live, also moving parts as well as hot surfaces during operation. In the event of inadmissible removal of the necessary covers, improper use, wrong installation or operation, there is the risk of serious damage to persons or property.

  • Page 7: Transport And Storage

    Transport and storage Transport and storage are to be done in an adequate way in the original packaging. Storage shall be in dry rooms protected against dust and moisture with slight tem- perature fluctuations. Please observe the climatic conditions according to EN 50178 and the marking on the packaging.

  • Page 8: Technical Data

    Technical data The technical data of the brief instructions and the operating instructions refer to the reference point of the frequency inverter. The reference point of the frequency in- verter is defined at the admissible mains voltage and a switching frequency of 2 kHz. This reference point is to be checked according to the requirements and redefined for the operating points of the application if need be.

  • Page 9: Control Inputs And Outputs

    Control inputs and outputs The modular structure of the frequency inverters enables a wide range of applications on the basis of the available hardware and software functionality. The functionality of the control inputs and outputs described in the brief manual and the operating instruc- tions are extended in the configurations 160, 460 and 260.

  • Page 10: Act Frequency Inverter Series

    2.2.2 ACT frequency inverter series The following illustration shows a possible solution of connecting the control terminals of the ACT frequency inverter in hoist and lift application. X210A +24V / 180mA GND 24V controller release / error acknowledgement S1IND lifting - start clockwise S2IND lowering - start anticlockwise S3IND...

  • Page 11: Commissioning Of The Frequency Inverter

    Commissioning of the frequency inverter Switch mains voltage on After the installation work has been completed, all the control and power connections should be checked again before the mains voltage is switched on. If all the electrical connections are correct, please ensure that the release of the frequency inverter has been switched off (control input S1IND open).

  • Page 12: Activation Of A Holding Brake

    For safety reasons, the inverted Operation mode 141 is not avail- able. In this operation mode, the brake is not released with the digi- tal output active. For example, this would also be the case with a voltage-free frequency inverter or during the initialization phase.

  • Page 13: Sequence Control

    Sequence control The logic signals to start and stop the drive can be specified by varying sources. The illustration shows the order of events during starting and stopping the drive with the time constants to be configured and the monitoring functionality to activate the safety switch and the holding brake.

  • Page 14: Current Monitoring

    4.2.1 Current monitoring The monitoring of the motor current supplements the functionality for the activation of a holding brake. Applications demanding a holding brake accelerate the motor by the specific load behavior when the brake is opened. The asynchronous motor must be supplied with sufficient current in all operation points in order to provide the necessary torque to avoid damage to property and per- sons.

  • Page 15: Starting The Drive

    Time t3 After expiry of 802 the reference signal for the release of the brake be- frequency comes active. Time t4 After expiry of 803 the frequency drive starts. The reference speed is in- threshold creased with the set ramp gradient.

  • Page 16: Stopping The Drive

    4.2.4 Stopping the drive Stopping the drive up to standstill of the drive can be parameterized via various time Stopping behavior constants. The parameterized 630 as a function of the digital sig- Start clockwise Start Anti-clockwise nals STR and STL is to be observed. If the internal reference frequency start command (output of the ramp function) is smaller...

  • Page 17: Interrupting The Start Or Stop Process

    Example: If the start command is deactivated (current monitoring is active, waiting for the re- lease of the brake) during the expiry of time t , the minimum current monitoring is deactivated straight away.

  • Page 18: Load Detection For Hoist Application And Luffing Jib Cranes

    Load detection for hoist application and luffing jib cranes The present documentation supplements the operating instructions for applications with an extended activation of a holding brake and the function for automatic load detection in hoist application and luffing jib cranes. The application manual documents the additional functionality of the frequency invert- ers in the software configurations 160, 260 and 460.

  • Page 19: Mechanical Time Constant

    5.1.1 Mechanical time constant mechanical time constant 811 is the time which the drive needs to accelerate from a standstill to rated speed with rated current. Neglecting the friction, dω ⋅ T is the rated torque of the machine, J the entire mass moment of inertia of the drive. dω...

  • Page 20: Turns Per Meter

    5.1.2 Turns per meter The number of mechanical turns of the motor per meter of lifting (Δh) must be input Turns/m in lifting applications via the parameter 812. For load estimation in a luffing jib crane, the number of mechanical turns of the motor for the alteration of length (Δl) of one meter of rope for the luffing jib must be input.

  • Page 21: Load Estimate

    5.1.3 Load estimate The load estimate is done in the basic speed area. In order to avoid faults at a stand- still and very low speeds, the load estimate is only done above a rotary frequency Fm lower value LE limit, which can be set with the parameter 813.

  • Page 22: Speed Switch-Off Limit

    5.1.4 Speed switch-off limit As an additional security element in the lowering of a load, a further monitoring has been implemented. The reference value of the speed is compared with the actual value of the speed. If the absolute value of the speed is larger than the actual speed Speed switch-off limit by the value entered in the parameter 817, the fault "F1110...

  • Page 23: Load Detection For Luffing Jib Cranes

    The torque-forming current available in the acceleration phase is a function of the rated current and the torque of the asynchronous machine resulting from it. stator frequency F torque-forming current I Operation mode LE If the parameter 822 is set to 3 or 4, the additional current for the acceleration is taken into account.
  • Page 24 The maximum speed can be scaled via two parameters. I limit Parameter • Current with which the load detection calculates the permitted maximum speed. Pull-out torque at Fmax • Parameter The pull-out torque relative to the rated torque of the asynchronous machine ad- missible at the maximum frequency.

  • Page 25: Torque-Forming Current Isq

    5.2.1 Torque-forming current Isq The maximum permitted speed during the lifting of the luffing jib is changed in such a way that the torque-forming current I corresponds to the figure set with parameter Desired Isq up 819 in the field weakening area. The permitted maximum speed is a function of the angle of the luffing jib.

  • Page 26: Fin

    During the lowering of the luffing jib, the machine works as a generator. Thanks to the properties of the machine, the frequency inverter and the mechanics, the effective value of the current is distinctly lower than in lifting, in particular in the field weaken- ing area, with the same speed and load.

  • Page 27: Limitation Of The Speed By Fixed Frequencies

    Limitation of the speed by fixed frequencies Fixed Frequency 1 The maximum permitted speed can be limited by the parameters Fixed Frequency 2 Fixed Frequency 3 Fixed Frequency 3 480, 481 , 482 and 483. Frequency upper limit source For this, the parameter 769 is to be set to the opera- tion mode 110.

  • Page 28: Parameter List

    Parameter list The parameter list is structured according to the menu branches of the operating unit. For better clarity, the parameters have been marked with pictograms: The parameter is available in the four data sets The parameter value is set by the SET-UP routine This parameter cannot be written in the operation of the frequency inverter.
  • Page 30 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 216 R0 tel: +39 051 647 3111 fax: +39 051 647 3126 Via Giovanni XXIII, 7/A bonfiglioli@bonfiglioli.com...

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