Конфигурация 610 контроллером крутящего момента. Опорный крутящий момент представлен в видепроцент и он передается в соответствующие эксплуатационные показателиприложение. Переключение между регулированием переменной скорости и регулированием крутящего моментаУправление осуществляется без рывков во время работ? Как подробнее узнать об этом режиме? Нужно обеспечить останов с заданным моментом на валу мотора

Summary of Contents for BONFIGLIOLI ACTIVE Cube ACU 201-01

Page 1 ACTIVE CUBE Operating Instructions Frequency inverter 230 V / 400 V 0.25 kW ... 132 kW...
Page 3: Table Of Contents
TABLE OF CONTENTS General information about the documentation ............10 Instruction manuals .................. 10 This document................... 12 Warranty and liability ................12 Obligation ....................13 Copyright ....................13 Storage ...................... 13 General safety instructions and information on use ............ 14 Terminology ....................
Page 4 Technical Data ......................30 General technical data ................30 Technical Data – Control Electronic Equipment ........31 ACU 201 (0.25 to 1.1 kW, 230 V) .............. 32 ACU 201 (1.5 to 3.0 kW, 230 V) ..............33 ACU 201 (4.0 to 9.2 kW, 230 V) ..............34 ACU 401 (0.25 to 1.5 kW, 400 V) ..............
Page 5 6.7.3 Configuration 410 – Sensorless Field-Oriented Control ........76 6.7.4 Configuration 411 – Sensorless Field-Oriented Control with Technology Controller 77 6.7.5 Configuration 430 – Sensorless FOC, Speed and Torque Controlled ..... 78 6.7.6 Configuration 210 – Field-Oriented Control, Speed Controlled ......79 6.7.7 Configuration 211 –...
Page 6 Set-up via the Communication Interface ..........116 Inverter Data ......................118 Serial Number ..................118 Optional Modules ..................118 Inverter Software Version ..............118 Set Password ..................118 Control Level ................... 119 User Name ....................119 Configuration ..................119 Language ....................122 Programming ..................
Page 7 12.6.2 Axle Positioning ..................... 147 13 Error and warning behavior ..................149 13.1 Overload Ixt .................... 150 13.2 Temperature ................... 150 13.3 Controller status ..................151 13.4 IDC Compensation Limit ................. 151 13.5 Frequency Switch-Off Limit ..............152 13.6 Motor Temperature ................. 152 13.7 Phase Failure ...................
Page 8 15.3.5 Brake release ....................186 15.3.6 Current Limitation ..................186 15.3.7 External Fan ....................186 15.3.8 Warning Mask ....................187 15.3.9 Application warning mask ................190 15.4 Digital inputs ................... 191 15.4.1 Start command ..................... 196 15.4.2 3-wire control ....................196 15.4.3 Error Acknowledgment ..................
Page 9 18.3 Bus controller ..................241 18.4 Brake Chopper and Brake Resistance ............. 243 18.4.1 Dimensioning of Brake Resistor ..............244 18.5 Motor Protection ..................245 18.5.1 Motor Protection Switch ................. 245 18.5.2 Motor Protection by I2t- Monitoring ..............248 18.6 V-belt Monitoring ..................
Page 10: General Information About The Documentation
Information on various subjects connected with the use of the frequency inverter is described specific to the application. If you need a copy of the documentation or additional information, contact your local representative of BONFIGLIOLI. Operating Instructions ACU 06/13...
Page 11 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 national BONFIGLIOLI agent. We would also like to point out that the contents of this documentation do not form part of any previ- ous or existing agreement, assurance or legal relationship.
Page 12: This Document
Warranty and liability BONFIGLIOLI VECTRON GmbH would like to point out that the contents of this user manual do not form part of any previous or existing agreement, assurance or legal relationship. Neither are they intended to supplement or replace such agreements, assurances or legal relationships. Any obligations of the manufacturer shall solely be based on the relevant purchase agreement which also includes the complete and solely valid warranty stipulations.
Page 13: Obligation
Copyright In accordance with applicable law against unfair competition, this user manual is a certificate. Any copyrights relating to it shall remain with BONFIGLIOLI VECTRON GmbH Europark Fichtenhain B6 47807 Krefeld Germany These user manual is intended for the operator of the frequency inverter. Any disclosure or copying of this document, exploitation and communication of its contents (as hardcopy or electronically) shall be forbidden, unless permitted expressly.
Page 14: General Safety Instructions And Information On Use
General safety instructions and information on use The chapter "General safety instructions and information on use" contains general safety instructions for the Operator and the Operating Staff. At the beginning of certain main chapters, some safety in- structions are included which apply to all work described in the relevant chapter. Special work-specific safety instructions are provided before each safety-relevant work step.
Page 15: Designated Use
Designated use The frequency inverter is designed according to the state of the art and recognized safety regulations. 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 ma- chine meets the requirements of the EC Machinery Directive 2006/42/EC and DIN EN 60204-1.
Page 16: Residual Risks
Residual risks Residual risks are special hazards involved in handling of the frequency inverter which cannot be elim- inated despite the safety-compliant design of the device. Residual risks are not obviously identifiable and can be a potential source of injury or health hazard. Typical residual hazards include: Electrical hazard Danger of contact with energized components due to a defect, opened covers or enclosures or im-...
Page 17: Warning Information And Symbols Used In The User Manual
Warning information and symbols used in the user manual 2.6.1 Hazard classes The following hazard identifications and symbols are used to mark particularly important information: DANGER Identification of immediate threat holding a high risk of death or serious injury if not avoided.
Page 18: Personal Safety Equipment
2.6.4 Personal safety equipment Symbol Meaning Wear body protection 2.6.5 Recycling Symbol Meaning Recycling, to avoid waste, collect all materials for reuse 2.6.6 Grounding symbol Symbol Meaning Ground connection 2.6.7 ESD symbol Symbol Meaning ESD: Electrostatic Discharge (can damage components and assemblies) 2.6.8 Information signs Symbol...
Page 19: Directives And Guidelines To Be Adhered To By The Operator
Directives and guidelines to be adhered to by the operator The operator must follow the following directives and regulations: • Ensure that the applicable workplace-related accident prevention regulations as well as other ap- plicable national regulation are accessible to the staff. •...
Page 20: Organizational Measures
2.10.2 Use in combination with third-party products Please note that BONFIGLIOLI VECTRON GmbH will not accept any responsibility for compatibility • with third-party products (e.g. motors, cables or filters). In order to enable optimum system compatibility, BONFIGLIOLI VECTRON GmbH office compo- •...
Page 21: The Five Safety Rules
2.10.5.1 The five safety rules When working on/in electrical plants, always follow the five safety rules: 1. Isolate 2. Secure to prevent restarting 3. Check isolation 4. Earth and short-circuit, 5. Cover or shield neighboring live parts. 2.10.6 Safe operation •...
Page 22: Maintenance And Service/Troubleshooting
2.10.7 Maintenance and service/troubleshooting Visually inspect the frequency inverter when carrying out the required maintenance work and • inspections at the machine/plant. • Perform the maintenance work and inspections prescribed for the machine carefully, including the specifications on parts/equipment replacement. •...
Page 23: Safety Instructions On Function „Safe Torque Off" (Sto)
Check the safety function at regular intervals according to the results of your risk assessment. BONFIGLIOLI VECTRON recommends that the check is performed after one year, at the latest.
Page 24 Warning! Dangerous voltage! The safety function “Safe Torque Off” may only be used if mechanical work is to be performed on the driven machines, not for work on live components. After disconnection of an external DC 24 V power supply, the DC link of the frequency inverter is still connected to mains supply.
Page 25: Scope Of Supply
3 Scope of Supply Thanks to the modular hardware components, the frequency inverters can be inte- grated in the automation concept easily. The scope of delivery described can be sup- plemented by optional components and adapted to the customer-specific require- ments.
Page 26: Acu 201 (4.0 To 9.2 Kw) And 401 (5.5 To 15.0 Kw)
ACU 201 (4.0 to 9.2 kW) and 401 (5.5 to 15.0 kW) Scope of Supply Scope of Supply Frequency inverter Terminal strip X10 (Phoenix ZEC 1.5/3ST5.0) Plug-in terminals for the relay output Standard fittings with fitting screws (M4x20, M4x60) for vertical assembly Brief Instructions and Operating Instructions on CD ROM Control terminals X210A / X210B (Wieland DST85 / RM3.5) Plug-in terminal for connection of the control signals...
Page 27: Acu 401 (18.5 To 30.0 Kw)
ACU 401 (18.5 to 30.0 kW) Scope of Supply Scope of Supply Frequency inverter Terminal strip X10 (Phoenix ZEC 1.5/3ST5.0) Plug-in terminals for the relay output Standard fittings with fitting screws (M4x20, M4x70) for vertical assembly Brief Instructions and Operating Instructions on CD ROM Control terminals X210A / X210B (Wieland DST85 / RM3.5) Plug-in terminal for connection of the control signals Please check incoming goods for quality, quantity and nature without delay.
Page 28: Acu 401 (37.0 To 65.0 Kw)
ACU 401 (37.0 to 65.0 kW) Scope of Supply Scope of Supply Frequency inverter Terminal strip X10 (Phoenix ZEC 1.5/3ST5.0) Plug-in terminals for the relay output Standard fittings with fitting screws (M5x20) for vertical assembly Brief Instructions and Operating Instructions on CD ROM Control terminals X210A / X210B (Wieland DST85 / RM3.5) Plug-in terminal for connection of the control signals Please check incoming goods for quality, quantity and nature without delay.
Page 29: Acu 401 (75.0 To 132.0 Kw)
ACU 401 (75.0 to 132.0 kW) Scope of Supply Scope of Supply Frequency inverter Terminal strip X10 (Phoenix ZEC 1.5/3ST5.0) Plug-in terminals for the relay output Control terminals X210A / X210B (Wieland DST85 / RM3.5) Plug-in terminal for connection of the control signals Brief Instructions and Operating Instructions on CD ROM Please check incoming goods for quality, quantity and nature without delay.
Page 30: Technical Data
Up to 4000 m at reduced power. Storage Storage according to EN 50178. BONFIGLIOLI VECTRON recommends that the unit be connected to mains volt- age for 60 minutes after one year, at the latest. Overload capability Continuous Operation: 100 % I...
Page 31: Technical Data - Control Electronic Equipment
Technical Data – Control Electronic Equipment Control terminal X210A Control terminal X210B X210A.1 DC 20 V output (I =180 mA) X210B.1 Digital input or DC 24 V ±10% input for external power supply Digital input STOB (sec- X210A.2 GND 20 V/ GND 24 V (ext.) X210B.2 safety ond shutdown path)
Page 32: Acu 201 (0.25 To 1.1 Kw, 230 V)
ACU 201 (0.25 to 1.1 kW, 230 V) Type ACU 201 Construction Size Output, motor side Recommended motor shaft power 0.25 0.37 0.55 0.75 Output current Long-term overload current (60 s) Short-time overload current (1 s) Output voltage Maximum input voltage, three-phase Protection Short circuit / earth fault proof Rotary field frequency...
Page 33: Acu 201 (1.5 To 3.0 Kw, 230 V)
ACU 201 (1.5 to 3.0 kW, 230 V) Type ACU 201 Construction Size Output, motor side Recommended motor shaft power 4) 5) Output current 12.5 Long-term overload current (60 s) 10.5 14.3 16.2 Short-time overload current (1 s) 14.0 19.0 19.0 Output voltage Maximum input voltage, three-phase...
Page 34: Acu 201 (4.0 To 9.2 Kw, 230 V)
ACU 201 (4.0 to 9.2 kW, 230 V) Type ACU 201 Construction Size Output, motor side Recommended motor shaft power Output current 18.0 22.0 32.0 35.0 Long-term overload current (60 s) 26.3 30.3 44.5 51.5 Short-time overload current (1 s) 33.0 33.0 64.0...
Page 35: Acu 401 (0.25 To 1.5 Kw, 400 V)
