BONFIGLIOLI ACTIVE CUBE Applications Manual
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BONFIGLIOLI ACTIVE CUBE Applications Manual

Spindle drive frequency inverter 230 v / 400 v
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ACTIVE CUBE
Application Manual
Spindle Drive
Frequency inverter 230 V / 400 V

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Summary of Contents for BONFIGLIOLI ACTIVE CUBE

  • Page 1 ACTIVE CUBE Application Manual Spindle Drive Frequency inverter 230 V / 400 V...

  • Page 3: Table Of Contents

    General Information about the Documentation This document ......................7 Warranty and liability ....................8 Obligation ........................ 8 Copyright ......................... 8 Storage ........................9 General safety instructions and information on use Terminology ......................10 Designated use ...................... 11 Misuse ........................11 2.3.1 Explosion protection ....................11 Residual risks ......................
  • Page 4 • Start-up procedure Turn mains voltage on ................... 24 Motor setup ......................24 Check speed sensors for sign error ............... 25 For Configuration 806 (PMSM): Self-configuration of resolver offset ....26 4.4.1 Carrying out of the self-setup ..................26 4.4.2 Safety measures before self-configuration of resolver offset ........27 4.4.3 Adjustment Parameter 383 ..................27 Operation...

  • Page 5: General Information About The Documentation

    WARNING Compliance with the documentation is required to ensure safe operation of the frequen- cy inverter. BONFIGLIOLI VECTRON GmbH shall not be held liable for any damage caused by any non-compliance with the documentation. In case any problems occur which are not covered by the documentation sufficiently, please contact the manufacturer.

  • Page 6: Warranty And Liability

    • Warranty and liability BONFIGLIOLI VECTRON GmbH would like to point out that the contents of these Operating Instruc- tions 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 7: Storage

    Storage The documentation form an integral part of the frequency inverter. It must be stored such that it is accessible to operating staff at all times. If the frequency inverter is sold on to other users, then the documentation must also be handed over. 11/13 Spindle Applications...

  • Page 8: 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 9: 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 10: 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 11: Warning Information And Symbols Used In The Operating Instructions

    Warning information and symbols used in the Operating Instruc- tions 2.6.1 Hazard classes The following hazard identifications and symbols are used in the Operating Instructions to mark par- ticularly important information: DANGER Identification of immediate threat holding a high risk of death or serious injury if not avoided.

  • Page 12: Recycling

    • 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: Components and assemblies sensitive to electrostatic energy 2.6.8 Information signs Symbol Meaning Tips and information making using the frequency inverter easier.

  • Page 13: 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. An authorized person must ensure, before using the frequency inverter, that the device is used in •...

  • Page 14: Organizational Measures

    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 offers compo- •...

  • Page 15: Handling And Installation

    2.11 Handling and installation • Do not commission any damaged or destroyed components. • Prevent any mechanical overloading of the frequency inverter. Do not bend any components and never change the isolation distances. • Do not touch any electronic construction elements and contacts. The frequency inverter is equipped with components which are sensitive to electrostatic energy and can be damaged if handled improperly.

  • Page 16: Safe Operation

    • 2.11.2 Safe operation • During operation of the frequency inverter, always comply with the applicable national and inter- national regulations/laws on work on electrical equipment/plants. • Before commissioning and the start of the operation, make sure to fix all covers and check the terminals.

  • Page 17: Maintenance And Service/Troubleshooting

    2.11.3 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. Work on the electrical components may only be performed by a qualified electrician according to •...

  • Page 18: Introductory Information About Spindle Applications

    • Introductory information about spindle applications The configurations for spindle applications typically control milling machines with asynchronous ma- chine (ASM) or permanent magnet synchronous machine (PMSM) Operation is without encoder at high speeds. In order to enable finer setting of the speed controller when tools with large diameters are used, using an encoder is possible.

  • Page 19: Software Identification

    Software identification 012 . The software installed can be identified via Parameter Inverter Software Version Example of Software identifier: 5 . a . b . cc / 086 - xx : counter, 086: stands for spindle application a . b . cc: running version, third point is variable stands for Frequency inverter range ACU Further information about the software can be obtained via the following parameters:...

