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Operating instructions ACU

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1. No Description Unit Setting range Chapter V EX 700 Amplification 0 00 8 00 17 5 1 V EF 701 Integral time ms 0 00 10 00 17 5 1 V E 713 Magnetizing current 50 flux 1 50 10 2 3 Vi E 714 Magnetizing current 80 flux 96 1 80 10 2 3 V E 715 Magnetizing current 110 flux 110 197 10 2 3 V 716 Rated magnetizing current A 0 01 l gi O L giN 10 2 3 vV E 717 Reference Flux 0 01 300 00 17 5 6 V 718 Rated slip correction factor 10 01 300 00 1024 719 Slip Frequency 96 0 10000 14 2 720 Operation mode Selection 17 5 4 V Ed 721 Amplification 1 0 00 200 00 17 5 4 722 Integral time 1 ms 0 60000 17 5 4 Vi E 723 Amplification 2 0 00 200 00 17 5 4 724 Integral time 2 ms 0 60000 17 5 4 725 Operation mode Selection 17 5 5 726 Minimum acceleration Hz s 0 1 6500 0 17 5 5 727 Mech time constant ms 1 60000 17 5 5 728 Current Limit A 0 0 0 len 17 5 4 1 729 Current limit generator operation A 0 1 0 len 17 5 4 1 Torque limit 17 5 4 1 Torque limit generator operation 17 5 4 1 P comp torque upper limit 17 5 4 1 P comp torque lower limit 17 5 4 1 734 Isq limit source motor operati
2. No Description Unit Display range Chapter 210 Stator Frequency Hz 0 00 999 99 19 2 211 R m s Current A 0 0 I max 19 2 212 Output Voltage V 0 0 Uri 19 2 213 Active Power kW 0 0 Pmax 19 2 214 Active Current A 0 0 Imax 19 2 215 Isd A 0 0 Imax 19 2 216 Isq A 0 0 Imax 19 2 217 Encoder 1 Frequency Hz 0 00 999 99 19 2 218 Encoder 1 Speed l min 0 60000 19 2 221 Slip Frequency Hz 0 0 999 99 19 2 222 DC Link Voltage V 0 0 Ugmax 25 19 1 223 Modulation 96 0 100 19 1 224 Torque Nm 9999 9 19 2 225 Rotor Flux 96 0 100 19 2 226 Winding Temperature deg C 0 999 19 2 227 Act Rotor Time Constant ms 0 s Tra 19 2 228 Internal ref frequency Hz 0 00 fmax 19 1 229 Reference percentage 96 300 00 19 1 230 Actual percentage value 300 00 19 1 231 Peak value long term xt 0 00 100 00 19 3 232 Peak value short term xt 96 0 00 100 00 19 3 Operating I nstructions ACU 215 Goo Bonfiglioli 276 Repetition Frequency Input oO uency Input m No Description Unit Display range Chapter 235 Flux forming voltage V 0 0 Uri 19 2 236 Torque forming voltage V 0 0 Uri 19 2 238 Flux value 0 0 100 0 19 2 239 Reactive current A 00 5 lax 19 2 240 Actual speed l min 0 60000 19
3. im o o e E CoO of e 9 10N QW Y uou M 88 5 Ib in fo Rb2 ZK O is s Dae TS L1 L2 L3 Sn R L1L2L3 QU o o 0 o L11213 PE o o 3ph 400V AC Threaded bolt M8x20 68 Operating I nstructions ACU 06 13 wv Bonfiglioli o O ooooo Ba pie oj eo V Ww OO OO o0 o d o Rb2 ZK goas LL t2 E3 UL VLW a i Star connection Delta connection Threaded bolt M8x20 10 Nm oo 88 5 Ib in U fo Rb2 ZK Que geas ep LI L2 L3 Cm To Ro o o o o ZK Rb2 o o T1o T2 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 06 13 Operating I nstructions ACU 69 amp Bonfiglioli
4. th OT Operation time pee t tb Braking time cycle tace Cycle time Example tp 48 s teycle 120s _ tp n E DC 2 0 4 40 tys teycle In the case of infrequent short braking operations typical values of the operation time OT are at 10 for long braking operations gt 120 s typical values are at 100 In the case of frequent deceleration and acceleration operations it is recom mended that the operating time OT be calculated according to the above formula The calculated values for Pp peak Rp and OT can be used by the resistor manufactur ers for determining the resistor specific permanent power Operating Instructions ACU 06 13 tv Bonfiglioli 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 PTC KTY PT100 Thermal contact 2 Indirect monitoring of the motor temperature Monitoring of the motor current based on the K characteristic of an integrat ed motor circuit breaker Emulation of the motor heating by using a temperature relevant mathemat ical model t The choice of thermal control is mainly determined by type and operating conditions of the motor
5. Integral Time 445 Differential Time 61 d cL 9 D of cl f Sl E lt 2 oO 9 S s o TFR 9 Lo Ca gt S Ug POSS BP o oY Yt Zepo aco w SE S S Y o Syg Doe NE amp Q xu NOTE Minimum Frequency 418 is not limiting in mode 4 Speed This can lead to a long time operation of the motor in the current injection current frequency 624 cutoff frequency in configurations 411 and 611 Prevent an impermissible motor tempera ture rise through to long operation in the current injection The operating mode 4 speed controller can lead to a reversal of the drive Operating I nstructions ACU 223 Goo Bonfiglioli 224 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 The calculation corresponds to the Law of Proportionality which is generally valid for centrifugal machines Adaptation to the application in question and measurement are done via the nd vol ume flow control factor 446 The actual values are calculated from the system data to be parameterized reference pressure and volume flow according to the bad point method as described in chapter Volu
6. 1 eeeeeeeeeee eene e eene nennen nnns 39 ACU 401 75 0 to 132 0 kW 400 V eeeeeeeeeeeeeeeee ener nnn nnn nana 40 Operation diagrams 1 ee ee ceei eere eese eene na auam a uana naa a uana aaa annua an 41 5 Mechanical Installation 5 1 5 2 53 5 4 5 5 ACU 201 up to 3 0 kW and 401 up to 4 0 KW 43 ACU 201 4 0 to 9 2 kW and 401 5 5 to 15 0 kW 44 ACU 401 18 5 to 30 0 kW eeeeeeeeee eee ieeeie eene nnne n nnt nana 45 ACU 401 37 0 to 65 0 kW 11cceeeeeeeeeeee eee eeeeennnn nnne n nnn hann 46 ACU 401 75 0 to 132 0 kW 1eeeeeeeeeee ee eieeeein nennen rnnt 47 6 Electrical I nstallation 6 1 6 2 6 3 6 4 6 4 1 6 4 1 1 6 4 2 6 4 3 6 4 3 1 6 4 3 2 6 4 3 3 6 4 3 4 6 4 3 5 6 4 4 6 5 6 5 1 6 5 2 6 5 3 6 5 4 6 5 5 6 6 6 6 1 6 6 2 6 6 3 6 6 4 6 7 6 7 1 6 7 2 EMC Information 1 ee ee eeeiee eee eee aee ana nanus na dana a ad annuas usan nasus una nan 50 Block diagram 52 Optional Components sseeeecneseeeeeneeseeseneuseeeeeneaseeseneaseeseeneaseessnaaeeesenoas 53 Connection of Unit cccseseeeeeeeeseeeeeeeseeeeesnaseeseeneueeseeneaseeseneeaseeseaseneseonnees 54 Dimensioning of conductor cross section sssssssee e 54 Typical ChOSS SECUONS utere ttt n
7. 10V lt 20 mA zero point tolerance band neg minimum value X1 Y1 f 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 tolerance band in the negative direction Then the output variable follows the set characteristic 15 1 1 4 Filter Time Constant The time constant of the filter for the analog reference value can be set via the pa rameter Filter Time Constant 451 The time constant indicates the time during which the input signal is averaged by means of a low pass filter e g in order to eliminate fault effects The setting range is between 0 ms and 5000 ms in 15 steps f Filter deactivated analog reference value is 0 Time Constant 0 ms forwarded unfiltered 2 Time Constant 2 ms Filter activated averaging of the input signal via 4 Time Constant 4 ms the set value of the filter time constants 8 Time Constant 8 ms 16 Time Constant 16 ms 32 Time Constant 32 ms 64 Time Constant 64 ms 128 Time Constant 128 ms 12 256 Time Constant 256 ms 06 13 Operating I nstructions ACU 175 GO Bonfiglioli 15 1 1 5 Error and warning behavior For monitoring the analog input signal an operation mode can be selected via pa rameter Error warning behavior 453 0 Off The input signal is not monitored 1 Wa
8. No Description Function 285 Volumetric flow Calculated volume flow with the unit m h 286 Pressure Pressure calculated according to the character istic with the unit kPa 06 13 Operating I nstructions ACU 263 G Bonfiglioli 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 of errors 362 shows the number of errors which have occurred since initial commissioning of the frequency inverter In the VAL menu branch of the control unit the error code FXXXX is displayed The meaning of the error key is described in the following chap ter Error Messages Via the PC program the number of operation hours h opera tion minutes m and the fault message can additionally be read out The current operating hours can be read off via the Operation hours counter 245 The fault re port can be acknowledged via the keys of the operating unit and according to the assignment Error acknowledgment 103 Function hhhhh mm FXXXX fault message hhhhh mm FXXXX fault message No Description 310 Last error 311 Last error but one 312 to 325 Error 3 to error 16 Number of errors occurred after the initia
9. ES fe Lum m op ri 3 7 5 3 Selecting the Source The parameters of the ALL and Act sub function in the CPY menu branch can be pa rameterized to meet the requirements of the specific application The available memory space of the control unit is shown on the seven segment display e Use the arrow keys to select the data source Src for the copy operation up load The data sets of the frequency inverter Src x or the files of the control unit Src Fy can be used as the data source e Confirm the data source selected by pressing the ENT key and continue by se lecting the target D Empty files not yet filled with data will not be offered as signal source The memory of the control unit is managed dynamically Chapter 7 5 Copy Menu CPY 92 Operating Instructions ACU 06 13 7 5 4 vv Bonfiglioli Selecting the Destination Select the destination dSt of the copy operation application specific The data source is transferred to the selected target download e 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 x or still empty files of the control unit dSt F y are avail able as the target e Confirm your selection by pressing the ENT key The copy operation will start and COPY will be displayed dst 1 dSt F8 The data are copied to file 8 of the control unit
10. 1000 depending on switching frequency Switching frequency kHz 2 4 8 12 16 Min brake resistance 32 Recommended brake resistor Uaec 770 V R Q 80 58 48 48 32 Mains current 3ph PE 1 TAT 12 158 200 260 282 Mains voltage 320 528 Mains frequency 45 66 Fuses i JA 136 025 35 UL type 600 VAC RK5 LOL AJ o 20 30 40 Dimensions Weight approx Degree of protection Terminals Form of assembly vertical Ener dissipation 2 Hast frequency P el ui odd 2m s Coolant temperature 0 40 3K3 DIN IEC 721 3 3 Storage temperature EE 25 55 Transport temperature Tr c 25 70 Rel air humidity 15 85 not condensing If required by the customer the switching frequency may be increased if the output current is reduced at the same time Comply with the applicable standards and regulations for this operating point Switching frequency eee Emu eke 5 5 kW 14 0 A 14 0 A 14 0 A 11 8 A 7 5 kW 18 0 A P 18 0 A 9 18 0 AP 151A 12 2A 9 2 kw 23 0A 22 7 A 22 0 A 18 5 A 15 0 A 11 kw 25 0A 25 0A 25 0A 21 0A 17 0A 15 kW 32 0A 9 32 0A 9 32 0A 9 26 9 A P 21 8 A D Three phased connection demands mains commutating choke 2 Mains current with relative mains impedance gt 1 see chapter Electrical installation 3 Reduction of switching frequency in thermal limit range 4 Maximum current in continuous operation 06 13 Operati
11. 85 not condensing If required by the customer the switching frequency may be increased if the output current is reduced at the same time Comply with the applicable standards and regulations for this operating point Switching frequency Frequency inverter nominal power 8 kHz 12 kHz 16 kHz 0 25 kW 1 6 A 0 37 kW 2 5 A 0 55 kW 3 0 A 0 75 KW 4 0 A 1 1 kW 54A29 5 447 1 Three phase connection requires a commutating choke 2 One and two phase connection requires a commutating choke 3 Mains current with relative mains impedance gt 1 see chapter Electrical installation 4 Maximum output current 9 5 A with single phase and two phase connection 5 Reduction of switching frequency in thermal limit range 9 Maximum current in continuous operation 7 The device for single phase connection is not listed in the product catalogue and only available on request 32 Operating I nstructions ACU 06 13 j Bonfiglioli 4 4 ACU 201 1 5 to 3 0 kW 230 V ACU 201 LE d c x oy NENNEN 2 Construction Size Recommended motor shaft power P kw 15 22 3097 Output current L1 A 70 4 95 1 155 Long term overload current 60 s A 105 43 16 2 Short time overload current 1 s LE faf 10 ee 19 0 Output voltage V Maximum input voltage three phase Protection Eo e Short circuit earth fault proof Rotary field frequency 0 1000 depending on switching frequency Switching frequency 2 4
12. Application Warning affected via parameter Application Warn ings 273 Operation modes 70 to 76 of the digital inputs in verted LOW active Reference orientation 469 of axle positioning was reached or Target position Distance 1202 of a positioning 282 Target Position Reached operation was reached the current act position is within the range set in parameter Target win dow 1165 for a minimum period of Target win dow time 1166 Inverted signal status on digital input 284 STOA inverted S1IND STOA first shutdown path STOA of safety function STO Safe Torque Off 85 270 to 276 Inverted signal status on digital input STOB inverted S7IND STOB second shutdown path STOB of safety function STO Safe Torque Off Signal status on digital input S1IND STOA first 292 STOA shutdown path STOA of safety function STO Safe Torque Off Signal status on digital input S7IND STOB sec 29 STOB ond shutdown path STOB of safety function STO Safe Torque Off 9 3 Signal on digital input 1 of an expansion module 20 EM SIIND EM or remote operation via communication inter face 21 2 2 3 Signal on digital input 2 of an expansion module 3 EM S2IND EM or remote operation via communication inter face Signal on digital input 3 of an expansion module 322 EM S3IND EM or remote operation via communication inter face 520 EM SIIND inverted Operation mode 320 inverted 521 EM S2IND inverted