ACU 401 (0.25 to 1.5 kW, 400 V) Type ACU 401 Construction Size Output, motor side Recommended motor shaft power 0.25 0.37 0.55 0.75 Output current Long-term overload current (60 s) Short-time overload current (1 s) Output voltage Maximum input voltage, three-phase Protection Short circuit / earth fault proof Rotary field frequency...
Page 36: Acu 401 (1.85 To 4.0 Kw, 400 V)
ACU 401 (1.85 to 4.0 kW, 400 V) Type ACU 401 Construction Size Output, motor side Recommended motor shaft power 1.85 Output current Long-term overload current (60 s) 11.7 13.5 Short-time overload current (1 s) 11.6 15.6 18.0 Output voltage Maximum input voltage, three-phase Protection Short circuit / earth fault proof...
Page 37: Acu 401 (5.5 To 15.0 Kw, 400 V)
ACU 401 (5.5 to 15.0 kW, 400 V) Type ACU 401 Construction Size Output, motor side Recommended motor shaft power 11.0 15.0 Output current 14.0 18.0 22.0 25.0 32.0 Long-term overload current (60 s) 21.0 26.3 30.3 37.5 44.5 Short-time overload current (1 s) 28.0 33.0 33.0...
Page 38: Acu 401 (18.5 To 30.0 Kw, 400 V)
ACU 401 (18.5 to 30.0 kW, 400 V) Type ACU 401 Construction Size Output, motor side Recommended motor shaft power 18.5 22.0 30.0 Output current 40.0 45.0 60.0 Long-term overload current (60 s) 60.0 67.5 90.0 Short-time overload current (1 s) 80.0 90.0 120.0...
Page 39: Acu 401 (37.0 To 65.0 Kw, 400 V)
4.10 ACU 401 (37.0 to 65.0 kW, 400 V) Type ACU 401 Construction Size Output, motor side Recommended motor shaft power 37.0 45.0 55.0 65.0 Output current 75.0 90.0 110.0 125.0 Long-term overload current (60 s) 112.5 135.0 165.0 187.5 Short-time overload current (1 s) 150.0 180.0...
Page 40: Acu 401 (75.0 To 132.0 Kw, 400 V)
4.11 ACU 401 (75.0 to 132.0 kW, 400 V) Type ACU 401 Construction Size Output, motor side Recommended motor shaft power Output current Long-term overload current (60 s) Short-time overload current (1 s) Output voltage Maximum input voltage, three-phase Protection Short circuit / earth fault proof Rotary field frequency 0 ...
Page 41: Operation Diagrams
4.12 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 dimension- ing (derating) of the frequency inverters is possible based on the following diagrams. Installation height Power reduction (Derating), max.
Page 42: Mechanical Installation
5 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. WARNING To avoid serious physical injuries or major material damage, only qualified persons are allowed to work on the devices.
Page 43: Acu 201 (Up To 3.0 Kw) And 401 (Up To 4.0 Kw)
ACU 201 (up to 3.0 kW) and 401 (up 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 ≥...
Page 44: Acu 201 (4.0 To 9.2 Kw) And 401 (5.5 To 15.0 Kw)
ACU 201 (4.0 to 9.2 kW) and 401 (5.5 to 15.0 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 standard fitting. Standard installation ≥...
Page 45: Acu 401 (18.5 To 30.0 Kw)
ACU 401 (18.5 to 30.0 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 standard fitting. Standard installation ≥ 100 mm fixing bracket top fixing bracket bottom (fixing with screws M4x20...
Page 46: Acu 401 (37.0 To 65.0 Kw)
ACU 401 (37.0 to 65.0 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 standard fitting. Standard installation ≥ 100 mm fixing braket top fixing braket bottom (fixing with screws M5x20...
Page 47: Acu 401 (75.0 To 132.0 Kw)
ACU 401 (75.0 to 132.0 kW) The frequency inverter is mounted in a vertical position on the assembly panel. The following illustration shows the standard fitting. Standard installation 300 mm 300 mm The diameter of the fixing holes is 9 mm. Assembly is done by screwing the back wall of the frequency inverter to the assembly panel.
Page 48: Electrical Installation
6 Electrical Installation WARNING The electrical installation must be carried out by qualified electricians according to the general and regional safety and installation directives. The documentation and device specification must be complied with during installa- tion. Before any assembly or connection work, discharge the frequency inverter. Verify that the frequency inverter is discharged.
Page 49 Interference-free operation with residual current device is guaranteed at a trip- • ping current ≥ 30 mA if the following points are observed: − one-phase power supply (L1/N): Pulse current and alternating current sensi- tive residual current devices (Type A to EN 50178) two-phase power supply (L1/L2) or −...
Page 50: 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 51 Mains Connection The length of the mains supply cable is not lim- ited. However, it must be installed separate from the control, data and motor cables. DC link connection The frequency inverters are to be connected to the same mains potential or a common direct voltage source.
Page 52: Block Diagram
Block diagram S3OUT L2 L3 X210A +20 V / 180 mA 24 V GND 20 V S1IND S2IND S3IND U, I S4IND S5IND X210B S6IND S7IND S1OUT MFO1 +10 V / 4 mA MFI1 GND 10 V Relay connection S3OUT Change-over contact, response time approx.
Page 53: Optional Components
Optional Components Thanks to the modular hardware components, the frequency inverters can be inte- grated in the automation concept easily. The standard and optional modules are rec- ognized during the initialization, and the controller functionality is adjusted automati- cally. For the information required for installation and handling of the optional mod- ules, refer to the corresponding documentation.
Page 54: Connection Of Unit
Connection of Unit 6.4.1 Dimensioning of conductor cross-section The cable dimensions should be selected according to the current load and voltage drop to be expected. Select the cable cross-section of the cables such that the voltage drop is as small as possible. If the voltage drop is too great, the motor will not reach its full torque.
Page 55 230 V: Three-phase connection (L1/L2/L3) Mains cable PE-conductor Motor cable 0.25 kW 0.37 kW 0.55 kW 0.75 kW 2x1.5 mm² or 1.5 mm² 1.5 mm² 1.1 kW 1x10 mm² 1.5 kW 2.2 kW 3 kW 4 kW 2x4 mm² or 4 mm²...
Page 56: Mains Connection
When the frequency inverter is disconnected from power supply, the mains, DC-link voltage and motor terminals may still be live for some time. BONFIGLIOLI VECTRON recommends using shielded cables for the connection of the motor and the brake resistor to the frequency inverter. The shield is to be connected to PE potential properly, i.e.
Page 57: Length Of Motor Cables, Without Filter
The voltage drop results in an increase of the output current. Check that the frequency inverter can deliver the higher output current. This must be considered in the projecting phase already. If the motor cable length exceeds 300 m, please consult BONFIGLIOLI. Operating Instructions ACU 06/13...
Page 58: Group Drive
6.4.3.4 Group drive In the case of a group drive (several motors at one frequency inverter), the total length shall be divided across the individual motors according to the value given in the table. Please note that group drive with synchronous servomotors is not possible. Use a thermal monitoring element on each motor (e.g.
Page 59: Connection Of A Brake Resistor
Do not cover the brake resistor. CAUTION Bonfiglioli Vectron recommends using a temperature switch. Depending on the selected resistor the temperature switch is integrated as a standard or optional available. The temperature switch disconnects the frequency inverter from mains supply if the brake resistor is overloaded.
Page 60: Connection Of Types
Connection of types 6.5.1 ACU 201 (up to 3.0 kW) and 401 (up to 4.0 kW) The mains connection of the frequency inverter is via plug-in terminal X1. The con- nection of motor and brake resistor to the frequency inverter is done via plug-in ter- minal X2.
Page 61 Motor connection ACU 201 (up to 3.0 kW) and 401 (up to 4.0 kW) Phoenix ZEC 1,5/ .. ST7,5 0.2 … 1.5 mm AWG 24 … 16 0.2 … 1.5 mm AWG 24 … 16 0.25 … 1.5 mm AWG 22 … 16 0.25 …...
Page 62: Acu 201 (4.0 To 9.2 Kw) And 401 (5.5 To 15.0 Kw)
6.5.2 ACU 201 (4.0 to 9.2 kW) and 401 (5.5 to 15.0 kW) DANGER Disconnect the frequency inverter from mains voltage and protect it against being energized unintentionally. Verify that the frequency inverter is discharged. Wait for some minutes until the DC link capacitors have discharged before starting to work at the unit.
Page 63 Motor connection ACU 201 (4.0 to 9.2 kW) and 401 (5.5 to 15.0 kW) Delta connection Star connection 4.0 kW … 9.2 kW 11.0 kW … 15.0 kW 6qmm / RM7,5 16qmm / RM10+15 0.2 … 6 mm 0.2 … 16 mm AWG 24 …...
Page 64: Acu 401 (18.5 To 30.0 Kw)
6.5.3 ACU 401 (18.5 to 30.0 kW) DANGER Disconnect the frequency inverter from mains voltage and protect it against being energized unintentionally. Verify that the frequency inverter is discharged. Wait for some minutes until the DC link capacitors have discharged before starting to work at the unit.
Page 65 Motor connection ACU 401 (18.5 to 30.0 kW) 2.5 Nm 22.1 lb-in 18.5 kW … 30 kW 25/ 6-15,00 0.5 … 35 mm AWG 20 … 2 0.5 … 25 mm AWG 20 … 4 1.00 … 25 mm AWG 18 … 4 1.5 …...
Page 66: Acu 401 (37.0 To 65.0 Kw)
6.5.4 ACU 401 (37.0 to 65.0 kW) DANGER Disconnect the frequency inverter from mains voltage and protect it against being energized unintentionally. Verify that the frequency inverter is discharged. Wait for some minutes until the DC link capacitors have discharged before starting to work at the unit.
Page 67 Motor connection ACU 401 (37.0 to 65.0 kW) 37.0 kW … 65.0 kW threaded bolt M8x25 wire cross section up to 70 mm 8 Nm 70.8 lb-in Star connection Delta connection Connection of brake resistor with temperature switch 37.0 kW … 65.0 kW threaded bolt M8x25 Wire cross section up to 70 mm 8 Nm...
Page 68: Acu 401 (75.0 To 132.0 Kw)
6.5.5 ACU 401 (75.0 to 132.0 kW) DANGER Disconnect the frequency inverter from mains voltage and protect it against being energized unintentionally. Verify that the frequency inverter is discharged. Wait for some minutes until the DC link capacitors have discharged before starting to work at the unit.
Page 69 Motor connection ACU 401 (75.0 to 132 kW) 10 Nm 88.5 lb-in Star connection Delta connection Threaded bolt M8x20 Connection of brake resistor with temperature switch 10 Nm 88.5 lb-in Threaded bolt M8x20 Optional, the inverters in this size can be purchased without brake chopper and are then not provided with the terminal Rb2 for a brake resistor connection.
Page 70: Control Terminals
Control Terminals The control and software functionality can be configured as required to ensure a reliable and economical operation. The operating instructions describe the factory 30 as well as the settings of the standard connections in the relevant Configuration software parameters to be set up. CAUTION The unit may only be connected with the power supply switched off.
Page 71 Control terminal X210A Ter. Description - Voltage output 20 V, I =180 mA - input for external power supply DC 24 V ±10% GND 20 V and GND 24 V (ext.) Digital signal, STOA (1st shutdown path for safety function STO – „Safe Torque Off “), U =DC 30 V, 10 mA at DC 24 V, input resistance: 2.3 kΩ, PLC compati- ble, response time approx.
Page 72: External Dc 24 V Power Supply
6.6.1 External DC 24 V power supply The bidirectional control terminals X210A.1/ X210A.2 can be used as a voltage output or voltage input. By connecting an external power supply of DC 24 V ±10% to termi- nals X210A.1/X210A.2, the function of inputs and outputs as well as the communica- tion can be maintained.
Page 73: Motor Thermo-Contact
6.6.3 Motor Thermo-Contact The ACU frequency inverters can evaluate the thermal switch of motor. By default, terminal X210B.1 (S6IND) is configured as an input for this evaluation. Connect the thermal switch to the digital input and the DC 24 V supply unit X210A.1. For configu- ration, refer to sections 13.6 “Motor Temperature”...
Page 74: Configurations Overview
Configurations overview Refer to following table in order to learn which combinations of functions and control methods are possible. Configurations „Standard“, „Technology Controller“ and „Torque Control“ will be described in the following sections. For configurations „Elec- tronic Gear“, „Positioning“ and „Brake Control“, please refer to the corresponding application manuals.
Page 75: Configuration 110 - Sensorless Control
6.7.1 Configuration 110 – Sensorless Control Configuration 110 contains the functions for variable-speed control of a 3-phase ma- chine in a wide range of standard applications. The motor speed is set according to the selected ratio of the reference frequency to the necessary voltage. Control terminal X210A X210A.1 Voltage output +20 V or input for...
Page 76: Configuration 410 - Sensorless Field-Oriented Control