  • Page 20: Operating Characteristics

    • Operating characteristics 412 defines the operating characteristics and enables choosing control via Parameter Local Remote contacts/control unit and/or the interface. Parameter Unit Setting range Default settings Identifier 44 - Ctrl. Cont.+KP, Selection Local Remote Dir. Cont.+KP Operation Modes of Parameter 412 Commands Start and Stop as well as definition of 0 - Control via Contacts sense of rotation via digital signals.

  • Page 21: Control Inputs And Outputs

    Control inputs and outputs NOTE Switch off power supply before connecting or disconnecting the control inputs and outputs. Other- wise, components may be damaged. • The unit may only be connected with the power supply switched off. Verify safe isolation from power supply. •...

  • Page 22: Start-Up Procedure

    • Start-up procedure Turn mains voltage on After completion of the installation work, make sure to check all control and power connections again before switching on the mains voltage. When all electrical connections are correct, make sure that the frequency inverter is not enabled (control inputs S1IND/STOA and S7IND/STOB open). After power-up, the frequency inverter carries out a self-test and the relay output (X10) reports "Fault".

  • Page 23: Check Speed Sensors For Sign Error

    In the “SETUP Select" section, via Parameter 796, select the type of setup, e.g. “10- • Setup Select Complete Setup, DS0”. For self-setup, activate S1IND/STOA and S7IND/STOB release. • Start setup. After motor setup, the machine is set up for sensor-less operation. Check speed sensors for sign error Q.441 and Q.430 should be compared using...

  • Page 24: For Configuration 806 (Pmsm): Self-Configuration Of Resolver Offset

    • For Configuration 806 (PMSM): Self-configuration of resolver offset During first commissioning, the position of the rotor winding of the resolver is adjusted to the rotor displacement angle of the synchronous motor by adjusting an offset. For operating a PMSM with re- solver, the offset must be adjusted in order to obtain perfectly true running and a maximum torque.

  • Page 25: Safety Measures Before Self-Configuration Of Resolver Offset

    4.4.2 Safety measures before self-configuration of resolver offset WARNING Risk of personal and machine damage In certain circumstances, the motor speed may reach high values. Before adjusting the resolver offset disconnect the motor from the load. • To avoid damage, make the following settings. •...

  • Page 26: Operation

    • Operation Permanent magnet synchronous machine (PMSM) – Configuration 806 5.1.1 Operation without encoder 5.1.1.1 Start In order to prevent the machine from tilting, PMSM will always be started with current impression. 5.1.1.2 Isd current For operation in the basic speed range, impression of a small positive Isd current (10% of rated cur- rent) in the machine is recommended.

  • Page 27: Determination Of The Flux Direction At Startup

    5.1.1.3 Determination of the flux direction at startup If the frequency inverter were started in sensor-less operation, there would be an alignment process of the PMSM at the impressed starting current, unless further measures are taken. Depending on iner- tia and attenuation, decreasing torsional vibrations would result from such an alignment process. To avoid this, the starting current is impressed in exactly the same direction as the flux when the fre- quency inverter is turned off.

  • Page 28: Operation With Field Weakening

    • 5.1.1.4 Operation with field weakening The amount of the induced voltage and thus the stator voltage to be applied by the frequency inverter will increase in PMSM with the torsional frequency. The maximum torsional frequency of the PMSM is limited initially by the maximum output voltage of the frequency inverter.

  • Page 29: Start

    5.1.2.1 Start Upon first startup after return of mains power, the orientation of the machine is unknown, when a speed sensor is used. The orientation will only be clear once the reference pulse has been detected. In order to enable field-oriented operation of a PMSM with speed sensor, the flux direction must either be known upon first startup after return of mains power or determined by means of the search run 645).

  • Page 30: Adjustment Of Resolver Offset

    • When a speed sensor is used, the current orientation is determined using the captured speed sensor pulses based on the identified flux direction of the machine. Once the reference pulse was captured twice at the correct distance, the mechanical orientation of the machine is considered as known. In this way, field-oriented operation of the PMSM is possible using a speed sensor instead of a resolver.