13. Bonfiglioli Vectron ACTIVE CUBE Operating Instructions Frequency inverter 230 V 400 V 0 25 kW 132 kW E ta E xq GD Bonfiglioli ontrol and green solutio tv Bonfiglioli ectron TABLE OF CONTENTS 1 General information about the documentation 1 1 Instruction manuals 1 e ee ceeie eee eene aenea na aua a aduana auda nana aua a na in 10 1 2 This document e eieieeeeeieii eee s eia saneaaa anam auda anas u a dana uad R nna a adu 12 1 3 Warranty and liability 11 1eeeeeieeiee ee eeeeee nenne aueh un nnn nnn 12 1 4 Obligation E 13 1 5 Copyright E 13 2 3 2 3 1 2 4 2 5 2 6 2 6 1 2 6 2 2 6 3 2 6 4 2 6 5 2 6 6 2 6 7 2 6 8 2 7 2 8 2 9 2 9 1 2 9 2 2 10 2 10 1 2 10 2 2 10 3 2 10 4 2 10 5 2 10 5 1 2 10 6 2 10 7 2 10 8 2 11 ur 15 Explosiom prot CctlOnh i i uiuos eerte ntu ener nei eadera E ard 15 Residual risks 1 eeeeeeeiee ee anapi n enean anu uu ana u uu nuu nad anna nansa 16 Safety and warning signs at frequency inverter 16 Warning information and symbols used in the user manual 17 Hazard classes is cun teteedei tet vene cett eniutesdut oed aaah depdud teda est s e ad ete yu dal 17 abr6lcEiuisme caeadedusie ndeatiastaewuadeve aeestadensmaeadeactse
14. Operating I nstructions ACU 87 G Bonfiglioli 7 1 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 a A ir RUN A Om t PARA X4 cPY Niue aoc c2 c c ZA s m Ww eS E l c5 c5 N c c OO V V v eni fso c fad on esc en sc VAL RUN c A byi CTRL v v PARA wv W ew v ME 34 EH bel B We 7 jm D e A 415i E A SLL HLE A DEEUF 7 2 Main Menu The various parameters and information of the frequency inverter can be displayed by means of the control unit The different functions and parameters are grouped together in four menu branches From any point in the menu structure you can re turn to the main menu by pressing the ESC key either continuously or repeatedly Note In the following description of the key functions a plus between the key symbols indicates that the keys have to be pressed at the same time A comma between the key symbols indicates that the keys have to be pressed one after the other w A m Menu branch VAL Display of actual values v Menu branch PARA A Oho Di
15. Repetition Frequency Signal on repetition frequency input according to Op 243 244 Working hours counter 250 Digital Inputs Input eration mode 496 252 Decimally coded status of the two digital outputs and 254 Digital Outputs of multifunctional output 1 in Operation mode 550 digital 255 Heat sink temperature Measured heat sink temperature 256 Inside temperature Measured inside temperature 257 Analog output MFO1A Output signal on multifunctional input 1 in Operation mode 550 analog Pulse width modulated signal at PWM input according cdd ub to Operation mode 496 259 Error message with error code and abbreviation Operating I nstructions ACU 257 Goo Bonfiglioli 258 269 Warning message with error code and abbreviation Application Warning message with error code and abbreviation The reference value signal is limited by the controller 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 function STO Safe Torque Off Output signal on multifunctional input 1 in Operation mode 550 repetition frequency 273 Application Warnings 275 Controller Status 278 Frequency MFOIF Additional to the described Actual values further Actual values are available for Fieldbus access These are notable parameters Current error 260 Warnings 270 and Applica
16. 50 00 18 8 69 439 Proportional Step 0 01 50 00 18 8 440 Operation mode Selection 17 3 441 Fixed frequency Hz 999 99 999 99 17 3 442 max P component Hz 0 01 999 99 17 3 443 Hysteresis 0 01 100 00 17 3 444 Amplification 15 00 15 00 17 3 445 Integral time ms 0 32767 17 3 446 Ind volume flow control factor 0 10 2 00 17 3 447 1 blocking frequency Hz 0 00 999 99 14 9 448 2 blocking frequency Hz 0 00 999 99 14 9 449 Frequency hysteresis Hz 0 00 100 00 14 9 450 Tolerance band 96 0 00 25 00 15 1 1 3 451 Filter Time Constant ms Selection 15 1 1 4 452 Operation mode Selection 15 1 453 Error warning behavior Selection 15 1 1 5 454 Point X1 96 0 00 100 00 15 1 1 1 455 Point Y1 96 100 00 100 00 15 1 1 1 456 Point X2 96 0 00 100 00 15 1 1 1 457 Point Y2 96 100 00 100 00 15 1 1 1 458 Operation mode Selection 12 6 459 Signal source Selection 12 6 1 Positioning distance 0 000 1 10 12 6 1 461 Signal correction 327 68 327 67 12 6 1 462 Load correction 32768 32767 12 6 1 463 Activity after positioning Selection 12 6 1 464 Waiting time ms 0 3 6 10 12 6 1 465 Operation mode Selection 18 7 2 466 Temperature
17. Application Safe Torque Off Safety function STO Application manual PLC Logic linking of digital signals Functions for analog signals such as comparisons and mathematical functions Graphic functional block programming Application manual Positioning Positioning functions of configurations x40 Application manual Electronic Gear Using at least 2 drives as electronic gear with Slave in config uration x15 or x16 Application manual Crane drives Extended Brake control for Crane and Hoist drives The products for CANopen amp communication comply with the specifications of the user organization CiA CAN in Automation The products for EtherCAT communication comply with the specifications of the user organization ETG EtherCAT Technology Group The present documentation was prepared with great care and it was subjected to extensive and re peated reviews For reasons of clarity it was not possible to include all details of all types of the prod uct in the documentation Neither was it possible to consider all conceivable installation operation or maintenance situations 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 Neither
18. D Already existing files will not be offered as copy target 7 5 5 Copy Operation 06 13 Before the parameter settings are transferred to the frequency inverter the individual parameter values are checked The value range and the parameter settings can differ according to the power range of the frequency inverter Parameter values which are outside of the value range will trig ger a copy error message If through the changing of parameters via copying a device fault is triggered this device fault is displayed after the copying of the parameters is finished While the copy operation is in process the message COPY Jii and as a progress indicator the number of the currently cop aa ied parameter will be displayed LHBPu In the case of the Act function the active parameter values are copied only Using the ALL function parameters which are not relevant to the selected configuration are copied too Depending on the configuration selected ALL or Act the copy HHH operation will be completed after approx 100 seconds and the E message rdY will be displayed ra Press the ENT key to switch to the copy menu Use the ESC key to switch to the target selection menu If the ESC key is pressed during the copy operation the copy 177 operation is aborted before the transmission of the data is complete The message Abr and the number of the last pa Uhr rameter which was copied are displayed Press the ENT key to return to th
19. Description X Fact sett 436 5s 437 5s 438 10 439 Proportional Step 0 0196 Input signals Traverse function Output signals Operation Mode 435 Reference Frequency 48 Acceleration Time 436 14 Sweep Output Handshake Traverse Function 49 Deceleration Time 437 15 Sweep Handshake Traverse Amplitude 438 from Master drive Proportional Step 439 Signal 14 Traverse Output is added to the reference frequency value 254 Operating Instructions ACU 06 13 vv Bonfiglioli Via parameter Operation mode 435 the drive is configured as a master drive or slave drive 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 48 Traverse mode becomes active as soon as the Reference frequency 48 is reached for the first time This frequency is reached via the values for Acceleration clockwise 420 and Acceleration Anticlockwise 422 and Deceleration clockwise 421 and Deceleration anticlockwise 423 n shot effect mode the values for Acceleration Time 436 and Deceleration Time 437 are active The frequency range for shot effect mode is limited by the Minimum frequency 418 and the Maximum frequency 419 During traverse operation the configured traverse parameter values cannot be changed The source of the handshake signal is selected via Han
20. EI 10 Group drive ienesis ene 58 H Hysteresis of analog input signal 175 Technology controller 218 l Installation s e reren 20 Electrical e 48 60 Mechanical reote eis 42 Instruction manuals sse 10 Intelligent current limits 210 Inverter data seeren 118 J JOG Frequency sieisen idoa 162 287 Goo Bonfiglioli L Level control 221 222 Limit value sources sssssese 231 M Machine data eee 104 105 123 Mains connection cece eee e eee 60 Modulation controller ss 239 Monitoring Active CUrrefib iode Yan ee 250 Analog input signal sssssss 176 Application warning mask 190 Controller intervention 151 DC component 151 Heat sink temperature 150 Boro 250 Motor temperature 152 245 Output frequency 152 Overload arainn aa 150 Phase failure 153 Warning mask eneee 187 Motor chopper seenm 251 Motor connection nsere 60 Motor Connection 56 Motor potentiometer 167 199 Motor protection ssssesee 245 Motor Protection Motor Protection by 2t Monitoring 248 Motor temperature ssseeeeese 252 Multi function input eee 172 Multi function output cee 177 Multiple
21. 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 X210A 1 Voltage output 20 V or input for external power supply DC 24 V 10 GND 20 V GND 24 V ext Digital input STOA 1st shutdown ath of safety function STO Fixed percentage value change over 1 X210A 5 no function assigned X210A 6 Speed sensor track B X210A 7 _ Speed sensor track A X210A 2 X210A 3 X210A 4 X210B 1 X210B 2 Motor thermal contact Digital input STOB 2 shutdown ath of safety function STO Run Signal Analog signal of actual frequenc ly voltage 10V X210B 6 Actual percentage value 0 10 V X210B 7 Ground 10 V 6 7 8 Configuration 230 Field Orientated Control Speed and Torque Controlled Configuration 230 extends the functionality of Configuration 210 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 Change over between variable speed control and torque dependent control is done jerk free during operation X210B 3 X210B 4 X210B 5 X210A 1 Voltage output 20 V or input for external power
22. No Description D Max Fact sett Slip Frequency 10000 330 14 3 Percentage Value Limits The setting range of the percentages is defined by the parameters Minimum refer ence percentage 518 and Maximum reference percentage 519 The relevant control methods use the two limit values for scaling and calculating the frequency No Description X Fact sett Minimum Reference Percentage 0 i n m a 0 00 Maximum Reference Percentage 0 00 300 00 100 00 14 4 Frequency reference channel The different functions for the defining the reference frequency are connected via the frequency reference value channel The Reference frequency source 475 determines the additive assignment of the available reference value sources depending on the hardware installed 154 Operating I nstructions ACU 06 13 vv Bonfiglioli Reference value source is the multifunctional input 1 in 1 Abs value analog value MFI1A analog Operation mode 452 Reference value source is the analog input of the ex 2 Abs Analog Value EM S1INA j nsion modul 4 Abs Value MFI 1A EM S1INA Combination of the operation modes 2 and 1 10 pis fed emery FA The fixed frequency according to the Fixed frequency 10 Abs value fixed frequency FF change over 1 66 and Fixed frequency change over 2 67 as well as the current data set Combination of the operation modes 10 and 1 Combination of the operation modes 10 and 2 14 Abs Value MFI1A EM SI
23. Stopping Behavior 2 5 15 3 6 Current Limitation Operation modes 15 to 19 link the digital outputs and the relay output to the functions of the intelligent current limits The reduction of power by the set figure in percent of the rated current depends on the selected operation mode Accordingly the event for intervention of the current limitation can be output via the operation modes of the digital outputs If the function of the intelligent current limits is deac tivated within the sensorless control operation modes 16 to 19 are switched off in the same way 15 3 7 External Fan 186 Operation mode 43 enables the control of an external fan Via the digital output the fan is switched on if the controller is released and Start clockwise or Start anti clockwise are switched on or if the Switch On Temperature 39 for the internal fan was reached Operating Instructions ACU 06 13 vv Bonfiglioli 15 3 8 Warning Mask The Warning mask signals via a digital signal if an afore configured warning applies The configuration of the Warning mask is carried out via Create warning mask 536 Warnings and controller status messages can be combined This enables internal or external control using a common output signal The display of Warning 269 and Controller Status 275 is not affected by the Warning mask Select a setting 1 43 for message activation Select a setting 101 143 for deactivation of a message 0 No Change Configur