6.7.3 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 a high drive dynamics at a high load moment.
Page 77: Configuration 411 - Sensorless Field-Oriented Control With Technology Controller
6.7.4 Configuration 411 – Sensorless Field-Oriented Control with Tech- nology Controller Configuration 411 extends the functionality of the sensorless field-oriented control of Configuration 410 by a Technology Controller. The Technology Controller enables a control based on parameters such as flow rate, pressure, filling level or speed. Control terminal X210A X210A.1 Voltage output +20 V or input for...
Page 78: Configuration 430 - Sensorless Foc, Speed And Torque Controlled
6.7.5 Configuration 430 – Sensorless FOC, Speed and Torque Controlled Configuration 430 extends the functionality of the sensorless field-oriented control of Configuration 410 by a Torque Controller. The reference torque is represented as a percentage and it is transmitted into the corresponding operational performance of the application.
Page 79: Configuration 210 - Field-Oriented Control, Speed Controlled
6.7.6 Configuration 210 – Field-Oriented Control, Speed Controlled The control methods 2xx can be used with HTL sensors (with or without reference track) connected to the basic device or to an expansion module. The control methods 2xx with TTL sensors require an expansion module. An expansion module EM-ABS is required for evaluation of Absolute encoders (Hiper- face, EnDat2.1, SSI).
Page 80: Configuration 211 - Field-Oriented Control With Technology Controller
6.7.7 Configuration 211 – Field-Oriented Control with Technology Controller Configuration 211 extends the functionality of the speed-controlled, field-oriented control of Configuration 210 by a Technology Controller. This enables a control based on parameters such as flow rate, pressure, filling level or speed. Control terminal X210A X210A.1 Voltage output +20 V or input for...
Page 81: Configuration 510 - Foc Of Synchronous Machine, Speed Controlled
6.7.9 Configuration 510 – FOC of Synchronous Machine, Speed Controlled An expansion module EM-RES for evaluation of resolver signals is required for opera- tion of a synchronous machine (control method 5xx). An expansion module EM-ABS is required for evaluation of Absolute encoders (Hiper- face, EnDat2.1, SSI).
Page 82 6.7.10 Configuration 530 – FOC of a Synchronous Machine, Speed and Torque Controlled Configuration 530 extends the functionality of Configuration 510 by functions for torque-dependent, field-oriented control. The reference torque is represented as a percentage and it is transmitted into the corresponding operational performance of the application.
Page 83: Configuration 610 - Sensorless Foc Of Synchronous Machine, Speed Controlled
6.7.11 Configuration 610 – Sensorless FOC of Synchronous Machine, Speed Controlled Configuration 610 contains the functions for speed-controlled, field-oriented control of a synchronous machine without resolver feedback. The separate control of torque and flux-forming current enables high drive dynamics with a high load moment. The missing resolver feedback compared to configuration 510 results in a small loss of dynamic and speed performance.
Page 84: Configuration 611 - Sensorless Foc Of A Synchronous Machine With Technology Controller
6.7.12 Configuration 611 – Sensorless FOC of a Synchronous Machine with Technology Controller Configuration 611 extends the functionality of the sensorless field-oriented control of Configuration 610 by a Technology Controller. The Technology Controller enables a control based on parameters such as flow rate, pressure, filling level or speed. Control terminal X210A X210A.1 Voltage output +20 V or input for...
Page 85: Configuration 630 - Sensorless Foc Of A Synchronous Machine, Speed And Torque Controlled
6.7.13 Configuration 630 – Sensorless FOC of a Synchronous Machine, Speed and Torque Controlled Configuration 630 extends the functionality of the sensorless field-oriented control of Configuration 610 by a Torque Controller. The reference torque is represented as a percentage and it is transmitted into the corresponding operational performance of the application.
Page 86: Installation Notes According To Ul508C
Installation notes according to UL508c The thermal motor protection according to UL508c can be realized in devices that are marked with “TM included” below the nameplate. For devices without the mark “TM included” note according to UL508c: Motor overtemperature sensing is not provided by the drive. The connection and the parameter settings for the temperature motor supervision is described in chapter 13.6 “Motor Temperature”, 15.4.5 “Thermo contact”...
Page 87: Control Unit Kp500
7 Control Unit KP500 The optional KP500 control unit is a practical tool for controlling the frequency invert- er and setting and displaying the frequency inverter parameters. The control unit is not absolutely necessary for the operation of the frequency invert- er and can be plugged on when required.
Page 88: Menu Structure
Menu Structure The menu structure of the control unit is arranged as shown in the following illustra- tion. Use the arrow keys as well as ESC and ENT to navigate through the menu. The software contains the full set of information and enables a flexible use of the parame- ter setting and control options.
Page 89: Actual Value Menu (Val)
Actual Value Menu (VAL) In the VAL menu branch, the control unit displays a variety of actual values, depend- ing 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 90: Parameter Menu (Para)
Parameter Menu (PARA) The parameters to be configured during the guided commissioning procedure 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 instruc- tions.
Page 91: Copy Menu (Cpy)
Copy Menu (CPY) With the copy function of the control unit you can copy parameter values from the frequency inverter to a non-volatile memory of the control unit (upload) and store (download) them to a frequency inverter again. The copy function makes the parameterization of recurring applications much easier. The function archives all parameter values, regardless of access control and value range.
Page 92: Menu Structure
7.5.2 Menu Structure The copy menu CPY contains three main functions. Use the arrow keys to select the required function. Select the source and the destination for the process. The memory space available in the non-volatile memory of the control unit is displayed on the three-digit seven-segment display as a percentage value.
Page 93: Selecting The Destination
7.5.4 Selecting the Destination Select the destination (dSt.) of the copy operation (application-specific). The data source is transferred to the selected target (download). • Use the arrow keys to select the destination (dSt.) of the copied data (down- load). Depending on the data source selected, either the data sets of the fre- quency inverter (dSt.
Page 94: Error Messages
7.5.6 Error Messages The copy function archives all parameters, regardless of the access control and the value range. Some of the parameters are only writable if the frequency inverter is not in operation. The controller enable input (S1IND/STOA, S7IND/STOB) may not be activated during the copy operation, otherwise the data transmission is aborted.
Page 95: Reading Data From Control Unit
Reading Data from Control Unit “Parameter transmission” enables the transmission of parameter values from the control unit KP 500 to the frequency inverter. In this operation mode, all other func- tions of the control unit are disabled, except for the COPY function. Transmission from the frequency inverter to the control unit is also disabled.
Page 96: Data Transfer
Activation via communication module CM Activation of the control unit through a communication connection is possible only if the frequency inverter is fitted with an optional communication module CM, and com- munication takes place via this module. The control unit must be connected to the frequency inverter.
Page 97: Resetting To Normal Operation
7.6.3 Resetting to Normal Operation A control unit KP 500 activated for parameter transmission can be reset to full func- tionality (standard operation) via a specific key code on the control unit or via each available communication module CM. Resetting on control unit •...
Page 98: Controlling The Motor Via The Control Unit
In the CTRL menu branch, various functions are available which make commissioning easier and enable the control of the inverter via the control unit. The frequency inverters can be controlled by means of the control unit and/or a communication module. If you want to control the frequency inverter via an optional communication module, the necessary adjustments can be made via parameter 412.
Page 99 The CTRL menu branch can be accessed via the navigation within the menu structure. The CtrL function contains sub- functions which are displayed according to the operating point of the frequency inverter. Pressing the RUN key leads to a direct change from anywhere within the menu structure to the motorpoti function Pot clockwise rotation or Potr for anticlockwise rotation.
Page 100 Key functions Reversal of the sense of rotation independent of the control signal on the terminals Clockwise S2IND or Anticlockwise S3IND. Cancel function and return to the menu structure. Switch from internal set point int or motor potentiometer function Pot to JOG frequency;...
Page 101: Commissioning Of The Frequency Inverter
8 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 inputs S1IND/STOA and S7IND/STOB open).
Page 102: Configuration
Switch to the next parameter. • • After initialization, confirm the selected configuration by pressing the ENT key. • Continue the guided commissioning procedure according to the following chap- ters. 8.2.1 Configuration Parameter 30 determines the assignment and basic function of the Configuration control inputs and outputs as well as the software functions.
Page 103 Configuration 211, field-oriented control with technology controller Configuration 211 extends the functionality of Configuration 210 by a Technology Controller. The Technology Controller enables a control based on parameters such as flow rate, pressure, filling level or speed. Configuration 230, field-oriented control with speed/torque control Configuration 230 extends the functionality of Configuration 210 by functions for torque-dependent, field-oriented control.
Page 104: Data Set
8.2.2 Data Set The data set change-over function enables the selection of one of four data sets for storing parameter settings. If data set 0 is selected (factory setting), the parameter values saved in data set 0 are copied to data sets 1 through 4. In this way, all values determined during the guided commissioning procedure are saved in all data sets.
Page 105: Machine Data
Parameterize the rated data according to the rating plate of the motor for the wiring of the motor winding. Consider the increased rated current of the connect- ed three-phase motor. Example: BONFIGLIOLI BN 90LA Motor Parameter Star Delta Rated voltage...
Page 106: Plausibility Check
8.2.5 Plausibility check After the machine data (and the speed sensor data, if applicable) have been entered, the calculation or examination of the parameters is started automatically. The display changes over to "CALC" for a short time. If the verification of the machine data is suc- cessful, the guided commissioning procedure continues with the identification of the parameters.
Page 107: Parameter Identification
8.2.6 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 108: Status Messages During Commissioning (Ss
8.2.7 Status messages during commissioning (SS…) The following status messages are possible during commissioning (setup): Status message Meaning SS000 Auto setup routine has been carried out. SS001 PC Phase 1 The plausibility check (PC) of the motor data is active. SS002 PC Phase 2 The calculation of dependent parameters is active.
Page 109 SA051 The machine data for star connection were entered, the motor, however, is connected in delta. For star operation, change the motor cable connection. For delta operation, check the entered rated motor values. Repeat the parameter identification. SA052 The machine data for delta connection were entered, the motor, however, is connected in star.
Page 110: Error Messages During Commissioning (Sf
8.2.9 Error messages during commissioning (SF…) After completion or during the parameter identification, error messages may be dis- played. Depending on the error code, the following instructions should be followed and the measures indicated should be taken. Error Messages Code Measures / Remedy SF000 No error message exists.