  • Page 31: Speed Sensor Monitoring

    5.1.2.6 Speed sensor monitoring In order to synchronize the machine orientation with the reference pulse, the speed sensor monitoring operation mode 760 must be set to “2 – Error” (default value). Operation Mode In this setting, a wrong number of division marks is reported automatically and individual missing division marks are corrected using the reference pulse.

  • Page 32: Brake Chopper Monitoring

    • 5.1.3 Brake chopper monitoring For PMSMs operating in the field weakening range, a sufficiently dimensioned brake chopper is re- quired to prevent frequency inverter damage in case of a shutdown. In operation in the field weakening range, it will be checked before any current impression of the spindle if a brake chopper is available.

  • Page 33: Detection Of Spindle With Inverse Behavior

    5.1.4 Detection of spindle with inverse behavior During setup, a PMSM with an angle deviating by 180 degrees (electrical) can be identified as an in- verse machine. Such machines are typically PMSM with buried magnets. For identification, a part of the flux direction identification normally carried out upon startup of a standing machine (depending on setting of Parameter 645, see Chapter 5.1.1.3 “Determination of the flux direction at startup”) is carried out during parameter identification.

  • Page 34: Asynchronous Machine (Asm) – Configuration 804

    • Asynchronous machine (ASM) – Configuration 804 5.2.1 Operation without encoder In sensor-less operation, the spindle application uses Configuration 410 (default sensor-less control) for asynchronous motors. 5.2.2 Operation with encoder As regards the changeover between field orientation with Speed Sensor 2 and sensor-less operation, the ASM behavior is analogous with the PMSM.

  • Page 35: Identification Of Reference Point Position

    5.3.1 Identification of reference point position When the frequency inverter is switched on during commissioning, the current position of the spindle is identified by a search mode. The search mode continues for three revolutions at the set frequency 809. As soon as the reference signal was recognized twice, the drive is Reference Profile Frequency positioned to the 469.

  • Page 36: Status Message "Target Position Reached

    • 5.3.3 Status message “Target Position Reached” Q.282 of the Scope func- Status message “60-Target Position reached” or Target Position Reached tion is set directly in the case of the “POS OK” signal, but canceled after a delay in the case of the “POS not OK”...

  • Page 37: Control Of Acceleration Ramps Via Digital Input

    Control of acceleration ramps via digital input 5.4.1 Switching ramp mode on or off Acceleration ramps can be selected via a digital input. This function is switched on or off via Parame- 830. Ramp Mode Parameter Unit Setting range Default settings Identifier Selection 0 –...

  • Page 38: Actual Values

    • Overview of sources The output values of the spindle function modules are available at the following sources: Frequency value [s Q.441 – Actual Speed Q.443 – Speed Sensor 2 Boolean values Q.282 - Target Position Reached Q.296 - Position (Error) Actual values Actual value parameters Description...

  • Page 39: Parameter

    Parameter The parameter is available in the four data sets Parameter Default set- Chap- No. Description Unit Setting range tings 037 Start Positioning of Axle Selection 75 – S6IND 382 Offset -360.0 .. 360.0 383 Voltage Constant* mVmin 0.0 .. 6500.0 4.4.3 44 –...

  • Page 40: Index

    • Index Hazard classes ........... 13 Acceleration ramps ........40 hazards ............. 12 accident prevention ........15 accident prevention regulations ....15 Installation ..........17 Actual speed source ......33, 37 Installation instructions ........ 7 Actual values ..........41 Instructed Person ........10 Adjustment of resolver offset ......
  • Page 41 Storage ..........9, 16 VPlus ............24 synchronous machine ......20, 28 Warning signs ..........12 Target Position Reached ......39 Warranty ............. 8 Transport ........... 16 Work safety ..........15 Voltage Constant ........27 11/13 Spindle Applications...
  • Page 43 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 44 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 773 R0 fax: +39 051 647 3126 Via Giovanni XXIII, 7/A bonfiglioli@bonfiglioli.com...

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