24. The technology controller is switched off the refer 0 off ence value specification is done via the reference percentage channel 1 Standard For pressure and volume flow control with linear op erating behavior and actual value monitoring Contents level control at defined motor speed with 2 Liquid Level 1 her actual value missing 3 4 Speed Controller Rn control with analog feedback of the actual 5 Indirect Volume Flow Volume flow control with square rooted actual value Control ae Contents level control at defined motor speed with Liquid Level 2 ae us actual value missing or high control deviation Operating I nstructions ACU 217 Goo Bonfiglioli 218 The behavior of the technology controller corresponds to a PID controller with the components proportional component Amplification 444 integral component ntegral time 445 differential component Derivative time 618 The sign of the amplification determines the direction of control i e with a rising actual value and pos sign of the amplification the output frequency is reduced e g in pressure control With a rising actual value and neg sign of the amplification the output frequency is increased e g in temperature control systems refrigerating machines condensers The integral component can be used to reduce the steady state control deviation deviation between actual value and reference value over a period of time If the integral co
25. Warning Limit Heat Sink Temp deg C 25 0 13 2 408 Warning Limit Inside Temp deg C 25 0 13 2 409 Controller status message Selection 13 3 412 Local Remote Selection 18 3 415 IDC Compensation Limit V 0 0 1 5 13 4 417 Frequency Switch Off Limit Hz 0 00 999 99 13 5 V E 3 amp 418 Minimum Frequency Hz 0 00 999 99 14 1 V amp 419 Maximum Frequency Hz 0 00 999 99 14 1 420 Acceleration clockwise Hz s 0 00 9999 99 14 7 421 Deceleration clockwise Hz s 0 01 9999 99 14 7 422 Acceleration anticlockwise Hz s 0 01 9999 99 14 7 423 Deceleration anticlockwise Hz s 0 01 9999 99 14 7 424 Emergency stop clockwise Hz s 0 01 9999 99 14 7 425 Emergency stop anti clockwise Hz s 0 01 9999 99 14 7 amp l 426 Maximum leading Hz 0 01 999 99 14 7 430 Ramp rise time clockwise ms 0 65000 14 7 431 Ramp fall time clockwise ms 0 65000 14 7 432 Ramp rise time anticlockwise ms 0 65000 14 7 433 Ramp rise time anticlockwise ms 0 65000 14 7 06 13 Operating I nstructions ACU 279 Goo Bonfiglioli No Description Unit Setting range Chapter 69 435 Operation mode Selection 18 8 69 436 Acceleration Time S 0 01 320 00 18 8 69 437 Deceleration Time S 0 01 320 00 18 8 69 438 Traverse Amplitude 0 01
26. 15 min In the operation modes with overload reserve Ixt there is a reduction of the output current when the threshold value is exceeded with a distinction being made between long and short term overload reserve After the short term overload 1 s has been used up the output current is reduced to the long term overload current matching the present switching frequency After the long term overload current has been used up 60 s the output current is reduced to the rated current which also depends on the switching frequency 210 Operating Instructions ACU 06 13 vv Bonfiglioli 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 Output signals Digital outputs can signalize the achievement of a limit value selected in Operation Mode 573 15 Warning Current Limitation Intelligent Current Limits active Output current is limited 16 Controller Current Limit The overload reserve for 60 s has been used up Long Term Ixt and the output current is being limited 17 Controller Current Limit The overload reserve for 1 s has been used up Short Term Ixt and the output current is being limited Intelligent Current Limits active Maximum heat 18 Contr
27. 18 4kW 4mm 1x10 mm 4mm Operating I nstructions ACU 06 13 230 V Three phase connection L1 L2 L3 vv Bonfiglioli 01 0 25 kW 03 0 37 kW 05 0 55 kW 07 0 75 kW 2x1 5 mm or 09 11kW Eee 1x10 mm kamm 11 1 5 kW 13 22kW 15 3 kW 18 4 kW 2x4 mm or 19 55 kW SIME 1x10 mm id 2x6 mm or 2 21 7 5 kW 6 mm 1x10 mm 6 mm 22 9 2 kW 10 mm 1x10 mm 10 mm 400V Three phase connection L1 L2 L3 01 025 kW 03 037 kW 05 055 kW 07 075 kW 09 1 1 kW 2x1 5 mm or 11 L5 kW Karmim 1x10 mm Aa m 12 1 85 13 22kW 15 3 kW 18 4 kW 19 5 5 kW 2x2 5 mm or 21 Z5 kW dud 1x10 mm zone 22 9 2 kW imm 2x4 mm or 1x10 imm 23 11kW mm iu 25 15 KW 6 mm ins uc 6 mm 27 18 5 kW 10 mm 1x10 mm 10 mm 29 22 kW 31 30 kW 16 mm 1x16 mm 16 mm 33 37 kW 35 mm 1x16 mm 25 mm 35 45 kw 50 mm 1x25 mm 35 mm 37 55 kW 50 mm 1x25 mm 50 mm 39 65 kW 70 mn 1x35 mm 70 mn 43 75 kW 70 mm 1x50 mm 95 mm 45 90 kW 95 mm 1x70 mm 2x70 mm 47 110 KW 2x70 mm 1x70 mm 2x70 mm 49 132 KW 2x70 mm 1x70 mm 2x70 mm 06 13 Operating I nstructions ACU 55 G Bonfiglioli 6 4 2 Mains Connection Disconnect the frequency inverter from mains voltage and protect it against being ener gized unintentionally Verify that the frequency inverte
28. 186 Brake resistance 243 Brake resistor er Tora ze uo CH 59 Dimensioning sese 244 Bus controller oie 241 C Cable length pere ene 57 CE conformity ctr ron nare irent 30 COMMISSIONING 101 Communication module n 53 Comparator s cere tent RR ARD nt eas 204 Comparison of actual values 204 Conductor cross section s 54 Configurations Connection diagrams sssssss 73 Overview 74 102 119 Control FUNCOMS isinna 210 Intelligent current limits 210 Power failure regulation 213 Technology controller 216 Voltage controller eres 211 Control signals ui eerie estne 191 Control terminals ssssss 70 290 Technical data ditta 31 Control unit oo eects 53 87 uS ane 88 Motor Control 98 Copy parameter values sssssss 91 Error messages iiie itr Ren 94 CODVFIGhE ostii ebria baut inea dona 13 Current controller essssesees 227 EXt nded cccccscssecsseeeseceeaeeeeeeeaeseeees 229 Current limit value controller 226 Current limitation 186 D Data set mee 104 Data set change over ssssssssss 198 Deceleration 2 dicetis da 163 Decommissioning s c 22 Demultiplexer sene 206 Designated use aane 15 Dlagnoslis c oiii t UR UR 271 Digita
29. 80 60 40 20 10 0 200 200 200 200 200 200 200 200 200 F 5 188 182 177 168 162 153 139 114 100 c 10 177 168 160 147 139 129 114 100 100 E 20 160 147 137 122 114 106 100 100 100 2 30 147 132 122 109 103 100 100 100 100 S 50 129 114 106 100 100 100 100 100 100 100 106 100 100 100 100 100 100 100 100 150 100 100 100 100 100 100 100 100 100 18 5 2 Motor Protection by 2t Monitoring 248 To protect the motor against overload the 12t monitoring provides a further possibility for the user This kind of motor protection is mainly used in servo technology When using servo motors the I2t monitoring is a proven alternative to motor protection switch By integrating temperature dependent parameters measurable or known the heat ing of a mathematical model is simulated The kind of the I t monitoring mode can be selected by Operation Mode 571 This parameter is switchable via data set The I t monitoring works by function I44 1 as shown in the figure The monitored value is evaluated via a PT1 element with the thermal time constant of the stator If the output of PT1 element is bigger than 12096 then an error message is generat ed and the drive switches off The threshold of 12096 prevents that an overshoot leads to an immediate shutdown In the application
30. Mains In the case of a mains phase failure the drive is stopped Shutdown after five minutes fault F0703 is displayed The drive is stopped immediately in the case of a motor phase failure after 5 minutes in the case of a mains phase failure i Mains amp Motor Shutdown 13 8 Automatic Error Acknowledgment The automatic error acknowledgment enables acknowledgment of the faults Overcur rent F0500 Overcurrent F0507 and Overvoltage F0700 without intervention by an overriding control system or the user If one of the aforementioned errors occurs the frequency inverter switches the power semi conductors off and waits for the time stated with the parameter Restart delay 579 f the error must be acknowledged the speed of the machine is determined with the quick Search Run function and synchro nized to the rotating machine The automatic error acknowledgment makes use of Quick Synchronization operation mode regardless of the Search run operation mode 645 The information given on this function in chapter Search run must be observed With parameter Allowed no of auto acknowl 578 you can define the number of automatic error acknowledgements which are permitted within 10 minutes An acknowledgement repeated above the permissible number within 10 minutes will result in the frequency inverter being switched off The errors Overcurrent F0500 Overcurrent F0507 and Overvoltage F0700 have sepa rate error acknowledgement c
31. Motor protection switch tripped check drive V belt monitoring reports no load on the drive Phase failure check motor and wiring Deviation Position Controller Please check Application manual Position ing Start monitoring Check brake amp limiting parameters at start like in example Current limit 728 Intelligent currents etc DC link voltage too high check deceleration ramps and connected brake resistor Electronics voltage DC 24 V too low check control terminal Electronics voltage too high check wiring of control terminals Brake Chopper Overcurrent refer to chapter 18 4 Brake Chopper and PI e Brake Resistance Output frequency too high check control signals and settings Max frequency reached by control check deceleration ramps and con nected brake resistor Overspeed Check Application manual Crane drives Table Fault Messages continued on next page 06 13 Operating I nstructions ACU 265 Goo Bonfiglioli 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 Fault message of 5 second monitoring Shut down paths STOA and STOB were not actuated at the same time but with an offset of more than 5 seconds Check addressing of shut down paths or control of protective circuitry 00 Earth fault on output check motor and wiring 0 Set IDC compensation limit 415 reached che
32. No Description Min Max Fact sett Integral time speed synch 60000 ms 5000 ms 17 5 5 Acceleration Pre Control 236 The acceleration pre control is active in the speed controlled configurations and can be activated via parameter Operation mode 725 0 Off The control system is not influenced The acceleration pre control is active according to 1 On t the limit values The acceleration pre control controlled parallel to the speed controller reduces the reaction time of the drive system to a change of reference values The minimum ac celeration time defines the modification speed of the reference speed value as from which a torque necessary for acceleration of the drive is pre controlled The accelera tion of the mass is a function of the Mech time constant 727 of the system The value calculated from the increase of the reference value and the multiplication factor of the torque required is added to the output signal of the speed controller No Description Min Max Fact sett O 1Hz s 6500 0 Hz s 1 0 Hz s 60000ms 10ms For optimal setting the acceleration pre control is switched on and the mechanical time constant is set to the minimum value The output value of the speed controller is compared to the minimum acceleration time during the acceleration processes The frequency ramp is to be set to the highest value occurring in operation at which the output figure of the speed controller is not yet l
33. Refer to the application manual Electronic gear for further details 10 Refer to the operating instructions of the expansion modules with system bus 194 Operating I nstructions ACU 06 13 750 OUT PZD3 Boolean 751 OUT PZD4 Boolean vv Bonfiglioli Process data for Profibus communication Module CM PDP with Profibus interface is necessary Process data for Profibus communication Module CM PDP with Profibus interface is necessary 752 OUT PZD5 Boolean 753 OUT PZD6 Boolean 810 Obj 0x3003 DigOut 1 to to 814 Obj 0x3003 DigOut 5 832 Obj 0x3005 Demux to Out 1 to Obj 0x3005 847 Demux Out 16 876 Position Comparator Out 877 Position Comparator Out inverted 887 MBC Start Clockwise 988 MBC Start Anticlock wise Motion Block Digital Ben Signal 1 Motion Block Digital Rye Signal 2 Motion Block Digital Bots Signal 3 Motion Block Digital Hi Signal 4 Process data for Profibus communication Module CM PDP with Profibus interface is necessary Process data for Profibus communication Module CM PDP with Profibus interface is necessary Source of CAN objects for CANopen communication Module CM with CAN interface necessary Source of the demultiplexer output for CANopen communication Module CM with CAN interface necessary The current actual value is in the range between Switch on position 1243 and Switch off posi tion 1244 Operation mode 876 inverted Message clockwise op