Page 111: Application Data
8.2.10 Application data Due to the wide range of drive applications with the resulting parameter settings it is necessary to check further 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. At the control unit KP500 parameter numbers >...
Page 112: Quitting Commissioning
8.2.11 Quitting commissioning Confirm the "End" display by pressing the ENT key. The guided commissioning of the frequency inverter is terminated via a reset and the initialization of the frequency inverter. The relay output X10 signalizes a fault, 532 = “103 - Inv. Error because of the factory setting Op.
Page 113: Check Direction Of Rotation
Check direction of rotation WARNING The electrical installation must be carried out by qualified electricians according to the general and regional safety and installation directives. The documentation and device specification must be complied with during installa- tion. Before any assembly or connection work, discharge the frequency inverter. Verify that the frequency inverter is discharged.
Page 114: Speed Sensor
Speed sensor For some configurations an incremental speed sensor must be connected. Dependent on the speed sensor type it can be connected to the basic device or to an expansion module. Some applications require the connection to the basic device as well as to the expansion module.
Page 115: Speed Sensor 1
8.4.1 Speed sensor 1 Connect the speed sensor tracks to the digital inputs S5IND (track A), S4IND (track B) and S6IND (track Z). The speed sensor type and the evaluation required are adjusted via the Operation 490 of speed sensor 1. Mode For a detailed description of possible settings refer to section 10.4.
Page 116: Set-Up Via The Communication Interface
Set-up via the Communication Interface Parameter-setting and commissioning of the frequency inverter via one of the op- tional communication interfaces include the plausibility check and the parameter identification functions. The parameters can be adjusted by qualified users. The pa- rameter selection during the guided commissioning procedure includes the basic pa- rameters.
Page 117 Function SETUP Selection Additional motor data are measured, dependent Calc. and para ident., 33 - parameters are calculated and the parameter val- ues are saved in data set 3. Additional motor data are measured, dependent Calc. and para ident., 34 - parameters are calculated and the parameter val- ues are saved in data set 4.
Page 118: Inverter Data
5.4.0 Inverter software version Nameplate: Version: 5.4.0 ; Software: 15 000 190 (C) 2013 BONFIGLIOLI VECTRON Copyright Set Password 27 can be As a protection against unauthorized access, the parameter Set password set such that anyone who wants to change parameters must enter this password this password before.
Page 119: Control Level
Control Level 28 defines the scope of the functions to be parameterized. The op- Control level erating instructions describe the parameters on the third control level. These parame- ters should only be set by qualified users. Parameter Settings Description Min. Max.
Page 120 Configuration 210, field-oriented control Configuration 210 contains the functions for speed-controlled, field-oriented control of a 3-phase machine with speed sensor feedback. The separate control of torque and flux-forming current enables high drive dynamics with a high load moment. The necessary speed sensor feedback results in a precise speed and torque performance. Configuration 211, field-oriented control with technology controller Configuration 211 extends the functionality of Configuration 210 by a Technology Controller, which enables a control based on parameters such as flow rate, pressure,...
Page 121 In the table, you will find a list of functions which are available in the different configurations. Configuration Character- field-oriented control istic Sensorless Sensorless Servo Servo sen- Sensor 2xx sorless 6xx Function Chapter 110 111 410 411 430 210 211 230 510 530 610 611 630 17.5.4 Speed control Torque control...
Page 122: Language
Language The parameters are stored in the frequency inverter in various languages. The pa- rameter description is displayed by the PC control software (e.g. VPlus) in the select- Language Function Language 0 - Deutsch Parameter description in German. 1 - English Parameter description in English.
Page 123: Machine Data
10 Machine Data The input of the machine data is the foundation for the functionality of the control functions and methods. In the course of the guided commissioning, the necessary parameters are inquired according to the selected Configuration 10.1 Rated Motor Parameters Set the rated parameters of the three-phase asynchronous machine according to the rating plate or the data sheet of the motor.
Page 124: Further Motor Parameters
10.2 Further motor parameters In particular the field-oriented control requires the determination of further data which cannot be read off the rating plate of the 3-phase machine for the precise calculation of the machine model. In the course of the guided commissioning, the parameter identification was carried out to measure the further motor parameters.
Page 125: Magnetizing Current
10.2.3 Magnetizing Current 716 is a measure of the flux in the motor and thus of Rated magnetizing current the voltage which is present at the machine in no-load condition depending on the speed. The guided commissioning determines this value at about 30% of the Rated 371.
Page 126: Voltage Constant
During the guided commissioning (via keypad and VPlus) for Bonfiglioli motors the voltage constant is pre-allocated. For Non-Bonfiglioli motors the voltage constant should be entered if it is known. If 383 to 0 mV before the com- the voltage constant is unknown, set Voltage constant missioning to ensure the automatic calculation and measurement.
Page 127: Change Sense Of Rotation
(anti clockwise) (clockwise) BONFIGLIOLI VECTRON defines with view on the motor A side and correct connection of the motor phases the sense of rotation clockwise (forward) with a positive set value. With a changed sense of rotation, the motor reverses with the same set value. Existing gear boxes and transmissions have to be considered.
Page 128: Speed Sensor 1
10.4 Speed Sensor 1 The frequency inverters are to be adapted to the application depending on the re- 30 demand continuous measure- quirements. A part of the available Configuration ment of the actual speed for the control functions and methods. The necessary con- nection of an incremental speed sensor is done on the digital control terminals S5IND (track A) and S4IND (track B) of the frequency inverter.
Page 129 Function Operation mode Two-channel speed sensor with recognition of direc- Single evaluation tion of rotation via track signals A and B, reference 1001 – with reference track track via digital input S6IND. One signal edge is eval- uated per division mark. Two-channel speed sensor with recognition of direc- Double evaluation tion of rotation via track signals A and B, reference...
Page 130: Division Marks, Speed Sensor 1
In configurations 210, 211 and 230, digital input S4IND is by default set for the evalu- ation of a speed sensor signal (track B). 11 or If an operation mode without sign is selected ( Operation Mode Operation 12), this input is not set for the evaluation of a speed sensor signal and can be Mode used for other functions.
Page 131: Gear Factor Speed Sensor 1
This can filter can be applied in cases, where the speed sensor fluctuates (in example due to mechanical reasons). Bonfiglioli Vectron recommends to change the value in small steps and check the result and not to change the values in big steps.
Page 132: Sensor Evaluation
10.5 Sensor evaluation In the field of drive engineering, TTL and HTL sensors with 512, 1024 or 2048 divi- sion marks are widely used. However, other division mark values are used, too. These division marks (often also referred to as „increments“) determine the resolu- tion (accuracy) at which a machine can be operated.
Page 133: System Data
11 System Data The various control functions and methods according to the selected Configuration 30 are supplemented by control and special functions. For monitoring the applica- tion, process parameters are calculated from electrical control parameters. 11.1 Actual System Value The parameter 389 can be used if the drive is monitored Actual system value factor via the actual value...
Page 134: Operational Behavior
12 Operational Behavior The operational behavior of the frequency inverter can be adjusted to the application by setting the parameters appropriately. In particular the acceleration and decelera- 30. Additional- tion behavior can be selected according to the selected Configuration ly, features such as Auto Start, and the synchronization and positioning functions facilitate the integration in the application.
Page 135 Starting Behavior Operation mode In this operation mode, the current set with the parame- 781 is impressed into Current during flux-formation the motor for magnetization after release. The output frequency is kept at zero Hz for the Maximum flux- 780. After the time has elapsed, the out- formation time put frequency is increased according to the set accelera- Magnetization +...
Page 136: Starting Current
12.1.1.1 Starting Current 623 ensures, particularly for high-torque start, a sufficient Starting current 624 is reached. torque until the Frequency limit Applications in which high current is permanently needed at a low speed are to be realized using forced-ventilated motors to prevent thermal overload. Parameter Settings Description...
Page 137: Flux Formation
12.1.2 Flux Formation Field-oriented control in the configurations 2xx and 4xx are based on separate regu- lation of the flux-forming and torque-forming current components. Upon startup, the machine is magnetized and a current is impressed first. With the parameter Current 781 the magnetization current I is set, with the parameter during flux formation...
Page 138: Stopping Behavior
12.2 Stopping Behavior The stopping behavior of the three-phase machine can be defined via parameter 630. Via the logic signals or digital inputs for the parameters Operation mode Start 68 and 69, stopping is activated. Assign digital inputs clockwise Start anticlockwise or logic signals to these parameters.
Page 139 Stopping behaviors 3, 6 and 7 are only available in the configurations for V/f sensor-less control (1xx). Please refer to the notes for controlling a mechanical brake in chapter 15.3.5 Brake release. For connection of a synchronous motor BONFIGLIOLI VECTRON recommends the 630 = 22. setting of Operation Mode...
Page 140: Switch-Off Threshold
12.2.1 Switch-Off Threshold 637 defines the frequency as from which a Switch-off threshold stop function standstill of the drive is recognized. This percentage parameter value is relative to 419. the set Maximum frequency The switch-off threshold is to be adjusted according to the load behavior of the drive and the device output, as the drive must be controlled to a speed below the switch- off threshold.
Page 141: Auto Start
Contact-controlled: 632 is set to the value 0.0 s, the direct current brake If the parameter Braking time is controlled by the Start clockwise and Start anticlockwise signals. The time monitor- 632 are deactivated. The braking current will be ing and limitation by Braking time impressed until the controller enable control signal (S1IND/STOA and S7IND/STOB) becomes logical 0 (low).
Page 142: Search Run
12.5 Search Run The synchronization to a rotating drive is necessary in applications which drive the motor by their behavior or in which the drive is still rotating after a fault switch-off. 645, the motor speed is synchronized to the current Operation mode search run motor speed without an "Overcurrent"...
Page 143 ment. In operation modes 10 to 15, it cannot be ruled out that a wrong direction of rotation is determined in quick synchronization. For example, a frequency not equal to zero may be determined although the drive is at a standstill. If there is no overcurrent, the drive is accelerated accordingly.
Page 144: Positioning
12.6 Positioning Positioning is done in operation mode "Reference positioning" via the definition of the positioning distance or in operation mode "Axle positioning" via the definition of the position angle. Reference positioning uses a digital reference signal from a selectable signal source for positioning the drive independent of the speed.
