BONFIGLIOLI Vectron ACTIVE CUBE Applications Manual
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BONFIGLIOLI Vectron ACTIVE CUBE Applications Manual

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ACTIVE CUBE
Application Manual
Winding Drive
Frequency inverter 230 V / 400 V
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Summary of Contents for BONFIGLIOLI Vectron ACTIVE CUBE

  • Page 1 Power, Control & Green Solutions ACTIVE CUBE Application Manual Winding Drive Frequency inverter 230 V / 400 V +31(0)88 7865800 elsto.eu +31(0)88 7865899 info@elsto.eu...

  • Page 2: Table Of Contents

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 General Information about the Documentation This document ......................5 Warranty and liability ....................6 Obligation ........................ 6 Copyright ......................... 6 Storage ........................6 General safety instructions and information on use Terminology ......................
  • Page 3 elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 Applications Example: Indirect traction control ................ 22 Example: Dancer control ..................23 Example: Unwinding at constant speed ..............24 Function blocks Dancer control ....................... 25 5.1.1 General control parameters..................25 5.1.2 Parameters for limitation of controller output and ramping..........26 5.1.3 Behavior in an emergency stop or stop ..............26...

  • Page 4: 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 5: Warranty And Liability

    +31(0)88 7865800 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 6: General Safety Instructions And Information On Use

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 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.

  • Page 7: Designated Use

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 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.

  • Page 8: Residual Risks

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 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 a health hazard.

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

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 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 10: Hazard Symbols

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 2.6.2 Hazard symbols Symbol Meaning Symbol Meaning General hazard Suspended load Electrical voltage Hot surfaces 2.6.3 Prohibition signs Symbol Meaning No switching; it is forbidden to switch the ma- chine/plant, assembly on 2.6.4 Personal safety equipment Symbol...

  • Page 11: Information Signs

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 2.6.8 Information signs Symbol Meaning Tips and information making using the frequency inverter easier. 2.6.9 Font style in documentation Example Font style 1234 bold Representation of parameter numbers Parameter italic, Representation of parameter names Font Times New Roman...

  • Page 12: Directives And Guidelines To Be Adhered To By The Operator

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 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 appli- cable national regulation are accessible to the staff.

  • Page 13: 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 offers compo- •...

  • Page 14: Handling And Installation

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 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.

  • Page 15: Safe Operation

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 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 •...

  • Page 16: Maintenance And Service/Troubleshooting

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 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 •...

  • Page 17: Introductory Information About Winder Applications

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 Introductory information about winder applications Configurations for winder applications For winder applications, the following configurations are available: 217: Winder application in field-oriented control • • 417: Winder application in sensor-less field-oriented control 517: Winder application in field-oriented control for synchronous machines •...

  • Page 18: Operating Behavior

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 Operating behavior Local Remote 412 defines the operating characteristics and enables choosing control via Parameter contacts/control unit and/or the interface. Parameter Unit Setting range Default settings Identifier 44 - Ctrl. Cont.+KP, Local Remote LocalRemote table Dir.

  • Page 19: Control Inputs And Outputs

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 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. •...
  • Page 20 elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 Relay output X10 Control terminal X210B Inverter error message X210B.1 Digital Input Digital Input STOB X210B.2 safety rele- Control terminal X210A (second shut-down vant path) X210A.1 DC 20 V output (I =180 mA) or DC 24 V ±10% input for X210B.3...

  • Page 21: Applications

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 Applications This chapter describes typical examples of winder applications. The function blocks used are described in Chapter 5 “Function blocks”. Example: Indirect tension control The tension of a web is to be maintained at a fairly constant value. Tension-feedback which might be used for direct control is not available.

  • Page 22: Example: Dancer Control

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 Limits of indirect tension control: If the torque required for turning the empty winding mandrel is 15% higher than the torque required for developing the minimum tension (at D ), a method with direct tension control should be pre- ferred.

  • Page 23: Example: Unwinding At Constant Speed

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 Example: Unwinding at constant speed The unwinding speed is to be kept at a given speed. If a diameter sensor is available, this can simply be realized as follows: Wickelanwendungen 11/13...

  • Page 24: Function Blocks

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 Function blocks For winder applications, the special function blocks described below are available. Dancer control The dancer control is a universal-use PID controller. The reference and actual values are defined via Source Reference Value Source Actual Value 801 and...

  • Page 25: Parameters For Limitation Of Controller Output And Ramping

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 5.1.2 Parameters for limitation of controller output and ramping Negative Limit Controller Output Positive 806 and The controller output is limited via Parameters Limit Controller Output 807. Parameter Unit Setting range Default settings Identifier Negative Limit Controller Output...

  • Page 26: Output Values

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 5.1.5 Output values The output values can be obtained from the following sources: Frequency values [Hz] Output frequency of controller Q.8900 - Percentages [%] Current control difference Q.8940 – Diameter calculator The function block for diameter calculation can determine the diameter either via a sensor or from the Mode Diam- line speed and winding diameter.
  • Page 27 elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 Release Enable Diame- The actual diameter value is determined only if the logic source selected in Parameter ter Calculation 881 has value TRUE. Parameter Unit Setting range Default settings Identifier Enable Diameter Calculation Sources logic table 161 - Run Signal...