34. Symbol Meaning Ground connection 2 6 7 ESD symbol Meaning o lt 3 e ESD Electrostatic Discharge can damage components and assemblies 2 6 8 I nformation signs Symbol Meaning Tips and information making using the frequency inverter easier 18 Operating I nstructions ACU 06 13 vv Bonfiglioli 2 7 Directives and guidelines to be adhered to by the operator The operator must follow the following directives and regulations e Ensure that the applicable workplace related accident prevention regulations as well as other ap plicable national regulation are accessible to the staff e An authorized person must ensure before using the frequency inverter that the device is used in compliance with its designated use and that all safety requirements are met e Additionally comply with the applicable laws regulations and directives of the country in which the frequency inverter is used Any additional guidelines and directives that may be required additionally shall be defined by the operator of the machine plant considering the operating environment 2 8 Operator s general plant documentation e In addition to the user manual the operator should issue separate internal operating instructions for the frequency inverter The user manual of the frequency inverter must be included in the user manual of the whole plant 2 9 Operator s oper
35. The display of the control unit reads dEFLt Parameters Control level 28 Language 33 as well as Configuration 30 are not changed during resetting to factory settings Program ming 34 4444 122 Operating Instructions ACU 06 13 vv Bonfiglioli 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 30 10 1 Rated Motor Parameters 06 13 Set the rated parameters of the three phase asynchronous machine according to the rating plate or the data sheet of the motor The default settings of the machine pa rameters are based on the nominal data of the frequency inverter and the corre sponding four pole three phase motor The machine data required for the control functions and methods are checked for plausibility and calculated in the course of the commissioning Check the rated values specified by default No Description X Fact sett 370 Urn 3n len 372 373 374 costos 375 Rated frequency 50 00 Hz 376 Prin Ursin Nominal Voltage of Frequency inverter typically 400 V or 230 V lpn Nominal Output current of Frequency inverter Pein Nominal Output of Frequency inverter 0 Overload capability of Frequency inverter The Parameter Rated cosine g 374 is not available in configurations 5xx and 6xx Synchronous mo
36. all specific regulations relevant to the application as well all na tional directives are to be complied with The Auto Start function is suitable for applications which permit a start at mains volt age by their function By activation of the auto start function via parameter Opera tion mode 651 the frequency inverter accelerates the drive after application of the mains voltage The controller enabling signal and the start command are necessary according to the regulations When the motor is switched on it is accelerated accord ing to the parameterization and the reference value signal The drive is accelerated after application of the mains 0 Off voltage as soon as the controller enabling signal and the start command are switched from stop to start edge evaluation The drive is accelerated by the frequency inverter as 1 Switched on f A soon as the mains voltage is applied level evaluation Operating I nstructions ACU 141 G9 Bonfiglioli 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 Via Operation mode search run 645 the motor speed is synchronized to the current motor speed without an Overcurrent fault message After this the motor is acceler ated to the reference speed at the set acceleration This synchronization function determines the current rotary frequen
37. is done by parameter FT target output 1 1350 or FT target output 2 1351 The output signal of a function table instruction The output signal is the signal source 2404 FT Output buffer 4 The signal source contains the value of the FT instruction output which is as signed to the signal source 2404 The assignment is done by parameter FT target output 1 1350 or FT target output 2 1351 Sources of CAN objects For communication module CM with CAN interface necessary Operation modes inverted LOW active 1 Refer to the application manual Electronic gear for further details Refer to the application manual Positioning for further details 3 Refer to the application manual Function table for further details Refer to the operating instructions of the expansion module with CAN interface 182 Operating Instructions ACU 06 13 vv Bonfiglioli Vectron 15 3 1 Digital Signal 06 13 The signals selected for parameters Op Mode Digital Output 1 530 Digital Opera tion 554 and Op Mode Digital Output 3 532 can be linked with inverter functions Signal at digital output 1 in The Signal which is selected via Op Mode Digital Out 175 Digital Signal 1 put 1 530 Signal at multifunction output MFO1 The Signal which is selected via Digital Operation 554 176 Digital Signal 2 Sat Operation Mode 550 1 Digital Signal at digital output 3 relay output i The Signal which is selected via Op Mo
38. 00 s m h 198 Operating I nstructions ACU 06 13 vv Bonfiglioli 15 4 8 Fixed Value Change Over As a function of the selected configuration the reference figures are specified via the assignment of the Reference frequency source 475 or Reference percentage source 476 Accordingly there can be a change between the fixed values by connec tion of the logic signals with the parameters Fixed frequency change over 1 66 Fixed frequency change over 2 67 or the parameters Fixed percent change over 1 75 Fixed percent change over 2 76 By combining the logic states of the fixed frequency change over modes 1 and 2 fixed frequencies 1 through 4 can be selected Fixed frequency Fixed frequency Function active fixed value change over 1 66 change over 2 67 0 FixedFrequency2481 0 contact open 1 contact closed By combining the logic states of the fixed percentage change over modes 1 and 2 fixed frequencies 1 through 4 can be selected Fixed percentage Fixed percentage Function active fixed value change over 1 75 change over 2 76 Fixed Percentage 1 520 0 O Fixed Percentage 2 521 Fixed Percentage 3 522 Fixed Percentage 4 523 0 contact open 1 contact closed 15 4 9 Motor Potentiometer The parameters Reference frequency source 475 and Reference percentage source 476 contain operation modes with motor potentiometer The Operation mode 474 defines the behavior of the motor potentiomete
39. 1 0 0 off on i on off i below above above below Example Op Mode Comparator I 540 7 Abs Actual Frequency Comparator On above 541 80 00 Comparator Off below 542 50 00 Maximum Frequency 419 50 00 Hz gt Comparator will switch on if Actual Frequency 241 gt 40 00 Hz gt Comparator will switch off if Actual Frequency 241 lt 25 00 Hz Output signals Digital signals indicate the result of the comparison Comparator 1 171 Output Comparator 1 The comparison selected via Op Mode Compar 20 Comparator 1 2 ator 1 540 is true The comparison selected via Op Mode Compar ator 1 540 is true The output level of the com arator is inverted Negated Output Com 1 es parator 1 Comparator 2 173 Output Comparator 2 The comparison selected via Op Mode Compar 21 Comparator 2 2 ator 2 543 is true The comparison selected via Op Mode Compar 174 Negated DHEpub Com aj ator 2 543 is true The output level of the com parator 2 dn doo 4pamatorisinvrted 0 0 0 0 0 0 0 0 1 For linking with inverter functions For digital output 15 5 3 Function table 06 13 The function table allows to link external digital signals and internal logic signals of the frequency inverter with each other Besides standard AND OR and XOR combina tions different more advanced logic functions like RS Flip Flop are available The corresponding output valu
40. 13 is deactivated Deactivate Warning neg f 114 HW Limit Switch Warning 14 is deactivated 115 Deactivate OAN gnau Warning 15 is deactivated ing Error 116 Deactivate Warning Encoder Warning 16 is deactivated 117 Deactivate Warning User 1 Warning 17 is deactivated 118 Deactivate Warning User 2 Warning 18 is deactivated 1 Refer to the application manual Positioning for further details 190 Operating I nstructions ACU 06 13 vv Bonfiglioli The selected warning mask application can be read out via the parameter Actual Appl Warning Mask 627 The above operation modes of parameter Create Appl Warning Mask 626 are encoded in the Actual Appl Warning Mask 627 The code results from hexadecimal addition of the individual operation modes and the match ing abbreviation 0040 Enc Output signals The output of a warning message is signaled 215 Warning Mask Output of a warning message which is activated in Cre 27 Application 2 ate Appl Warning Mask 626 1 For linking with inverter functions 2 For digital output Parameter Warning Application 273 shows the Application Warnings independent from the created Warning mask In the error environment Application Warning Status 367 shows the current warn ings of the positioning functions independent from the created Warning mask 15 4 Digital inputs The assignment of the control signals to the available software functions c
41. 2 241 Actual frequency Hz 0 0 999 99 19 2 242 Actual System Value Hz 0 0 999 99 19 4 1 243 Digital inputs Hardware 00 255 19 1 244 Working hours counter h 99999 19 1 245 Operation hours counter h 99999 19 1 249 Active data set 1 4 19 1 250 eee inputs 00 255 19 1 251 Analog input HELIA 3 e1000 191 0 0 999 99 254 Digital Outputs 00 255 19 1 255 Heat sink temperature 0 Tkmax 19 1 256 Inside temperature Oese Tmax 19 1 257 Analog output MFO1A 0 0 24 0 258 PWM Input 259 Current error 0 00 100 00 269 Warnings 19 1 273 Application Warnings 19 1 275 Controller Status 19 1 277 STO Status 19 1 278 Frequency MFOI1F 19 1 285 Volumetric flow m3 h 0 99999 19 4 2 286 Pressure kPa 0 0 999 9 19 4 2 287 Peak value Vdc V 0 0 Udmax 19 3 288 Average value Vdc V 0 0 Uamax 19 3 289 Peak value heat sink temp deg C 0 Tkmax 19 3 290 Average value heat sink temp deg C 0 Tkmax 19 3 291 Peak Value Inside Temperature deg C 0 Timax 19 3 292 Average Value Inside Temperature deg C 0 Timax 19 3 293 Peak Value Irms A 0 0 0 Ig 19 3 294 Average Value Irms A 0 0 0 len 19 3 295 Peak value active power pos kW 0 0 O Prin 19 3 296 Peak value active power neg kW 0 0
42. 2 ms Umax DC 30 V 10 mA at 24 V PLC com patible frequency signal DC 8 30 V 10 mA at DC 24 V fmax 150 kHz 3 Digital input S71 ND STOB STOB Digital signal STOB 2nd shutdown path for safety function STO Safe Torque Off response time approx 10 ms On 10 us Off Umax DC 30 V 10 mA at DC 24 V PLC compatible 9 Digital output SLOUT Digital signal DC 24 V Imax 50 mA PLC compatible overload and short circuit proof Multi Function Output MFO1 Analog signal DC 24 V Imax 50 mA pulse width modulated fpwm 116 Hz Digital signal DC 24 V Imax 50 mA PLC compatible Frequency signal DC 0 24 V max 40 mA fmax 150 kHz overload and short circuit proof Multi Function Input MFI 1 Analog signal resolution 12 Bit 0 10 V Ri 70 kQ 0 20 mA Ri 500 Q Digital signal response time approx 4 ms Uma DC 30 V 4 mA at 24 V PLC com patible Operating Instructions ACU 06 13 Bonfiglioli Vectron 6 3 Optional Components A 06 13 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 The hardware modules at slots
43. 518 and Maximum reference percentage 519 but does not consider the Gradient percentage ramp 477 of the reference percentage value chan nel The assignment is done with the help of the parameters sq limit source motor op eration 734 and Isq limit source generator operation 735 for the torque forming current component Isq The sources for the torque limits can be selected via the parameters Torque limit source motor op 736 and Torque limit source generator op 737 The source is the multifunctional input 1 in ana pote ATaToH In pM MEER log Operation mode 452 105 Repetition frequency input The frequency signal on the repetition frequency F3 input corresponding to Operation mode 496 110 Fixed limit The selected parameter figures for limiting the speed controller are taken into account The limit values and assignment to different limit value sources are data set related in the configurations The use of the data record change over demands an examination of the parameters in question 06 13 Operating I nstructions ACU 235 G Bonfiglioli 17 5 4 3 I ntegral 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 chronization 515 The setup is effective in operation modes 4 speed synchroniza tion DG 1 and 5 speed synchronization DG 2 for parameter Actual speed source 766
44. 6 6 Control Terminals A 70 The control and software functionality can be configured as required to ensure a reliable and economical operation The operating instructions describe the factory settings of the standard connections in the relevant Configuration 30 as well as the software parameters to be set up The unit may only be connected with the power supply switched off Verify that the frequency inverter is discharged Switch off power supply before connecting or disconnecting the control inputs and outputs Verify that the keyed control inputs and outputs are deenergized before connecting or disconnecting them Otherwise components may be damaged Wieland DST85 RM3 5 fp 014 1 5mm AWG 30 16 0 4 1 5 mm AWG 30 16 0 25 1 0 mm AWG 22 18 0 25 0 75 mm AWG 22 20 0 2 0 3 Nm 1 8 2 7 Ib in Operating Instructions ACU 06 13 vv Bonfiglioli Ter 1 Desripion 3 Voltage output 20 V Imax 180 mA P or 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 Umax DC 30 V 10 mA at DC 24 V input resistance 2 3 kQ PLC compati ble response time approx 10 ms Digital input S2IND Umax 30 V 10 mA at DC 24 V Input resistance 2 3 kO PLC compatible response time approx 2 ms Digital input S3IND Umax 30 V 10 mA at DC 24 V Input resistance 2 3 kQ P