Page 145 The minimum number of revolutions needed until the required position is reached 241 and ) 421 (or depends on the Actual frequency Deceleration clockwise Decel- 423) as well as the 373 of the motor. eration anticlockwise No. of pole pairs = min.
Page 146 The behavior of the positioning after the required position of the drive is reached can 463 parameter. be defined via the Activity after positioning Function Activity after positioning The drive is stopped with the stopping behavior 0 - End positioning 630.
Page 147: Axle Positioning
Examples of reference positioning as a function of the parameter settings selected. 459 parameter − The reference point is registered according to the Signal sources in operation mode 16–S6IND, pos. edge by a signal on digital input 6. 460 with parameter value 0.000U (default) defines a −...
Page 148 The positioning is started by a start command from a signal source (e.g. digital input) 37. The signal which must be assigned to the parameter Start Positioning of Axle source can be selected from the operation modes for digital inputs described in chap- ter "Digital inputs".
Page 149: Error And Warning Behavior
37 is recognized by the frequency The current position after Start Positioning of Axle inverter as follows: During commissioning, after switching on the frequency inverter, a search mode − is performed for 3 rotations at a rotational frequency of 1 Hz in order to detect the reference signal.
Page 150: Overload Ixt
13.1 Overload Ixt The admissible load behavior depends on various technical data of the frequency inverters and the ambient conditions. 400 defines the rated current and the available The selected Switching frequency overload for one second and sixty seconds, respectively. The Warning Limit Short 405 and 406 are to be parameterized ac-...
Page 151: Controller Status
13.3 Controller status The intervention of a controller can be indicated via the control unit or LED's. The selected control methods and the matching monitoring functions prevent a switch-off of the frequency inverter. The intervention of the function changes the operating behavior of the application and can be displayed by the status messages with param- eter 275.
Page 152: Frequency Switch-Off Limit
13.5 Frequency Switch-Off Limit The maximum allowed output frequency of the frequency inverter can be set with the 417. If this frequency limit is exceeded by the parameter Frequency switch-off limit 210 or 241, the frequency inverter switches off Stator frequency Actual frequency with fault message “F1100”.
Page 153: Phase Failure
13.7 Phase Failure A failure of one of the three motor or mains can lead to a damage in the frequency inverter, the motor and the mechanical drive components. To prevent damage to these components, the phase failure is monitored. Parameter Phase supervision allows to adjust the behavior in case of a failure.
Page 154: Reference Values
14 Reference Values The ACU series frequency inverters can be configured specific to the application and enable customer-specific adaptation of the module hardware and software structure. 14.1 Frequency Limits The output frequency of the frequency inverter and thus the speed setting range are defined by the parameters 418 and 419.
Page 155 Function Reference frequency source Reference value source is the multifunctional input 1 in Abs. value analog value MFI1A analog 452. Operation mode Reference value source is the analog input of the ex- Abs. Analog Value EM-S1INA pansion module. Abs. Value MFI1A + EM-S1INA Combination of the operation modes 2 and 1.
Page 156: Block Diagram
14.4.1 Block diagram The following table describes the software switches shown in the circuit diagram as a 475. function of the selected Frequency reference value source Switch position on circuit diagram Operation Signal MFI1A mode S1INA Abs. value Abs. value Abs.
Page 157 Circuit diagram of frequency reference value channel Operating Instructions ACU 06/13...
Page 158: Reference Percentage Channel
14.5 Reference percentage channel The reference percentage channel combines various signal sources for definition of the reference figures. The percentage scaling facilitates integration into the applica- tion, taking various process parameters into account. 476 determines the additive assignment of the Reference Percentage Source available reference value sources depending on the hardware installed.
Page 159: Block Diagram
14.5.1 Block diagram The following table describes the software switches shown in the circuit diagram as a 476. function of the selected Reference percentage source Switch position on circuit diagram Operation MFI1A Sign mode S1INA Abs. value Abs. value Abs. value Abs.
Page 160 Circuit diagram of percent reference value channel Operating Instructions ACU 06/13...
Page 161: Fixed Reference Values
14.6 Fixed reference values The fixed reference values are to be parameterized as fixed frequencies or fixed per- centages according to the configuration and function. The signs of the fixed reference values determine the direction of rotation. A positive sign means a clockwise rotation; a negative sign means an anticlockwise rotation. The direction can only be changed via the sign if the Reference frequency 475 or...
Page 162: Jog Frequency
14.6.2 JOG frequency The JOG function forms part of the functions for controlling the drive mechanism via the control unit. Use the arrow keys to change the JOG frequency within the function. The frequency of the output signal is set to the entered value if the FUN key is 489.
Page 163: Frequency Ramps
14.7 Frequency ramps The ramps determine how quickly the frequency value is changed if the reference value changes or after a start, stop or brake command. The maximum admissible ramp gradient can be selected according to the application and the current con- sumption of the motor.
Page 164 426 limits the difference between the output of The parameter Maximum leading the ramp and the current actual value of the drive. The set maximum deviation is a dead time for the control system which should be kept as low as possible. In case the drive is loaded heavily and high acceleration and deceleration values are selected it is possible, that a set controller limit is reached while the drive is acceler- ated or decelerated.
Page 165 Setting the ramp time to 0 ms deactivates the function S curve and enables the use of the linear ramps. The data set change-over of the parameters within an accelera- tion phase of the drive mechanism demands the defined take-over of the values. The controller calculates the values required in order to reach the reference value from the ratio of the acceleration to the ramp time and uses it until the acceleration phase is complete.
Page 166: Percentage Value Ramps
14.8 Percentage Value Ramps The percentage value ramps scale the change of the reference value (in percent) for the corresponding input function. The acceleration and deceleration of the drive are parameterized via the frequency ramps. 477 corresponds to a function which takes The behavior Gradient percentage ramp the time behavior of the drive system into account.
Page 167: Motor Potentiometer
14.10 Motor Potentiometer Via the motor potentiometer function, the motor speed is controlled via − digital control signals (function Motorpoti MP) or via − the keys of the control unit KP 500 (Function Motorpoti KP) The control up/down commands are assigned the following functions: Activation Motorpoti (MP) Motorpoti (KP)
Page 168: Motorpoti (Mp)
474 of the motor potentiometer function defines the behavior Operation mode of the function at various operating points of the frequency inverter. Function Operation mode In the operation mode motor potentiometer non- 0 - non-storing storing (not Latching), the drive goes to the set minimum reference value at each start.
Page 169: Controlling The Motor Via The Control Unit
The keys on the control unit have the following functions: Key functions ▲ / ▼ Increase / reduce frequency. Reversal of the sense of rotation independent of the control signal on the terminals Clockwise S2IND or Anticlockwise S3IND. Save the selected function as default value. The direction of rotation is not (1 sec) changed.
Page 170: Pwm-/Repetition Frequency Input
14.11 PWM-/repetition frequency input The use of a PWM (pulse-width modulated) frequency signal completes the various possibilities of the reference value specification. The signal at one of the available 496. digital inputs is evaluated according to the selected Operation mode PWM frequencies in the range between 50 Hz and 150 kHz can be evaluated.
Page 171 The signal frequency at the selected repetition frequency input can be scaled via the 497. The parameter figure is comparable with the division marks parameter Divider of a speed sensor per rotation of the drive mechanism. The frequency limit of the parameterized digital input is to be taken into account for the frequency of the input signal.
Page 172: Control Inputs And Outputs
15 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 control inputs and outputs of terminals X210A and X210B described in the following can be linked to software modules freely via the described parameters.
Page 173 The following characteristic is set by default and can be adapted to the application via the parameters mentioned. (X2=98%/Y2=100%) pos. maximum value Point 1: 50 Hz 2.00% ⋅ 0.20 0.00% ⋅ 50.00 0.00 (X1=2%/Y1=0%) Point 2: 98.00% ⋅ 9.80 9.8 V 0.00% 50.00 0.00...
Page 174: Scaling
15.1.1.2 Scaling The analog input signal is mapped to the freely configurable characteristic. The max- imum admissible setting range of the drive can be set via the frequency limits or percentage limits according to the configuration selected. In the case of the parame- terization of a bipolar characteristic, the set minimum and maximum limits for both directions of rotation are effective.
Page 175: Filter Time Constant
418 or 518 extends the pa- The default Minimum Frequency Minimum Percentage rameterized tolerance band to the hysteresis. (X2/Y2) pos. maximum value pos. minimum value +10 V neg. minimum value (+20 mA) zero point tolerance band (X1/Y1) neg. maximum value Tolerance band with set minimum frequency For example, the output variable coming from positive input signals is kept on the positive minimum value until the input signal becomes lower than the value for the...
Page 176: Error And Warning Behavior
15.1.1.5 Error and warning behavior For monitoring the analog input signal, an operation mode can be selected via pa- 453. rameter Error/warning behavior Function Error/Warning Behavior 0 - Off The input signal is not monitored. If the input signal is lower than 1 V or 2 mA, a 1 - Warning <...
Page 177: Multi-Function Output Mfo1
15.2 Multi-Function Output MFO1 Multifunction output MFO1 can either be configured as a digital, analog or a repeti- 550 for the multi- tion frequency output. Depending on the selected Operation mode function output, a link to various functions of the software is possible. The operation modes not used are deactivated internally.
Page 178: Output Characteristic
15.2.1.1 Output Characteristic The voltage range of the output signal at multifunction output 1 can be adjusted. The 553 is value range of the actual value selected via parameter Analog operation assigned to the value range of the output signal which is adjusted via the parameters 551 and 552.
Page 179: Frequency Output Mfo1F
15.2.2 Frequency Output MFO1F The multifunctional output MFO1 can be used as a frequency output in the setting of 550 = “3 - Repetition Frequency”. The DC 24V output signal is as- Operation Mode signed to the abs. value of the speed or frequency via the parameter Repetition 555.
Page 180: Digital Outputs
15.3 Digital Outputs 530 and the relay output with the parameter Operation mode Digital output 1 532 link the digital outputs to various functions. Operation mode Digital output 3 The selection of the functions depends on the parameterized configuration. The use of the multifunctional output MFO1 as a digital output demands selection of an Oper- 550 and linking via parameter...
Page 181 Operation mode 530,532,554 Function Warning of 581 of V-belt moni- Operation Mode 22 - Warning V-belt toring. 790 gen- The selected Operation Mode Timer 1 23 - Timer 1 erates an output signal of the function. 793 gen- The selected Operation Mode Timer 2 24 - Timer 2 erates an output signal of the function.
Page 182 Operation mode 530,532,554 Function Message on status of a travel order during a positioning operation. The conditions set for pa- Motion-Block Digital Sig- rameter 1219 were fulfilled. 63 - Digital Signal 2 nal 2 “Start”, “Reference value reached” and “End” of a travel order were evaluated.