  • Page 28: Parameters For Operation Mode 1 - Sensor

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 5.2.2 Parameters for Operation Mode 1 – Sensor The diameter sensor is typically connected to one of the analog inputs of the frequency inverter (0- 10V). Thus, the diameter is available to the Diameter Calculator as a percentage (e.g. 0-100%). Percentage source Source Diameter-Sensor 892.
  • Page 29 elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 Reference values for line speed Line Speed Reference Value 883 in The reference values for the line speed are set in Parameters Line Speed Reference Value Hz [mm/s] and 884 in [Hz]. An absolute value function is applied internally to the line speed and winder speed be- fore the calculation.

  • Page 30: Output Values

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 Frequency source for winder drive Source Actual Value Speed 885. The source for the actual frequency is selected via Parameter Parameter Unit Setting range Default settings Identifier Source Actual Value Speed Source-frequency table 155 –...

  • Page 31: Actual Value Parameters From Diameter Calculation

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 Coil Size Limit Reached (filtered) Q.8926 – 5.2.5 Actual value parameters from diameter calculation Actual value parameter Unit Description Identifier Actual Value Diameter Dact mm Value corresponds to source Q.8960, but the diameter is output with 2 decimal places.

  • Page 32: Output Values

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 Gear factor Gear Factor Numerator at Dmin Gear Factor Denominator at Dmin 832 and 833 define Parameters the numerator and denominator of the gear factor at minimum diameter. Parameter Unit Setting range Default settings Identifier...

  • Page 33: Limitation Of Web Tension (Tension Setpoint)

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 Limitation of web tension (Tension Setpoint) With this function block, the web tension can be kept at a constant level in winding operations. It limits the torque required for building up the web tension to a diameter-dependent value. −...

  • Page 34: Compensation Calculator (Torque Compensation)

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 Rated torque M of the machine in [Nm] is calculated from the motor data: rated 60 · P.376 · 1000 —————————— rated 2 · π · P.372 with P.376 = rated power in [kW] P.372 = rated speed in [rpm] Compensation calculator (Torque Compensation) The compensation calculator provides the torque required for compensation of losses in the system...

  • Page 35: Compensation Of Dynamic Frictional Losses

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 5.5.1.2 Compensation of dynamic frictional losses Dynamic frictional losses are speed-dependent. They are produced, for example, by the viscosity of the gear oil and - if a motor fan is installed - by fan losses. Dynamic Friction Compensation 866.

  • Page 36: Compensation Of Acceleration Torque

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 5.5.2 Compensation of acceleration torque The torque of the drive required for acceleration is defined by the moment of inertia of the system which is made up of a constant and a diameter-dependent component. The torque is determined “experimentally”...

  • Page 37: Compensation Of Diameter-Dependent Acceleration Torque

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 5.5.2.2 Compensation of diameter-dependent acceleration torque In addition to the constant component of the moment of inertia, there is a component which depends on the current winder diameter. It increases proportionally to the fourth degree of the diameter and reaches its maximum at maximum diameter.

  • Page 38: Limit For Detection Of Acceleration Process

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 5.5.2.3 Limit for detection of acceleration process Minimum Deviation for Comp. Acceleration 869, you can set when an acceleration Via Parameter process is detected. Acceleration pre-control via Parameters 870 and 871 will only be activated when the deviation between ramp input and ramp output is greater than Parameter 869.

  • Page 39: Overview Of Sources

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 Overview of sources The output values of the winder function blocks can be obtained from the following sources: Frequency [s Output frequency of controller Q.8900 – Output frequency of gear stage Q.8900 –...

  • Page 40: Parameter

    elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 Parameter The parameter is available in the four data sets. Parameter Chap- Description Setting range Default set- Unit tings 44 – Ctrl. Local/Remote Local-Remote table Cont.+KP, Dir. Cont.+KP Frequency Switch-off Limit 0.00 ..
  • Page 41 elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 Parameter Chap- Description Setting range Default set- Unit tings 161 - Run Sig- Enable Diameter Calculation Sources logic table 5.2.1 Source-frequency Source Line Speed 9 - zero table Line Speed Reference Value mm/s 0.01 ..
  • Page 42 elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 Index Digital inputs ..........21 acceleration pre-control ......38 Digital output ..........21 Acceleration pre-control ......39 Directives ..........13 acceleration torque........37 discharge time ........... 16 acceleration torque (compensation)..... 37 disposal .............
  • Page 43 elsto.eu Voorhout • Groningen • Weert • Hoogerheide +31(0)88 7865800 Limit Message ..........28 General............ 7 limitation ........... 26 safety instructions........7 limitation of controller output ...... 26 safety rules ..........15 Limitation of web tension (Tension Setpoint) 34 Safety signs..........9 line speed ..........
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