45. 6 7 6 Configuration 210 Field Oriented Control Speed Controlled 06 13 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 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 X210A 1 X210A 2 X210A 3 X210A 4 X210A 5 X210A 6 X210A 7 Voltage output 20 V or input for external power supply DC 24 V 10 GND 20 V GND 24 V ext Digital input STOA 1st shutdown ath of safety function STO Start of clockwise operation Start of anticlockwise operation Speed sensor track B Speed sensor track A X210B 1 X210B 2 X210B 3 X210B 4 X210B 5 X210B 6 X210B 7 Motor thermal contact Digital input STOB 2 shutdown ath of safety function STO Run Signal Analog signal of actual frequenc Supply voltage 10V for reference value potentiometer Reference speed 0 10V Ground 10 V Operating I nstructions ACU 79 G Bonfiglioli 6 7 7 Configuration 211
46. 8 12 16 Min brake resistance Recommended brake resistor Uagc 385 V Mains current 3ph PE A NE 9 5 105 9 Lph N PE 2ph PE 13 2 188 2 165247 Mains voltage I Mains frequency ESH EN a lph N 2ph 16 20 20 lph N 2ph 15 20 20 250 x 60 x 175 1 6 P20 EN60529 37 R Q 75 55 37 Dimensions Weight approx Degree of protection Terminals Energy dissipation 2 kHz switching P W 84 115 170 frequency Coolant temperature 0 40 3K3 DIN IEC 721 3 3 Storage temperature 25 55 Transport temperature 25 70 Rel air humidity 15 85 not condensing If required by the customer the switching frequency may be increased if the output current is reduced at the same time Comply with the applicable standards and regulations for this operating point Switching frequency D Three phase connection requires a commutating choke 2 One and two phase connection requires a commutating choke 3 Mains current with relative mains impedance gt 1 see chapter Electrical installation Maximum output current 9 5 A with single phase and two phase connection 5 Reduction of switching frequency in thermal limit range Maximum current in continuous operation 7 The device for single phase connection is not listed in the product catalogue and only available on request Frequency inverter nominal power 06 13 Operating I nstructions ACU 33 Goo Bonf
47. 9 2 kW with integrated EMC filter comply with the emission limits of the product standard EN 61800 3 up to a motor cable length of 10 m without additional measures being required Increased requirements in connection with the specific application of the frequency inverter are to be met by means of optional components Commutating chokes and EMC filters are optional ly available for the series of devices e Operation on unearthed mains IT mains is admissible after disconnection of the Y capacitors in the interior of the device Operating Instructions ACU 06 13 vv Bonfiglioli e Interference free operation with residual current device is guaranteed at a trip ping current gt 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 three phase power supply L1 L2 L3 All current sensitive residual current devices Type B to EN 50178 Use EMC filters with reduced leakage current or if possible do not use EMC filters at all The length of the shielded motor cable is lt 10 m and there are no additional capacitive components between the mains or motor cables and PE 06 13 Operating I nstructions ACU 49 Go Bonfiglioli 6 1 50 EMC I nformation The frequency inverters are designed according to the requirements and limit values of product norm EN 61800 3 with an in
48. B and C may only be assembled and disassembled after the frequency inverter has been disconnected safely from power supply Wait for some minutes until the DC link capacitors have discharged before starting the work The unit may only be connected with the power supply switched off Make sure that the frequency inverter is discharged Control Unit KP500 Connection of the optional control unit KP500 or an interface adapter KP232 9 Communication module CM QO Plug in section for connection to various communication protocols CM 232 RS232 interface CM 485 RS485 interface CM PDP Profibus DP interface B CM CAN CANopen interface 9 Expansion module EM Slot for customer specific adaptation of the control inputs and outputs to various applications EM ENC extended speed sensor evaluation EM RES resolver evaluation EM IO analog and digital inputs and outputs EM SYS system bus system bus in combination with CM CAN communi cation module upon request If two optional components with CAN Protocol controller are installed the system bus interface in the EM expansion module is deactivated Operating I nstructions ACU 53 GW Bonfiglioli 6 4 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 tha
49. Digital signal Low Signal DC 0 3 V High Signal DC 12 V 30 V response time 4 ms PLC compati ble Cable size The signal terminals are suitable for the following cable sizes with ferrule 0 25 1 0 mm without ferrule 0 14 1 5 mm 06 13 Operating I nstructions ACU 31 Goo Bonfiglioli 4 3 ACU 201 0 25 to 1 1 kW 230 V ACU 201 q M 3 0s Or jJ 09 Construction Size o 1 Recommended motor shaft power P kW 0 25 0 37 0 55 0 75 11 Output current i Jaf 16 25 30 40 54 Long term overload current 60s A 32 50 45 60 73 Short time overload current 1s a 32 50 60 80 80 Output voltage Maximum input voltage three phase Protection Eo e Short circuit earth fault proof Rotary field frequency 0 1000 depending on switching frequency Switching frequency 2 4 8 12 16 Min brake resistance 100 Recommended brake resistor R Q 430 300 230 160 115 Uagc 385 V Lph N PE 2ph PE 2 9 4 5 5 4 7 2 9 5 2 Mains voltage 184 264 Mains frequency 45 66 1ph N 2ph 10 16 lph N 2ph 10 15 190 x 60 x 175 1 2 P20 EN60529 Dimensions Weight approx Degree of protection Terminals Energy dissipation 2 kHz switching f P W 32 38 43 53 73 requency Coolant temperature 0 40 3K3 DIN IEC 721 3 3 Storage temperature 25 55 Transport temperature 25 70 Rel air humidity Em 15
50. Fact sett J OG frequency 999 99 Hz 999 99 Hz 5 00 Hz 14 6 3 Fixed Percentages The four percentage values define reference values which are selected via the Fixed percent change over 1 75 and Fixed percent change over 2 76 The Reference per centage source 476 defines the addition of the various sources in the reference per centage channel No Deed X Fact sett 520 0 00 521 20 00 522 50 00 523 100 00 By combining the logic states of the fixed percentage change over modes 1 and 2 fixed frequencies 1 through 4 can be selected Fixed percentage Fixed percentage change over 1 75 change over 2 76 URGE ONS ACV KEU NAME 100 0 0 Fixed Percentage 1 520 31 o Pied Percenage 2 821 Fixed Percentage 3 522 0 1 ie Percentage 4 823 0 contact open 1 contact closed 162 Operating Instructions ACU 06 13 vv Bonfiglioli 14 7 Frequency ramps 06 13 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 If the settings of the frequency ramps are identical for both directions of rotation the parameterization via the parameters Acceleration clockwise 420 and Deceleration clockwise 421 is sufficient The values of the frequency ramps are taken over for Acceleration anti
51. Goo Bonfiglioli 13 5 Frequency Switch Off Limit The maximum allowed output frequency of the frequency inverter can be set with the parameter Frequency switch off limit 417 f this frequency limit is exceeded by the Stator frequency 210 or Actual frequency 241 the frequency inverter switches off with fault message F1100 Description Min Max Fact sett No x Frequency Switch Off Limit 0 00Hz 999 99 Hz 999 99 Hz 13 6 Motor Temperature The configuration of the control terminals includes the monitoring of the motor tem perature The monitoring function can be parameterized specific to the application via the parameter Motor Temp Operation Mode 570 The integration into the applica tion is improved by an operating mode with a delayed switch off ing only trol unit and parameter Warnings 269 The fault switch off is displayed by message F0400 The fault switch off can be acknowledged via the control unit or the digital input 1 3 Error Switch Off The fault switch off according to operation mode 2 is 1 min del delayed by one minute 4 Error Switch Off The fault switch off according to operation mode 2 is 5 min del delayed by five minutes 5 Error Switch Off The fault switch off according to operation mode 2 is 10 min del delayed by ten minutes Output signals Warnings are displayed in parameter Warnings 269 and indicated via digital signals 168 1 Monitoring selected via Motor Temp War
52. Min X Fact b Morminal volumetric flow TES m h osa imos Line mains or channel characteristic H kPa Bi Pew method bad point method Q m h Point A in the figure describes the rating point of a pump The transition to partial load operation mode B1 can be affected at a constant pressure H change of convey ing flow Q pressure H remains constant The transition to partial load operation mode B2 can be affected according to the bad point method change of pressure H and conveying flow Q Both methods can be realized with the integrated technology controller in configurations 111 211 411 and 611 The actual values displayed are calculated according to the bad point method independently of the selected Opera tion mode 440 of the technology controller 06 13 Operating I nstructions ACU 133 GW Bonfiglioli 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 tion behavior can be selected according to the selected Configuration 30 Additional ly features such as Auto Start and the synchronization and positioning functions facilitate the integration in the application 12 1 Starting Behavior The start of the 3 phase machine can be parameterized in accordance with the con trol functions and methods In contrast to the sensorless control method the field orien
53. Operating I nstructions ACU 06 13 tv Bonfiglioli f frequency reference value channel ircuit diagram o C enie KAouenbaJj e uaJ9jed gzz ouenbai4 e ueJojau euU 69 95iVopop nuy ueis 6Lp AouenbauJ Xew 89 OSPOD ues 8Tt ouenbaJJ ui uone3oJ JO uon2ejes do3s 31e3S a Us syw Aouonboj4 njosqy 6p sis24915AH Aduenbei4 Umoq nodao3oj Aouenbau4 I 8t t Aouenbou4 pexiJ 28V ousnbaj4 pexiJ 8t z Aouenbe14 pextJ O8r T 2uenbeJ4 pexi4 8t v ouenbaej4 6up oig puz Lop ouenbau4 Durj o g IST 9 uvog nodio3o u A2uenbauJ Y ja c9 dn noduo3oiy AouenbouJ ouenbaJ Gur ojg QGNI9S WMd QGN IES INMd QGN IZS INMd SLY eounos A uenbaJJ e uaJo9Jod e2unos Aduenba y e uaJoJoy 157 Operating I nstructions ACU 06 13 GW Bonfiglioli 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 The Reference Percentage Source 476 determines the additive assignment of the available reference value sources depending on the hardware installed 1 Abs value analog value Reference v
54. Operating Instructions ACU 06 13 vv Bonfiglioli 10 4 3 Gear factor speed sensor 1 Setting of parameters EC Gear Factor Numerator 511 and ECI Gear Factor De nominator 512 is required if a gear is installed between the speed sensor and the motor shaft The parameters define the mechanical transmission ratio between the speed sensor and the motor side The parameters must be set such that the gear factor numerator corresponds to the motor rotations and the gear factor denominator corresponds to the sensor rotations No Description in X Fact sett M Ma 300 00 300 00 300 00 EC1 Gear Factor Numerator EC1 Gear Factor Denominator Example The motor shaft turns twice while the load shaft rotates once 16 8 16 teeth Pd Y v cT gt A A 18 teeth Motor Gear o Encoder Load Revolutions of motor axis EC 1 Gear Factor Numerator 511 Revolutions of load axis EC 1 Gear Factor Denominator 512 In this example parameter EC Gear factor Numerator 511 must be set to 2 and parameter EC Gear factor Denominator 512 must be set to 1 For optimum motor control BONFIGLIOLI VECTRON recommends installing a speed sensor directly at the motor 10 4 4 Filter time constant speed sensor 1 06 13 ECI Filter time constant 1193 can be used to filter the speed of speed sensor 1 This can filter can be applied in cases where the speed sensor fluctuates in example due
55. Operation mode 321 inverted 522 EM S3IND inverted Operation mode 322 inverted Refer to the application manual Positioning for further details Refer to the application manual Safe Torque Off for further details Refer to the operating instructions of the expansion modules with digital inputs 06 13 Operating I nstructions ACU 193 G Bonfiglioli 526 S2IND Hardware Digital input S2IND X210A 4 527 S3IND Hardware Digital input S3IND X210A 5 Digital input S4IND X210A 6 i Multifunction input MFI1 X210B 6 in Operation See MELD Hardware Mode 452 3 digital input 532 EM S1IND Hardware Digital input 1 of an expansion module EM 533 EM S2IND Hardware Digital input 2 of an expansion module EM 534 EM S3IND Hardware Digital input 3 of an expansion module EM Operation modes 526 to 534 of the digital inputs ae ne inverted LOW active Warning Position Con Contouring error monitoring message The con 604 troller g touring error monitoring range adjusted with parameter Warning Threshold 1105 was left 614 Homing Done A homing operation was started and the refer ence position for positioning was set A homing operation was started The signal is aiae Homing FeQuested reset at the end of the reference travel operation Message of phasing function For positioning in combination with the function of the electronic gear the value Phasing Offset 1125 was reached Synchroniz