Page 183: Digital Signal
15.3.1 Digital Signal 530, The signals selected for parameters Op. Mode Digital Output 1 Digital Opera- 554 and 532 can be linked with inverter functions. tion Op. Mode Digital Output 3 Signal at digital output 1 The Signal which is selected via Op.
Page 184: Setting Frequency
15.3.2 Setting Frequency If operation mode 4 - “Setting Frequency” is selected for a digital output, the corre- 210 exceeds sponding output becomes active if the actual value Stator Frequency 510. the value of Setting Frequency 210 falls The relevant output is switched over again as soon as the Stator Frequency 510 minus 517”.
Page 185: Reference Value Reached
15.3.3 Reference value reached In operation mode 5 - “Reference Frequency reached” for a digital output, a signal is generated via the corresponding output when the actual frequency has reached the reference value. In operation mode 6 - “Reference Percentage reached” for a digital output, a signal is generated via the corresponding output when the actual percentage value has reached the reference value.
Page 186: Flux Forming Finished
15.3.4 Flux Forming finished If operation mode 30 is selected for a digital output the corresponding output be- comes active when the flux formation is ended. The time for the flux formation re- sults from the operating state of the machine and the set parameters for magnetizing the machine.
Page 187: Warning Mask
15.3.8 Warning Mask The Warning mask signals via a digital signal if an afore configured warning applies. 536. The configuration of the Warning mask is carried out via Create warning mask Warnings and controller status messages can be combined. This enables internal or 269 and external control using a common output signal.
Page 188 Function Create Warning Mask The DC link voltage has exceeded the Controller Udc Limita- Reference UD 33 - tion 680. limitation 605 accelerates the Controller Dyn. Voltage Pre-Control 34 - Voltage Pre-Control control characteristics. 35 - Controller I abs The output current is limited. Controller The output power or the torque is limited by the 36 -...
Page 189 Warning code Create Warning Mask FFFF FFFF 1 - Activate everything 0000 FFFF 2 - Activate all Warnings FFFF 0000 3 - Activate all Controller States 0000 0001 10 - Warning Ixt 0000 0002 IxtSt 11 - Warning Short-Term Ixt 0000 0004 IxtLt...
Page 190: Application Warning Mask
15.3.9 Application warning mask The Application Warning mask signals via a digital signal if an afore configured warn- ing applies. The configuration of the Application Warning mask is carried out via Cre- 626. ate Appl. Warning Mask As soon as limit switches are reached or contouring error limits are exceeded, a warning can be issued.
Page 191: Digital Inputs
The selected warning mask application can be read out via the parameter Actual 627. The above operation modes of parameter Appl. Warning Mask Create Appl. 626 are encoded in the 627. The code Warning Mask Actual Appl. Warning Mask results from hexadecimal addition of the individual operation modes and the match- ing abbreviation.
Page 192 Digital Inputs Function Signal on digital input S5IND (X210A.7) or re- 74 - S5IND mote operation via communication interface. Signal on digital input S6IND (X210B.1) or re- 75 - S6IND mote operation via communication interface. Signal at multifunction input MFI1 (X210B.6) in 452 = 3 - digital input or re- 76 - MFI1D Operation Mode...
Page 193 Digital Inputs Function Failure of the mains voltage and power regulation 179 - Mains Failure active according to 670 for the Operation Mode voltage controller. 571 of the motor Warning Motor Protection Parameterized Operation Mode 180 - Switch protection switch has triggered. Digital Signal 4, EM- Signal according to operation mode for the digital 181 -...
Page 194 Digital Inputs Function 526 - S2IND (Hardware) Digital input S2IND (X210A.4) 527 - S3IND (Hardware) Digital input S3IND (X210A.5) 528 - S4IND (Hardware) Digital input S4IND (X210A.6) 529 - S5IND (Hardware) Digital input S5IND (X210A.7) 530 - S6IND (Hardware) Digital input S6IND (X210B.1) Multifunction input MFI1 (X210B.6) in Operation 531 - MFI1D (Hardware)
Page 195 Digital Inputs Function Process data for Profibus-communication. Module 750 - OUT-PZD3 Boolean CM-PDP with Profibus interface is necessary. Process data for Profibus-communication. Module 751 - OUT-PZD4 Boolean CM-PDP with Profibus interface is necessary. Process data for Profibus-communication. Module 752 - OUT-PZD5 Boolean CM-PDP with Profibus interface is necessary.
Page 196: Start Command
15.4.1 Start command 68 and 69 can be linked to the The parameters Start Clockwise Start Anticlockwise available digital control inputs or the internal logic signals. The drive is only acceler- ated according to the control method after a start command. The logic functions are used for the specification of the direction of rotation, but also for using the parameterized 620 for the starting behavior and...
Page 197: Error Acknowledgment
15.4.3 Error Acknowledgment The frequency inverters feature various monitoring functions which can be adapted via the error and warning behavior. Switching the frequency inverter off at the vari- ous operating points should be avoided by an application-related parameterization. If there is a fault switch-off, this report can be given via the parameter Pro- 34 or the logic signal can be acknowledged with parameter gram(ming)
Page 198: Data Set Change-Over
15.4.7 Data Set Change-Over Parameter values can be stored in four different data sets. This enables the use of various parameter values depending on the current operation point of the frequency inverter. The change-over between the four data sets is done via the logic signals 70 and assigned with the parameters Data set change-over 1...
Page 199: Fixed Value Change-Over
15.4.8 Fixed Value Change-Over As a function of the selected configuration, the reference figures are specified via the 475 or assignment of the Reference frequency source Reference percentage 476. Accordingly, there can be a change between the fixed values by connec- source tion of the logic signals with the parameters Fixed frequency change-over 1...
Page 200: Handshake Traverse Function
15.4.10 Handshake Traverse Function 49, the signal source is selected for Via parameter Handshake Traverse Function specification of the direction of rotation of the slave drive of the shot-effect function. 435. The shot-effect function is switched on via parameter Operation mode 15.4.11 User warning For setting up external warnings parameters...
Page 201: Function Modules
15.5 Function Modules 15.5.1 Timer The timer function can be linked to various functions for time-control of digital sig- nals. The parameters 790 and 793 de- Operation Mode Timer 1 Operation Mode Timer 2 fine the evaluation of the digital input signals and the unit of time of the time func- tion.
Page 202: Timer - Time Constant
15.5.1.1 Timer – Time Constant The logic sequence of input and output signals is to be set separately for both timer functions via the time constants. The default parameter values result in a direct link of the input and output signal without a delay. Before starting the timer, select the operation mode and set the time constants in or- der to avoid non-defined states.
Page 203 AND connection, positive edge Parameter 790 or 793 = 3 Operation Mode Timer 1 Operation Mode Timer 2 Input Time 1 Time 1 Time 2 Time 1 Time 2 Output 1) As soon as the positive signal edge is received at the input, time 1 (signal delay) is started.
Page 204: Comparator
15.5.2 Comparator With the help of software functions Comparator 1 and 2, various comparisons of ac- tual values with percentage-adjustable fixed values can be done. The actual values to be compared can be selected from the following table with the 540 and 543.
Page 205: Function Table
The setting of the percentage limits of the comparators enables the following logical links. The comparison with signs is possible in the corresponding operation modes of the comparators. below above above below Example: Op. Mode Comparator 1 540 = 7- Abs. Actual Frequency Comparator On above 541 = 80.00 % (of Maximum Frequency 419) Comparator Off below 542 = 50.00 %...
Page 206: Multiplexer/Demultiplexer
15.5.4 Multiplexer/Demultiplexer The multiplexer/demultiplexer enables the transfer of various digital signals between an overriding controller and frequency inverters via field bus or between frequency inverters via the system bus. For parameterization of the multiplexer and demulti- plexer using the VTable application, the commissioning and diagnosis software VPlus, version 4.0.2 or higher is required.
Page 207 Example: Transfer of a user-defined status word from a slave to a master via sys- tem bus or Profibus, parameterization of multiplexer and demultiplexer using PC ap- plication VTable in VPlus VTable User-defined Status word Multiplexer 927 - MUX-Output Parameter /Index Assign signal sources: Systembus: TxPDO1 Word1...
Page 208: F-Characteristic
16 V/f-Characteristic The sensorless control in configurations 110 and 111 is based on the proportional change of output voltage compared to the output frequency according to the config- ured characteristic. By setting the V/f-characteristic, the voltage of the connected 3-phase motor is con- trolled according to the frequency.
Page 209: Dynamic Voltage Pre-Control
603 (UC) and 604 (FC) are derived The default Cut-off voltage Cut-off frequency 370 and 375. With the parame- from the motor data Rated voltage Rated frequency 600 (US), the linear equation of the V/f-characteristic re- terized Starting voltage sults. −...
Page 210: Control Functions
17 Control Functions The frequency inverters provide a selection of established control methods in Config- 30. The selected control structure can be parameterized as required and uration optimized for the application by further functions. 17.1 Intelligent current limits The current limits to be set according to the application avoid inadmissible loading of the connected load and prevent a fault switch-off of the frequency inverter.
Page 211: Voltage Controller
If the output current has already been reduced due to the fact that the long-term overload has used up, the short-term overload is no longer available even if it has not been used up beforehand. The defined overload reserve (Ixt) of the frequency in- verter is available again after a power reduction lasting 10 minutes.
Page 212 When an operation mode with motor chopper is selected, set the Trigger Threshold 507 < ( 680 - 10 V). See chapter 18.7.1 “Motor Chop- Reference DC-Link Limitation per”. 30 = 5xx), the motor chopper function is de- For synchronous motors ( Configuration activated to prevent damages to the motor.
Page 213 Operation mode power failure regulation. 670 = 2 Voltage controller: Parameter Operation mode With the power failure regulation, short-term power failures can be bridged. Mains failure is detected when the DC link voltage has dropped below the set value of pa- 671.
Page 214 Parameter Settings Description Min. Max. Fact. sett. 671 Mains failure threshold -200.0 V -50.0 V -100.0 V 672 Reference mains support value -200.0 V -10.0 V -40.0 V The frequency inverter reacts to the signals at the control inputs both when the power failure regulation is switched on and in normal operation.
Page 215 If the mains failure with or without shutdown takes so long that the frequency in- verter shuts off completely (LED's = OFF), the frequency inverter will be in the "Standby" state when the mains supply is restored. If the inverter is released again, the drive will start.
Page 216: Technology Controller
17.3 Technology Controller The technology controller, the behavior of which corresponds to a PID controller, is available as an additional function in configuration 111, 211, 411 and 611. The con- nection of reference and actual value of the application with the functions of the fre- quency inverter enables process control without further components.
Page 217 58 the technology controller can be Via parameter Technology Controller Release halted. The P and D part remain at the value before switching off. The output value and the I part resets with each switching off of the Technology Controller Release 68 to the logic signal of the The default assignment of parameter Start clockwise...
Page 218 Derivative time ferential component is enabled the system tends to oscillate, so that the differential component should be enabled and set carefully. BONFIGLIOLI VECTRON recommends setting the values of 445 and Integral time 618 higher than the sample time, which is 2 ms at the ACU device.