56. Pactive neg 16 Energy positive 17 Energy negative 101 All Average Values 19 4 Actual Values of the System The calculation of the actual figures of the system is based on the parameterized system data Specific to the application the parameters are calculated from the fac tors electrical variables and the controls The correct display of the actual figures is a function of the data of the system to be parameterized 19 4 1 Actual System Value The drive can be monitored via the actual value Actual System Value 242 The Actual frequency 241 to be monitored is multiplied by the Actual system value factor 389 and can be read out via the parameter Actual system value 242 i e Ac tual frequency 241 x Actual system value factor 389 Actual system value 242 No Description Function 242 Actual System Value Calculated frequency of drive 262 Operating I nstructions ACU 06 13 vv Bonfiglioli 19 4 2 Volume Flow and Pressure The parameterization of the factors Nominal Volumetric Flow 397 and Nominal Pressure 398 is necessary if the matching actual values Volumetric Flow 285 and Pressure 286 are used to monitor the drive The conversion is done using the elec trical control parameters Volume flow 285 and Pressure 286 are referred to the Effective current 214 in the case of the sensorless control methods In the case of the field oriented control methods they are referred to the torque forming current component Zsq 216
57. STOB becomes logical 0 low _ Description Min Max Fact sett 2000s 100s To avoid current surges which can possibly lead to a fault switch off of the frequen cy inverter a direct current may only be impressed into the motor after the motor has been demagnetized As the demagnetization time depends on the motor used it can be set with the parameter Demagnetizing time 633 The selected demagnetizing time should be approximately three times the Act Rotor Time Constant 227 JDesenpuon Min Max Fact sett 5 05 The selected stopping behavior is supplemented by a current controller to control the direct current brake The PI controller checks the current impression of the set Brak ing current 631 The proportional and integrating parts of current controller can be adjusted via parameters Amplification 634 and Integral time 635 respectively The control functions can be deactivated by setting the parameters to 0 Description x Fact sett mast ME I 00 1 00 635 Integral time Oms 1000ms 50ms 12 4 Auto Start A 06 13 Comply with standard EN 60204 and VDE provision 0100 part 227 and provision 0113 in particular Sections 5 4 protection against automatic restart after main line voltage failure and voltage recovery and Section 5 5 undervoltage protection Appropriate measures must be taken to exclude any risk for staff machines and pro duction goods In addition to that
58. Single evaluation sense of rot via contact with ref track 1031 Double evaluation sense of rot via contact with ref track 1032 Single evaluation 1101 inverted with refer ence track Double evaluation 1102 inverted with refer 98e as operation mode 1002 The actual speed val ue is negative ence track g ion mer em Ez rd d N Same as operation mode 1001 The actual speed val ue is negative 1104 tion inverted with Same as operation mode 1004 The actual speed val reference track Ue E Negative Single evaluation inv with sense of Same as operation mode 1011 The actual speed val rot without sign ue is negative with ref track Double evaluation inv with sense of Same as operation mode 1012 The actual speed val rot without sign ue is negative with ref track 1111 1112 One channel speed sensor via track signal A The actual speed value is negative for signal Low and positive for signal High at digital input S4IND One signal edge is evaluated per division mark The refer ence track is connected to digital input S6I ND One channel speed sensor via track signal A The actual speed value is negative for signal Low and positive for signal High at digital input S4IND Two signal edges are evaluated per division mark The reference track is connected to digital input S6IND Single evaluation inv sense of rot via contact with ref track 1131 Double e
59. Star connection tv Bonfiglioli 11 0 kW 15 0 kW 16qmm RM10 15 Ft 02 16mnr AWG 24 6 f 6 02 16 mm AWG 24 6 0 25 10 mn AWG 22 8 FC T 025 10 mnf AWG 22 8 x2 U V W Rb Ro2 CD A Rb2 T1 T2 Rb1 4 11 0 kW 15 0 kW 16qmm RM10 15 o 02 16mnf AWG 24 6 a 02 16 mr AWG 24 6 0 25 10 mnf AWG 22 8 SC E39 025 10mnf AWG 22 8 Operating I nstructions ACU 63 Go Bonfiglioli 6 5 3 ACU 401 18 5 to 30 0 kW 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 When the frequency inverter is disconnected from power supply the mains DC link voltage and motor terminals may still be live for some time Switch off power supply before connecting or disconnecting the mains cable to from terminal X1 the motor cables and the brake resistor to from terminal X2 e The unit may only be connected with the power supply switched off e Make sure that the frequency inverter is discharged 18 5 kW 30 0 kW PHOENIX MKDSP 25 6 15 00 F 2 5 Nm 0 5 35 mn 22 1 Ib in AWG 20 2 BEES 05 25mm AWG 20 4 1 00 25 mnt AWG 18 4 3
60. Therm Contact Selection 15 4 5 278 Operating Instructions ACU 06 13 vv Bonfiglioli No Description Unit Setting range Chapter 237 Reset memory Selection 19 3 369 Motor Type Selection 8 2 3 370 Rated voltage V 0 17 Ugw 2 Uriy 10 1 371 Rated current A 0 01 Igy 10 0 lfi 10 1 372 Rated speed U min 96 60000 10 1 V EX 373 No of pole pairs 1 24 10 1 Ej 374 Rated cosine Phi 0 01 1 00 10 1 375 Rated frequency Hz 10 00 1000 00 10 1 376 Rated mech power kW 0 1 Peiy 10 Pri 10 1 V E3 377 Stator Resistance mOhm 0 65535 10 2 1 V Eh 378 Leakage Coefficient 96 1 0 20 0 10 2 2 383 Voltage constant mVmin 0 0 850 0 10 2 5 384 Stator Inductance mH 0 1 500 0 10 2 6 389 Factor Actual Value System 100 000 100 000 11 1 397 Nominal volumetric flow m3 h 1 99999 11 2 398 Nominal pressure kPa 0 1 999 9 11 2 400 Switching frequency Selection 18 1 401 Min switching frequency Selection 18 1 405 Warning limit short term Ixt 6 100 13 1 406 Warning limit long term I xt 6 100 13 1 407
61. VTable in VPlus User defined Status word VTable 927 MUX Output lt 15 4 3 2 1 0 Multiplexer Y Parameter Index Assign signal sources iSystembus TxPDOI Word 950 t Mux input 1252 1 160 Standby message Transmitter Profibus PZD3_IN Word 1302 Mux input 1252 2 lt 163 Reference frequency reached Mux input 1252 3 lt 169 General warning Mux input 1252 4 lt 162 Error signal Systembus i eed Further a Further ss Profibus Systembus 704 RxPDO1 Word1 Profibus 754 OUT PZD3 Word Y l DeMux Input 1253 gt 15 4 3 2 140 Demultiplexer Signal sources 910 Output DeMux Bit 0 2 911 Output DeMux Bit 1 912 Output DeMux Bit 2 Receiver Standby message Reference frequency reached General warning L gt 913 Output DeMux Bit 3 Error signal 925 Output DeMux Bit 15 Settings on transmitter e n VPlus start application VTable via the button bar e n VTable assign the required signal sources for sending to parameter Mux in puts 1252 index 1 to index 16 a setting for index 0 results in this setting being taken over for all other indices e Assign a TxPDO process data parameter of the system bus or a PZDx IN process data parameter of Profibus to signal source 927 Output MUX Settings on receiver e Assign the co
62. X210B ten ida iania aae 71 288 Operating I nstructions ACU 06 13 vv Bonfiglioli 1 X2108 1234567 X210A 123456 Functions of the control terminals table out X10 sou Aepy INOES D u Aepy GND in TIJN UAU S 000 T64 42u17 2uu bumes Alope ANYS EL 9 42Un T LULL 8SL OL I 4240 2FUVYJ 12 DID TUL O3 PAUN c pequop uedo Ajeuuou o u peuo pasop Aj amp uuou D u 4ndino 3ndui feuomeauipiq ue se bumps opez Jdu uonpung niniw TIN pauenult Jeupis oug peeds 2U2 PJY papanu Jeubis oug en e s6bequequed jenpy EOLS Jo VOLS En 3ueuus6pejwoubpe JOU 4ndino Aejeu INOES andur ebeyo Go Andino Gojeue se bumes opez 3ndno uopuny ANN TOJN ando jeyHiq NOTS andu jey6iq ANIS NITS papau jJeubis oug Enba enje SHheyUSoed DUPY L 9 JO paads eouajSj9d 5 S To orod a 5 t TON fouanba jermy fouenbaJ Jeny fouenba Jenny x INOTS jeubis uny jeubis und jeubis und Z aNs quae pamo pe au3 gO 1S puau pamowpe Jou3 gO 1S puau pamowpe Jo13 gO1S T GNI9S PERUO JELLO Jo1olA PERUO jeuueun JO OW PLU JELLLEU JO OW ES em vopen Z DO vopen JNO vopen m Josuss pads o6ueup yes eq JOSUSS peads o6ueup es gead Josues paeds aie ripe g pen cL eno gpeg gT BNO gpeg S Josuss pads o6ueup Jes eq JOSUSS peads o6ueup es gead JOSUSS paeds
63. and Rb2 The parameter Trigger threshold 506 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 trigger threshold 506 Description ACU Min Max Fact sett 390 Trigger threshold 1000 0 V 780 The parameter Trigger threshold 506 is to be set in such a way that it is between the maximum DC link voltage which the mains can generate and the maximum ad missible DC link voltage of the frequency inverter Upe 1 1 42 lt Ud lt Ud pa If the parameter Trigger threshold 506 is set larger than the maximum admissible DC link voltage the brake chopper cannot become active the brake chopper is switched off If the parameter Trigger threshold 506 is set to a value below the DC link voltage generated by the mains error message F0705 chapter Error Messages is dis played if the start command is issued to the frequency inverter If the DC link voltage exceeds the maximum value of 400 V for the ACU 201 series of devices or 800 V for the ACU 401 series of devices the error message F0700 is dis played chapter Error Messages The sampling time of the function is 125 us The brake chopper remains on for at least 125 us after the set trigger threshold was exceeded even if the value drops below the trigger threshold within this period again U 4
64. because of the factory setting Op Mode Digital Output 3 532 103 Inv Error Signal Inv inverted g a After successful initialization of the frequency inverter the factory set parameter Actual frequency 241 is displayed bl us The drive is accelerated to the set min frequency 418 factory setting 3 50 Hz in configurations 110 111 410 411 430 or to 0 00 Hz in configurations 210 211 230 510 by e signals at digital inputs S1IND STOA and S7IND STOB and e Start clockwise by rising signal edge at S21ND or Start anticlockwise by rising signal edge at S3IND Status signals 1 Indicates initialization and operating readiness of the 160 Ready Signal inverter 1 Ready or 2 Indicates initialization and operating readiness of the Standby Signal inverter 161 1 Indicates enable and start command output frequen Run Signal cy available 2 2 Indicates enable and start command output frequen cy available 162 Error Signal 1 Monitoring function signalizes a fault with display in 3 2 parameter Current Error 259 D For linking with inverter functions 2 For digital output 8 2 12 Selection of an actual value for display After commissioning the value of parameter Actual frequency 241 is displayed at the control unit KP500 If another actual value is to be displayed after a restart make the following settings e Use the arrow keys to select the actual val
65. behavior in op 3 taking over and storing dr tion mode 1 and2 Motorpoti MP l latching 2 taking over The Function Motorpoti MP is to be parameterized via the parameter Reference frequency source 475 or Reference percentage source 476 Frequency reference channel Via the digital control inputs the required functions Frequency motorpoti up 62 and Frequency motorpoti down 63 are triggered Limitation of the reference values is affected via parameters Minimum frequency 418 and Maximum frequency 419 Reference percentage channel Via the digital control inputs the required functions Percentage motorpoti up 72 and Percentage motorpoti down 73 are triggered Limitation of the reference values is affected via parameters Minimum percentage 518 and Maximum percentage 519 Motorpoti KP The function Motorpoti KP is only available in the reference frequency channel The function and its link to other reference value sources can be selected via param eter Reference frequency source 475 Via the keys of the control unit KP 500 the required functions Frequency motorpoti up 62 and Frequency motorpoti down 63 are triggered Limitation of the reference values is affected via parameters Minimum frequency 418 and Maximum frequency 419 Control is performed as described in chapter PE em EN Control unit KP500 Controlling the Motor via the control unit If the function Motorpoti KP is activated inPF will be
66. by comparison between the calcu lated machine model and speed sensor 2 of an expansion 5 Speedtracking EC 2 module to increase speed accuracy Can be set in configu rations 4xx and 6xx Adjustment for parameter ntegral Time Speedtracking 515 is considered 1 Only available if expansion module is installed The control of the torque forming current components is done in the outer control loop by the speed controller Via parameter Operation mode 720 you can select the operation mode for the speed controller The operation mode defines the use of the parameterizable limits These are referred to the direction of rotation and the direc tion of the torque and depend on the selected configuration 0 Speed controller off The controller is deactivated or the torque forming component is zero The limitation of the speed controller assigns the up s per limit to the motor operation of the drive Inde Limits ips EE pendent of the direction of rotation the same limit is motor generator ne used The same applies in the case of regenerative peration with the lower limit The assignment of the limit is done by the sign of the Limits value to be limited Independent of the motor or gen pos neg torque erator operating points of the drive the positive limi tation is done by the upper limit The lower limit is regarded as a negative limitation 232 Operating I nstructions ACU 06 13 vv Bonfiglioli Operation mo