Page 219 Parameter Settings Description Min. Max. Fact. sett. 441 Fixed Frequency -999.99 Hz +999.99 Hz 0.00 Hz 442 Max. P-Component 0.01 Hz 999.99 Hz 50.00 Hz 443 Hysteresis 0.01 % 100.00 % 10.00 % 444 Amplification -15.00 +15.00 1.00 445 Integral Time 0 ms 32767 ms 200 ms...
Page 220 Operation mode standard, parameter 440 = 1 Operation mode This operation mode can be used, for example, for pressure or volumetric flow con- trol with linear operation behavior. The minimum value monitoring prevents an acceleration of the drive if the actual value is missing.
Page 221 Operation mode filling level 1, parameter 440 = 2 Operation mode This operation mode can be used, for example, for contents level control. If the actual value is missing, the function brings the output frequency to an adjusta- ble value. The minimum value monitoring prevents an acceleration of the drive if the actual value is missing.
Page 222 Operation mode filling level 2, parameter 440 = 3 Operation mode This operation mode can be used, for example, for contents level control. The minimum value monitoring prevents an acceleration of the drive if the actual value is missing. If the actual value is missing (< 0.5%) the output frequency is guided to the Fixed 441.
Page 223 Operation mode speed controller, parameter 440 = 4 Operation mode This operation mode is suited for speed controls with an analog actual value trans- mitter (e.g. analog speedometer via analog input or HTL encoder via frequency in- put). The motor is accelerated or decelerated according to the control deviation. The output frequency is limited by the 419.
Page 224 Operation mode indirect volume flow control, parameter 440 = 5 Operation mode This operation mode is suitable for volume flow control based on pressure measure- ment. The square rooted actual value enables, for example, direct measurement of the active pressure in the system via the intake nozzle of the fan. The active pressure has a square proportion to the volume flow and thus forms the control figure for the volume flow control.
Page 225 Structural image: Indirect volume flow control Technology controller Reference percentage source Actual values: Ind. volume flow control factor Volumetric flow Pressure Actual percentage source Operating Instructions ACU 06/13...
Page 226: Functions Of Sensorless Control
17.4 Functions of Sensorless Control The configurations of the sensorless control contain the following additional func- tions, which supplement the behavior according to the parameterized V/f characteris- tic. 17.4.1 Slip compensation The load-dependent difference between the reference speed and the actual speed of the 3-phase motor is referred to as the slip.
Page 227: Functions Of Field-Orientated Control
Behavior in motor operation: 613 is exceeded, the activated current If the current set via parameter Current limit limit value controller will reduce the output frequency until the current limit is no longer exceeded. The output frequency is reduced as a maximum to the frequency 614.
Page 228 The set-up of the two current controllers is identical and enables joint setting of am- plification as well as the integral time for both controllers. For this, the parameters 700 and 701 are available. The proportional and integra- Amplification Integral time tion and component of the current controllers can be switched off by setting the pa- rameters to zero.
Page 229: Extended Current Controller
17.5.2 Extended Current Controller For some machines it might be necessary, that for different current ranges different Amplification factors must be set up. The following classification applies: • Current < Current below P. 777 is in effect  Amplification low Current •...
Page 230: Torque Reference
17.5.3.1 Torque Reference The reference torque can be specified as follows: 164 to "6 - On" or link it to a digital − Set parameter n-/T-Control Change-Over signal and switch this on. 476 or − Via parameter Reference Percentage Source 1 Reference Percentage 494, select a source for the reference torque.
Page 231: Limit Value Sources
17.5.3.3 Limit Value Sources The limitation of the frequency can be done by setting fixed values and by linking to an analog input parameter. The analog value is limited via parameters Minimum 518 and 519, but does not reference percentage Maximum reference percentage 477 of the reference percentage value chan- consider the...
Page 232: Speed Controller
17.5.4 Speed controller The source of the actual speed value is selected via parameter Actual Speed 766. By default, speed sensor 1 is used as the actual speed source. If speed Source sensor 2 of an expansion module is to deliver the actual value signal for the speed controller, speed sensor 2 must be selected as the source.
Page 233 Operation mode 2 clockwise clockwise anticlockwise anticlockwise generator generator motor motor motor generator motor generator Current limit Current limit generator op. The properties of the speed controller can be adapted for adjustment and optimiza- tion of the controller. The amplification and integral time of the speed controller are 721, 722.
Page 234: Limitation Of Speed Controller
The optimization of the speed controller can be done with the help of a reference value leap. The amount of the leap is defined by the set ramp or limitation. The op- timization of the PI controller should be done at the maximum admissible reference figure change rate.
Page 235: Limit Value Sources
Parameter Settings Description Min. Max. Fact. sett. 728 I limit 0.0 A ü ⋅ I ü ⋅ I 729 Current limit generator operation -0.1 A ü ⋅ I ü ⋅ I 730 Torque limit 0.00 % 650.00 % 650.00 % 731 Torque limit generator operation 0.00 % 650.00 %...
Page 236: Integral Time Speed Synchronization
17.5.4.3 Integral time speed synchronization For speed synchronization and in order to increase the speed accuracy, the integrat- ing portion of the speed control can be set via parameter Integral time speed syn- 515. The setup is effective in operation modes „4 – speed synchroniza- chronization tion DG 1“...
Page 237: Field Controller
17.5.6 Field Controller The flux-forming current component is controlled by the field controller. The guided commissioning optimizes the parameters of the field controller by measuring the time constant and magnetizing curve of the connected 3-phase machine. The parameters of the field controller are selected such that they can be used without changes in most applications.
Page 238: Limitation Of Field Controller
778 reduces the standstill current if a stopping Parameter Reduction Factor Flux behavior with the function “R->0, Stop” is selected. This stopping behavior is select- 630 is set to 2x (20 … 27 – „R->0, Stop, … “) or x2 ed if parameter Operation Mode (2, 12, 22, 32, 42, 52, 62, 72 –...
Page 239: Modulation Controller
17.5.7 Modulation Controller The modulation controller, which is designed as an I regulator, automatically adapts the output value of the frequency inverter to the machine behavior in the basic speed area and in the field weakening area. If the modulation exceeds the figure set with 750, the field-forming current component and thus parameter Reference modulation...
Page 240: Special Functions
18 Special Functions The configurable functions of the corresponding control methods enable another field of application of the frequency inverters. The integration in the application is made easier by special functions. 18.1 Pulse Width Modulation The motor noises can be reduced by changing over the parameter Switching fre- 400.
Page 241: Fan
18.2 The switch-on temperature of the heat sink fan can be set with the parameter Switch-on temperature If mains voltage is applied to the frequency inverter, and the heat sink temperature exceeds the set temperature, the heat sink fan is switched on. Independent from parameter 39, the heat sink fan will be switched on, as soon Switch-on temperature...
Page 242 412 defines the operating behavior and enables a The parameter Local/Remote change between the control via contacts or the control unit and/or the interface. Function Local/Remote The Start and Stop commands as well as the direction 0 - Control via Contacts of rotation are controlled via digital signals.
Page 243: Brake Chopper And Brake Resistance
18.4 Brake Chopper and Brake Resistance The frequency inverters feature a brake chopper transistor. The external brake resis- tor is connected to terminals Rb1 and Rb2. The parameter Trigger threshold defines the switch-on threshold of the brake chopper. The generator output of the drive, which leads to the increase in the DC link voltage, is converted to heat by the external brake resistor above the limit set via parameter 506.
Page 244: Dimensioning Of Brake Resistor
18.4.1 Dimensioning of Brake Resistor WARNUNG Connect a brake resistor following the instructions and safety information provided in chapter 6.4.4 “Connection of a Brake Resistor”. The following values must be known for dimensioning: Peak braking power P in W − b Peak −...
Page 245: Motor Protection
18.5 Motor Protection The protection of the motor against impermissible temperature rise requires monitor- ing mechanisms for recognizing a thermal overload to prevent a possible damage to the motor. The thermal state of a motor can be evaluated by different ways. 1.) Direct monitoring by temperature sensors inside the motor winding (see chapter 18.5.1).
Page 246 In case a motor is operated via the frequency inverter for which some setting values, e.g. minimum and maximum frequency, are changed via the data set switch-over, only one motor protection switch may be installed. This functionality can be differen- 571 for single motor operation or tiated by selecting the parameter Operation mode...
Page 247 Multiple motor operation 571 = 1,11, 101 or 111 Parameter Operation Mode In multiple motor operation, it is assumed that each data set is assigned to a corre- sponding motor. For this, one motor and one motor protection switch are assigned to each data set.
Page 248: Motor Protection By I2T- Monitoring
In calculation the tripping time the measured output current in operating points below the frequency limit is evaluated by a factor between 1 and 2. The determination of this factor is a function of the stator frequency. The increased thermal load of self- ventilated motors in the lower speed range is therefore considered.
Page 249 The output of the first PT1 element is linked to the input of the second PT1 element which includes the thermal motor time constant. This output may be permanently 100%. This corresponds to the complete thermal capacity of the motor. If 102% is reached, the drive switches off with an error message.
Page 250: V-Belt Monitoring
A warning limit allows the user to prevent an imminent I²t-fault trip through appro- priate measures. 615 is used to set the warning signal between 6% and Warning limit motor I 100% of thermal capacity. Parameter Settings Description Min. Max. Fact.
Page 251: Functions Of Field-Orientated Control
18.7 Functions of Field-Orientated Control The field-orientated control systems are based on a cascade control and the calcula- tion of a complex machine model. The various control functions can be supplemented by special functions specific to the application. 18.7.1 Motor Chopper The field-orientated control systems contain the function for adapted implementation of the generator energy into heat in the connected three-phase machine.
Page 252: Temperature Adjustment
18.7.2 Temperature Adjustment The field-orientated control systems are based on the most precise calculation of the machine model possible. The rotor time constant is an important machine variable for the calculation. The figure to be read out via the parameter Current rotor time con- 227 is calculated from the inductivity of the rotor circuit and the rotor re- stant...
Page 253: Speed Sensor Monitoring
The synchronization of the rotor time constant as a function of the winding tempera- ture can be adjusted. The default values should normally be sufficiently precise so that neither an adjustment of the rotor time constants via the parameter Rated slip 718 nor an adjustment of the temperature synchronization via the correction factor 466 is necessary.
Page 254: Traverse Function
18.8 Traverse function With the traverse function, a triangle-shaped frequency signal with the acceleration and deceleration times to be set is superimposed on the output frequency. The re- sulting signal courses of the reference frequency of master drive and slave drive are shown in the following diagrams.