67. clockwise taf 15s 100 ms 15 1s E tur acceleration time ramp rise time Operating Instructions ACU 165 69 Bonfiglioli 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 The behavior Gradient percentage ramp 477 corresponds to a function which takes the time behavior of the drive system into account If the parameter is set to 0 s this function is deactivated and a direct reference value modification for the following function is obtained The default value depends on the Configuration 30 No Description Min Max Fact sett 60000 s 14 9 Block Frequencies 166 In certain applications it is necessary to fade out reference frequencies In this way resonance points of the system as stationary operating points are avoided The pa rameters Ist block frequency 447 and 2nd block frequency 448 with the parameter Frequency hysteresis 449 define two resonance points A block frequency is active if the parameter values of the block frequency and the frequency hysteresis are not equal to 0 00 Hz The area faded out as a stationary working point by the hysteresis is passed through as quickly as possible according to the ramp set If the output frequency is limited as a result of the selected control parameter settings e g if the cur
68. coefficient 96 100 0 00 300 00 18 7 2 467 Adjusting temperature deg C 50 0 300 0 18 7 2 469 Reference orientation 0 0 359 9 12 6 2 471 Positioning frequency Hz 1 00 50 00 12 6 2 472 Max positional error 0 1 90 0 12 6 2 473 Ramp Keypad Motorpoti Hz s 0 01 999 99 14 10 3 474 Operation mode Selection 14 10 E 475 Reference frequency source Selection 14 4 476 Reference percentage source Selection 14 5 280 Operating I nstructions ACU 06 13 vv Bonfiglioli No Description Unit Setting range Chapter 477 Gradient percentage ramp s 0 60000 14 8 478 Actual percentage source Selection 17 3 EI 479 time constant positioning contr ms 1 00 9999 99 12 6 2 480 Fixed frequency 1 Hz 999 99 999 99 14 6 1 481 Fixed frequency 2 Hz 999 99 999 99 14 6 1 482 Fixed frequency 3 Hz 999 99 999 99 14 6 1 483 Fixed frequency 4 Hz 999 99 999 99 14 6 1 489 OG frequency Hz 999 99 999 99 14 6 2 69 490 Operation mode Selection 10 4 1 amp 491 Division Marks 1 8192 10 4 2 69 496 Operation mode Selection 14 11 497 Divider 1 8192 14 11 225 1000 0 201 306 rigger thresnola
69. current 96 1 00 100 00 12 5 648 Amplification 0 00 10 00 12 5 649 Integral time ms 0 1000 12 5 651 Operation mode Selection 12 4 652 PWM Offset 96 100 00 100 00 14 11 653 PWM Amplification 96 5 0 1000 0 14 11 EX 660 Operation mode Selection 17 4 1 Ej 661 Amplification 0 0 300 0 17 4 1 662 Max Slip Ramp Hz s 0 01 650 00 17 4 1 663 Minimum Frequency Hz 0 01 999 99 17 4 1 670 Operation mode Selection 17 2 671 Mains failure threshold V 200 0 50 0 17 2 672 Reference mains support value V 200 0 10 0 17 2 673 Mains support deceleration Hz s 0 01 9999 99 17 2 674 Acceleration on mains resumption Hz s 0 00 9999 99 17 2 675 Shutdown threshold Hz 0 00 999 99 17 2 225 387 5 201 676 Reference shutdown value V 425 715 401 17 2 677 Amplification 0 00 30 00 17 2 678 Integral time ms 0 10000 17 2 225 387 5 201 680 Reference DC link limitation V 425 775 401 17 2 681 Max frequency rise Hz 0 00 999 99 17 2 683 Gen ref current limit A 0 0 0 len 17 2 Operating I nstructions ACU 283 Goo Bonfiglioli 284
70. depends on the stator resistance In contrast to field oriented control systems sensorless control systems feature a current controller which controls the starting behavior The PI controller checks the current impression by parameter Starting current 623 The proportional and inte grating parts of current controller can be adjusted via parameters Amplification 621 and Integral time 622 respectively The control functions can be deactivated by setting the parameters to 0 Description x Fact sett L Amaifcson i 00 1 00 30000 ms 50ms 06 13 Operating I nstructions ACU 135 G Bonfiglioli 12 1 1 1 Starting Current The Starting current 623 ensures particularly for high torque start a sufficient torque until the Frequency limit 624 is reached Applications in which high current is permanently needed at a low speed are to be realized using forced ventilated motors to prevent thermal overload Description Min Max Fact sett m len Nominal Output current of Frequency inverter o Overload capability of Frequency inverter In the following settings the starting current impression is used for the starting be havior Configuration 30 1xx V f control of asynchronous motor Operation mode 620 2 4 12 or 14 Configuration 30 4xx FOC of an asynchronous motor Configuration 30 610 PMSM sensor less field orientated control DMC syn chronous motor 12 1 1 2 Frequency Limit The Star
71. dis EEE played for clockwise forward direction of rotation and inPr for anticlockwise reverse direction of rotation n eL RUN n Operating Instructions ACU 06 13 vv Bonfiglioli The keys on the control unit have the following functions A V Increase reduce frequency ENT Reversal of the sense of rotation independent of the control signal on the terminals Clockwise S21 ND or Anticlockwise S3l ND ENT Save the selected function as default value The direction of rotation is not 1sec changed ESC Cancel function and return to the menu structure FUN Switch from internal reference value inP to JOG frequency the drive will start Release the key to switch to the sub function and stop the drive RUN Start drive alternative to control signal S21 ND or S3IND STOP Stop drive alternative to control signal S21 ND or S3I ND 14 10 3 Controlling the Motor via the Control Unit The function Reference frequency source 475 enables linking of the reference sources in the reference frequency channel The operation modes can be set without the function Motorpoti KP If an operation mode without Motorpoti KP is selected a connected motor can be controlled via the keys of the control unit KP 500 The function is activated as described in chapter Control Unit KP500 Controlling the Motor via the Control Unit The speed of the modification of the reference value is limited by the parame
72. easily The configuration of the reference percentage source and the assignment of the actual percentage source are to be considered Structural image Technology Controller Technology controller Reference Q p m percentage source 476 Actual values Actual percentage value 230 Actual percentage source 478 Reference percentage value 229 Comply with the following chapters of the manual Parameter Chapter Controller reference value Reference Percentage Source 476 14 5 Reference percentage channel Monitoring of the current controller reference value Reference Percentage Value 229 19 1 Actual Values of the Frequency In verter Controller actual value Actual Percentage Source 478 is 17 3 Technology Controller Analog signal at multifunction input Operation Mode 452 15 1 Multi Function Input MFI1 Frequency signal at a digital input Operation Mode 496 14 11 PWM repetition frequency input Monitoring of the current controller actual value Actual Percentage Value 230 19 1 Actual Values of the Frequency In verter For the reference value the technology controller also demands the assignment of an analog application figure with the parameter Actual percentage source 478 The dif ference between reference and actual value is used by the technology controller to control the drive system The measured actual value is mapped via a signal converter onto the input signal of
73. elements e Sort and dispose of other component materials Electric scrap electronic components lubricants and other utility materials must be treated as special waste and may only be disposed of by specialized companies LKY In any case comply with any applicable national disposal regulations as regards envi GO ronmentally compatible disposal of the frequency inverter For more details contact the competent local authorities 22 Operating I nstructions ACU 06 13 Bonfiglioli Vectron 2 11 Safety Instructions on Function Safe Torque Off STO 06 13 The function Safe Torque Off STO is a functional safety provision i e it protects staff from damage provided that projecting installation and operation are performed properly This function does not disconnect the plant from power supply To disconnect the plant from power supply for example for service purposes an Emergency Stop circuit according to EN 60204 has to be installed For maintenance work a provision must be provided for disconnecting the plant from power supply Improper installation of the safety technique can cause an uncontrolled starting of the drive This may cause death serious injuries and significant material damage Safety functions may only be installed and commissioned by qualified staff The STO function is not suitable for emergency switch off as per EN 60204 An emer gency switch off can be realized by installing a mains c
74. error message is displayed again enter the value 110 for parame ter Configuration 30 sensorless regulation according to U f characteristic if value 410 was set so far Carry out the guided commissioning once for proper connection and check the contacts for corrosion and safe con tact Repeat the parameter identification SF022 The measurement of the rotor resistance did not deliver a plausible value Check the cables at the terminals of the motor and the frequency inverter for proper connection and check the contacts for corrosion and safe con tact Repeat the parameter identification SF026 The setup routine is aborted SF021 The measurement of the stator resistance did not deliver a plausible value Check the cables at the terminals of the motor and the frequency inverter 110 Operating Instructions ACU 06 13 Bonfiglioli Vectron 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 gt 999 are displayed hexadecimal at the leading digit 999 A00 B5 C66 8 2 10 1 Acceleration and deceleration The settings define how fast the output frequency changes after a reference value c
75. expansion cards No Description Function 222 DC Link Voltage Direct voltage in the DC link Output voltage of the frequency inverter relative to eee the mains voltage 100 Urun m Sum of the Frequency reference value sources 475 as 228 Internal ref frequency a reference value from the frequency reference value channel Sum of the Reference percentage sources 476 as a 229 Reference percentage reference value from the reference percentage chan nel Actual percentage val Actual value signal on the Actual percentage source 230 ue 478 Decimally coded status of the six digital inputs and of Digital Inputs Hard multifunctional input 1 in Operation Mode 452 digi ware tal input Displays the status of the physical inputs See also Digital Inputs 250 Operating hours in which the output stage of the in verter is active 245 Operation hours coun Operating hours of the frequency inverter in which ter supply voltage is available The data set actively in use according to Data set zii change over 1 70 and Data set change over 2 71 Decimally coded status of the six digital inputs and of multifunctional input 1 in Operation Mode 452 digi tal input Depending of the setting of parameter Lo cal Remote 412 the hardware signals or Fieldbus Systembus signals are displayed See also Digital Inputs Hardware 243 Input signal on multifunctional input 1 in analog Op 251 Analog input MFI1A ration mode 452
76. factory settings of the machine parameters are based on the nominal data of the frequency inverter and the corresponding four pole three phase motor The entered and calculated machine data are checked for plausibility during the guided commissioning procedure The user should verify the factory set rated data of the three phase motor Urun run Prun are rated values of the frequency inverter No Description Min Max Fact sett 370 Urun 371 Irun 372 Nn 374 cos o v 375 50 00 376 Prun e Use the arrow keys to select the required parameter and edit the parameter val ue e Use the ENT key to confirm the selected parameter and the parameter values entered The rated data of the motor are to be entered according to the specifications on the rating plate for the motor connection type used star or delta connection If the data entered deviate from the rating plate the parameters will not be identified correctly 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 370 Rated voltage 400 V 230 V 371 Rated current 3 7A 6 4A 372 Rated speed 1410 mint 1410 min 374 Rated cosine Phi 0 77 0 77 375 Rated frequency 50 Hz 50 Hz 376 Rated mechanical power 1 5 kW 1 5 kW Operating I nstructions ACU 105 G Bonfi