Page 255 435, the drive is configured as a master drive or Via parameter Operation mode slave drive. Function Operation mode 0 - Off The traverse function is deactivated. 1 - Master Drive Operation as master drive. 2 - Slave Drive Operation as slave drive. For traverse mode, the reference value source is selected via parameter Reference frequency...
Page 256: Converter Profibus From/To Internal Notation
18.9 Converter Profibus from/to Internal Notation The Converter Profibus/Internal notation can convert a 16 bit Word into an internal 32 Bit frequency value and vice versa. This is useful in example, when several devic- es are linked together via Systembus and for commercial reasons only one device is equipped with a Profibus Option.
Page 257: Actual Values
19 Actual Values The various control functions and methods include electrical control variables and various calculated actual values of the machine or system. The different actual values can be read out for operational and error diagnosis via a communication interface or in the VAL menu branch of the operating unit.
Page 258 Actual Values of the Frequency Inverter 269 Warnings Warning message with error code and abbreviation. Application Warning message with error code and 273 Application Warnings abbreviation. The reference value signal is limited by the controller 275 Controller Status coded in the controller status. Signal state of the shutdown paths STOA (digital input 277 STO Status S1IND/STOA) and STOB (S7IND/STOB) of the safety...
Page 259: Sto Status
19.1.1 STO Status 277 can be used for an extended diagnosis of the two digital Parameter STO Status inputs STOA and STOB. The states of the inputs are bit coded displayed. Significance Function Input STOA is missing. Input STOB is missing. Switch off input STOA.
Page 260: Actual Values Of The Machine
19.2 Actual Values of the Machine The frequency inverter controls the behavior of the machine in the various operating points. As a function of the configuration selected and the expansion cards installed, control variables and further actual value parameters of the machine can be dis- played.
Page 261: Actual Value Memory
19.3 Actual value memory The assessment of the operating behavior and the maintenance of the frequency inverter in the application are facilitated by storing various actual values. The actual value memory guarantees monitoring of the individual variables for a definable peri- od.
Page 262: Actual Values Of The System
237 parameter to be selected in the PARA menu branch of the Reset memory operating unit enables purposeful resetting of the individual mean and peak values. The peak value and the mean value with the values stored in the period are over- written with the parameter value zero.
Page 263: Volume Flow And Pressure
19.4.2 Volume Flow and Pressure 397 and The parameterization of the factors Nominal Volumetric Flow Nominal 398 is necessary if the matching actual values 285 and Pressure Volumetric Flow 286 are used to monitor the drive. The conversion is done using the elec- Pressure 285 and 286 are referred to the...
Page 264: Error Protocol
20 Error Protocol The various control methods and the hardware of the frequency inverter include functions which continuously monitor the application. The operational and error diag- nosis is facilitated by the information stored in the error protocol. 20.1 Error List The last 16 fault messages are stored in chronological order and the No.
Page 265 Heat Sink Code Meaning Heat sink temperature too high, check cooling and fan. Temperature sensor defective or ambient temperature too low. Inside Inside temperature too high, check cooling and fan. Inside temperature too low, check electrical cabinet heating. Motor Connection Motor temperature too high or sensor defective, check connection S6IND.
Page 266 Safety function STO Code Meaning Diagnosis error of function STO; at least one of the shut-down paths STOA and STOB is defective. Check units connected to shut-down paths; check cabling and EMC. Software self-diagnosis has detected an internal error. Consult BON- FIGLIOLI customer service.
Page 267 Positioning Code Meaning Positioning function fault. Please check Application manual Positioning. Absolute encoder: Absolute value interface Fault with Absolute encoder evaluation. Please check EM-ABS-01 manu- Modbus and VABus Communication error according to parameter CM: VABus Watchdog 413. Timer CANopen CAN Bus OFF CAN Guarding Error state SYNC error (SYNC timing)
Page 268 In addition to fault messages mentioned, there are further fault messages. However these messages are only used for internal purposes and are not listed here. If you receive fault messages which are not listed here, please contact the BONFIGLIOLI customer service.
Page 269: Error Environment
20.2 Error Environment The parameters of the error environment help troubleshooting both in the settings of the frequency inverter and also in the complete application. The error environment documents the operational behavior of the frequency inverter at the time of the last four faults.
Page 270 Error Environment Description Function 361 Checksum Check protocol of the error environment. Operating Instructions ACU 06/13...
Page 271: Operational And Error Diagnosis
21 Operational and Error Diagnosis Operation of the frequency inverter and the connected load are monitored continu- ously. Various functions document the operational behavior and facilitate the opera- tional and error diagnosis. 21.1 Status Display The green and red light-emitting diodes give information about the operating point of the frequency inverter.
Page 272: Controller Status
A decimal value is displayed, indicating the status of the digital signals in bits after conversion into a binary figure. Example: Decimal figure 33 is displayed. Converted into the binary system, the number reads OOIOOOOI. Thus, the following contact inputs or out- puts are active: −...
Page 273: Warning Status And Warning Status Application
21.4 Warning Status and Warning Status Application The current warning is displayed by a message in the warning status and can be used for an early message of a critical operational condition. If a warning is present, this is indicated by the flashing red LED and the display field WARN of the control unit.
Page 274 Example: The following warning status is displayed: A008D Ixt IxtLt Tc PTC The warning status results from the hexadecimal sum of the warning codes (0001+0004+0008+0080 = 008D). The short-term overload (1 s), warning limit heat sink temperature and warning limit motor temperature warnings are present. Output signals The output of a warning message is signaled.
Page 275: Parameter List
22 Parameter List The parameter list is structured according to the menu branches of the control unit. The parameters are listed in ascending numerical order. A headline (shaded) can appear several times, i.e. a subject area may be listed at different places in the table. For better clarity, the parameters have been marked with pictograms: The parameter is available in the four data sets.
Page 276 Actual Values of the Machine Description Unit Display range Chapter 235 Flux-forming voltage 0.0 ... U 19.2 19.2 236 Torque-forming voltage 0.0 ... U 238 Flux value 0.0 ... 100.0 19.2 19.2 239 Reactive current 0.0 ... I 240 Actual speed 1/min 0 ...
Page 277 Error List Description Unit Display range Chapter 310 Last error h:m; F 00000:00; FXXXX 20.1 20.1 311 Last error but one h:m; F 00000:00; FXXXX 312 Error 3 h:m; F 00000:00; FXXXX 20.1 313 Error 4 h:m; F 00000:00; FXXXX 20.1 314 Error 5 h:m;...
Page 278: Parameter Menu (Para)
Error Environment Description Unit Display range Chapter 367 Application Warning Status A0000 … AFFFF 21.4 Positioning 12.6 470 Rotations 0.000 ... 1⋅10 Digital Outputs 537 Actual warning mask AXXXXXXXX 15.3.8 15.3.9 627 Actual Appl. Warning Mask AXXXX Self-configuration 797 SET-UP Status OK / NOK 22.2 Parameter Menu (PARA)
Page 279 Actual value memory Description Unit Setting range Chapter 237 Reset memory Selection 19.3 Controlled commissioning 8.2.3 369 Motor Type Selection Rated Motor Parameters 370 Rated voltage 0.17⋅U ... 2⋅U 10.1 371 Rated current 0.01⋅I ...10⋅o ⋅ I 10.1 372 Rated speed U/min 96 ...
Page 280 Traverse function Description Unit Setting range Chapter 435 Operation mode Selection 18.8 436 Acceleration Time 0.01 … 320.00 18.8 437 Deceleration Time 0.01 … 320.00 18.8 438 Traverse Amplitude 0.01 … 50.00 18.8 439 Proportional Step 0.01 … 50.00 18.8 Technology Controller 440 Operation mode Selection...
Page 281 Percentage ramp Description Unit Setting range Chapter 477 Gradient percentage ramp 0 ... 60000 14.8 Technology Controller 478 Actual percentage source Selection 17.3 Positioning 479 time constant positioning contr. 1.00 ... 9999.99 12.6.2 Fixed Frequencies 480 Fixed frequency 1 -999.99 ... 999.99 14.6.1 481 Fixed frequency 2 -999.99 ...
Page 282 Digital Outputs Description Unit Setting range Chapter 542 Comparator Off below -300.00 ... 300.00 15.5.2 543 Operation mode comparator 2 Selection 15.5.2 544 Comparator On above -300.00 ... 300.00 15.5.2 545 Comparator Off below -300.00 ... 300.00 15.5.2 549 Max. Control Deviation 0.01 ...
Page 283 Starting Behavior Description Unit Setting range Chapter 620 Operation mode Selection 12.1.1 621 Amplification 0.01 ... 10.00 12.1.1 622 Integral time 1 ... 30000 12.1.1 623 Starting Current 0.0 ... o ⋅ I 12.1.1.1 624 Frequency Limit 0.00 ... 100.00 12.1.1.2 625 Brake release time -5000 …...
Page 284 Current Controller Description Unit Setting range Chapter 700 Amplification 0.00 ... 8.00 17.5.1 701 Integral time 0.00 ... 10.00 17.5.1 Further motor parameters 713 Magnetizing current 50% flux 1 ... 50 10.2.3 714 Magnetizing current 80% flux 1 ... 80 10.2.3 715 Magnetizing current 110% flux 110 ...
Page 285 Modulation Controller Description Unit Setting range Chapter 753 Operation mode Selection 17.5.7 Modulation Controller 754 Filter time constant 0…128 17.5.4 Modulation Controller 755 Reference Imr lower limit 0.01⋅I ... o⋅I 17.5.7.1 756 Control deviation limitation 0.00 ... 100.00 17.5.7.1 Current Controller 757 Current below P.
Page 286 Mux/DeMux Description Unit Setting range Chapter EEPROM: 0 … 16 1250 Mux Input Index (write) 15.5.4 RAM: 17 … 33 EEPROM: 0 … 16 1251 Mux Input Index (read) 15.5.4 RAM: 17 … 33 15.5.4 1252 Mux input Selection 1253 DeMux input Selection 15.5.4 User warnings...
Page 287: Index
Index Logic signals ........191 Acceleration ..........163 Technical data ........31, 52 Acceleration pre-control ......236 Digital outputs Actual value memory ....... 261 Logic signals ........180 Actual values Technical data ........31, 52 of the frequency inverter ...... 257 Direction of rotation of the machine ........
Page 288 Safe torque off .......... 23 Level control ........221, 222 Safety Limit value sources ........231 General ..........14 Safety function Machine data ......104, 105, 123 Status of the inputs ......259 Mains connection ........60 Service ............. 22 Modulation controller .......
Page 289: Functions Of The Control Terminals (Table)
Functions of the control terminals (table) 1 2 3 4 5 6 1 2 3 4 5 6 Bidirect. X210A X210B Operating Instructions ACU 06/13...
Page 290 Fax +90 (0) 232 328 04 14 www.bonﬁglioli.de - info@bonﬁglioli.de www.bonﬁglioli.com.tr info@bonﬁglioli.com.tr Bonﬁglioli España Bonﬁglioli United Kingdom TECNOTRANS BONFIGLIOLI S.A. Industrial Solutions Pol. Ind. Zona Franca sector C, calle F, n°6 08040 Barcelona Unit 7, Colemeadow Road Tel. (+34) 93 4478400 - Fax (+34) 93 3360402 North Moons Moat - Redditch, www.tecnotrans.com - tecnotrans@tecnotrans.com...
Page 292 Bonfiglioli has been designing and developing innovative and reliable power transmission and control solutions for industry, mobile machinery and renewable energy applicacations since 1956. Bonfiglioli Riduttori S.p.A. tel: +39 051 647 3111 COD. VEC 521 R4 fax: +39 051 647 3126 Via Giovanni XXIII, 7/A bonfiglioli@bonfiglioli.com...

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BONFIGLIOLI ACTIVE Cube ACU 201-01 Operating Instructions Manual

1 General Information about the Documentation

2 General Safety Instructions and Information on Use

3 Scope of Supply

4 Technical Data

5 Mechanical Installation

6 Electrical Installation

7 Control Unit KP500

8 Commissioning of the Frequency Inverter

9 Inverter Data

10 Machine Data

11 System Data

12 Operational Behavior

13 Error and Warning Behavior

14 Reference Values

15 Control Inputs and Outputs

16 F-Characteristic

17 Control Functions

18 Special Functions

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