77. input or output 6 21 3 Controller Status 272 The controller status can be used to establish which of the control functions are ac tive If a several controllers are active at the time a controller code composed of the sum total of the individual codes is displayed The display of the controller status by the control unit and the light emitting diodes can be parameterized via the Controller status message 409 TOM free Controller code Controller abbreviation C 00 00 C 00 01 UDdyn Voltage controller is in the rise phase according to Operation mode 670 The output frequency in the case of a power failure is below C 00 02 UDstop t Shutdown threshold 675 Failure of the mains voltage and power regulation active ac odio cording to Operation mode 670 of the voltage controller C 00 08 UDlim The DC link voltage has exceeded the Reference UD limita tion 680 C 00 10 Boost The Dyn voltage pre control 605 accelerates the control system C 00 20 Ilim The output current is limited by the current limit value con troller or the speed controller C 00 40 Tlim pu power or the torque is limited by the speed con C 00 80 Tctr Switch over of field orientated control between speed and torque controlled control method C 01 00 Rstp The Operation mode 620 selected in starting behavior limits the output current C 02 00 IxtLtLim Overload limit of the long term xt 60s reached intelligent current limits active C 04 00 IxtStLim Overload limit
78. laws on work on electrical equipment plants of the country when the frequency inverter is used e The cables connected to the frequency inverters may not be subjected to high voltage insulation tests unless appropriate circuitry measures are taken before e Only connect the frequency inverter to suitable supply mains 20 Operating I nstructions ACU 06 13 2 vv Bonfiglioli 10 5 1 The five safety rules When working on in electrical plants always follow the five safety rules 1 2 3 4 5 2 Isolate Secure to prevent restarting Check isolation Earth and short circuit Cover or shield neighboring live parts 10 6 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 Check the additional monitoring and protective devices according to the applicable na tional and international safety directives During operation never open the machine plant Do not connect disconnect any components equipment during operation The machine plant holds high voltage levels during operation is equipped with rotating parts fan and has hot surfaces Any unauthorized removal of covers improper use wrong installation or operation may result in serious injuries or material damage Some components e g th
79. limit 999 99 Hz 999 99 Hz 999 99 Hz Positive values limit the speed in clockwise direction negative values limit the speed in anticlockwise direction In example if both values are positive gt 0 Hz anticlock wise movement is inhibited If the torque control is activated while the actual frequency lies outside the defined range of Frequency Upper Limit 767 and Frequency Lower Limit 768 in example when switching on a stopped machine or when the Flying start synchronizes the allowed frequency is driven to without ramps The torque is only limited by the limita tions of the speed controller current and torque Therefore an unexpected dynamic behavior can occur Operating I nstructions ACU 06 13 vv Bonfiglioli 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 reference percentage 518 and Maximum reference percentage 519 but does not consider the Gradient percentage ramp 477 of the reference percentage value chan nel The assignment is done for the torque controller via parameters Frequency upper limit source 769 and Frequency lower limit source 770 The source is the multifunctional input 1 in ana cL a log Operation mode 452 T The selected parameter values are taken into ac ere ae count to limit the speed controller 201 Inv analog input MFI1A Operation mod
80. mains impedance gt 1 see chapter Electrical installation 3 Maximum current in continuous operation 38 Operating I nstructions ACU 06 13 Bonfiglioli 4 10 ACU 401 37 0 to 65 0 kW 400 V ACU 401 fs ll ae lle Se ee 39 Construction Size ee Recommended motor shaft Output current Long term overload current 60 s Short time overload current 1 s Output voltage Protection Rotary field frequenc ENE Short circuit earth fault T f H 1000 depending on switching frequenc 2 4 8 Min brake resistance Recommended brake resistor Uagc 770 V Mains current 3ph PE 1 a 8 0 1040 10 0 1200 Mains voltage ui v 320 28 Mains frequenc f Hu 45 Fuses fal wo s 35 15 UL type 600 VAC RK5 A 10 125 125 125 Dimensions 400x275x260 Degree of protection 1P20 EN60529 Terminals A mm up to 70 Form of assembly vertical Energy 2 kHz switching frequenc Coolant temperature Storage temperature Transport temperature Rel air humidit d 15 85 not condensing If required by the customer the switching frequency may be increased if the output current is reduced at the same time Comply with the applicable standards and regulations for this operating point Switching frequency 5 kW 1 Three phase connection requires a commutating
81. marks ssssee 130 Evaluation snee 128 132 Gear factor ete tetto 131 MOMONING zai ter e Ehe ho Cu Rn PER YR nuage 253 Speed sensor connection ssss 58 SS Status messages auto setup 108 Start anticlockwise 196 Start clockwise t tre b 196 Starting behavior 134 Stopping behavior ecer 138 sni rre EE 20 T Technical Data sssssseeeee 30 Technology Controller 216 Temperature adjustment 252 Temperature measurement 252 Thermal contact 73 197 Three wire Control eccere 196 Mu 197 201 Tolerance band ssssseseeeeees 174 Torque controller 229 Torque Reference 230 TRAINS DOTS c 20 Traverse function s c 254 U UL Approval iie tet ere ie 30 User warning ecer 200 V V f characteristic e 208 Voltage controller sssesess 211 Voltage Input iuueni Potente 72 Volume flow control 133 263 Volumetric flow control s 220 Ww Warning code of Application warning mask 191 of warning mask sssssss 188 189 Warning miasKusuiioec tie een tico es 187 Warning messages sessseeeee 213 of auto set up 108 Warning Status 213 ApplicatiQn 2 3 i certet tta dete neas 213 Warranty and liability esssssssss 12 X X2 TO iic daaa aa A aA A 71
82. ms The influences on the positioning which depend on the operating point can be cor rected empirically via the Load correction 462 parameter If the required position is not reached the deceleration duration is increased by a positive load correction val ue The distance between the reference point and the required position is extended Negative values accelerate the braking process and reduce the positioning distance The limit of the negative signal correction results from the application and the Posi tioning distance 460 Description Min Max Fact sett 32768 H 0 06 13 Operating I nstructions ACU 145 G Bonfiglioli 146 The behavior of the positioning after the required position of the drive is reached can be defined via the Activity after positioning 463 parameter eee The drive is stopped with the stopping behavior 0 End positioning of Operation mode 630 The drive is stopped until the next signal edge 1 Wait for positioning signal with a new edge of the position signal it is ac celerated in the previous direction of rotation The drive is held until the next signal edge with 2 Reversal by new edge a new edge of the position signal it is accelerat ed in the opposite direction of rotation none The drive is stopped and the power output stage J Positioning ot of the inverter is switched off The drive is stopped for the Waiting time 464 4 Start by time control after the waiting time it is
83. must be installed upstream on mains side of the frequency inverter The frequency inverters meet the requirements of the low voltage direc tive 2006 95 EC and the requirements of the EMC directive 2004 108 EC The EMC prod uct standard EN 61800 3 relates to the drive system The documentation provides information on how the applicable standards can be complied if the frequency invert er is a component of the drive system The declaration of conformity is to be issued by the supplier of the drive system Operating I nstructions ACU 51 69 Bonfiglioli 6 2 52 Block diagram X10 CPU dizi 5 410 V 4 mA MF A j 9 a e 7 GND 10 V Q Relay connection S30UT Change over contact response time approx 40 ms make contact AC 5 A 240 V DC 5 A ohmic 24 V break contact AC 3 A 240 V DC 1 A ohmic 24 V Voltage output input Bidirectional DC 20 V voltage output 1 442180 mA or input for external power sup ply DC 24 V 10 9 Digital input S11 ND STOA Digital signal STOA 1st shutdown path for safety function STO Safe Torque Off response time approx 10 ms On 10 us Off Umax DC 30 V 10 mA at DC 24 V PLC compatible Digital inputs S2IND S61ND Digital signal response time approx
84. of rotation Operation modes 1 4 and 5 define a direction of rotation for the search run and avoid a deviating direction The search run can accelerate drives by checking the rotary frequency if the drives have a low moment of inertia and or a small load mo Search Dir acc to 1 Preset Val DCB First clockw 2 then anticlockw DCB First anticlockw Quick Synchroniza 19s tion 11 142 Operating I nstructions ACU 06 13 06 13 vv Bonfiglioli 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 The direction of rotation is defined in operation modes 11 14 and 15 The synchronization changes the parameterized starting behavior of the selected configuration First the start command activates the search run in order to determine the rotary frequency of the drive In operation modes 1 to 5 the Current Rated motor current 647 is used for synchronization as a percentage of the Rated cur rent 371 No Description Min Max Fact sett 647 Current Rated Motor Current 1 00 96 100 00 96 70 00 96 The sensor less control is extended for the search run by a PI Controller which regu lates the parameterized Current Rated Motor Current 647 The proporti
85. of the short term Ixt 1s reached intelligent current limits active Max heat sink temperature TK reached intelligent current C UB 00 Tom limits of Operation mode 573 active C 10 00 PTClim Max motor temperature reached intelligent current limits of Operation mode 573 active The reference frequency has reached the Maximum frequen C 20 00 Flim Tu cy 419 The frequency limitation is active Example The controller status is displayed C0024 UDctr I lim The controller status results from the hexadecimal sum of the controller codes 0004 0020 0024 At the same the power failure regulation and also the current limitation of the speed controller are active Operating Instructions ACU 06 13 vv Bonfiglioli 21 4 Warning Status and Warning Status Application 06 13 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 If several warnings are present the warning status is displayed as the sum of the individual warning codes The warning masks created through parameters Create warning mask 536 and Cre ate warning mask application 626 have no influence on the warnings displayed Via the actual value parameters Warning 269 Application Warnings 273 Warning status 356 in error environment and Warning status application 367 in
86. or switching back to the previous menu within the menu structure Canceling the function or resetting the pa rameter value FUN Used for switching over the key function access to special functions Three digit 7 segment display to show the parameter number 9 One digit 7 segment display for display of the active data record direction of rotation etc Display of the selected menu branch Display actual values PARA _ Select parameters and adjust parameter values Select a function for adjustment and or display via the operating unit SEtUP guided commissioning CtrL_ motor potentiometer and jog function Copy parameters via the control unit ALL X Allthe parameter values are copied Act Active parameter values are copied only FOr Control unit memory is formatted and deleted 3 Status and operating messages WARN Warning about a critical operating behavior AULT Message indicating that the unit was switched off due to a fault Flashing signals readiness for operation Lights up signals that the unit is operating and the output stage is enabled Active remote control via interface connection Function switch over with the FUN key Five digit 7 segment display for display of parameter value and sign Physical unit of the parameter value displayed Active acceleration or deceleration ramp Current direction of rotation of the drive O lt gt J r and n 20 m rm c 2 eeceovo
87. speed and torque performance X210A 1 X210A 2 X210A 3 X210A 4 X210A 5 X210A 6 X210A 7 Voltage output 20 V or input for external power supply DC 24 V 10 GND 20 V GND 24 V ext Digital input STOA 1st shutdown ath of safety function STO Start of clockwise operation Start of anticlockwise operation Data set change over 1 Data set change over 2 X210B 1 X210B 2 X210B 3 X210B 4 X210B 5 X210B 6 X210B 7 Motor thermal contact Digital input STOB 2 shutdown ath of safety function STO Run Signal Analog signal of actual frequenc Supply voltage 10V for reference value potentiometer Reference speed 0 10V Ground 10 V Operating I nstructions ACU 81 G Bonfiglioli 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 Change over between variable speed control and torque dependent control is done jerk free during operation X210A 1 Voltage output 20 V or input for external power supply DC 24 V 10 GND 20 V GND 24 V ext Digital input STOA 1st shutdown ath of safety function STO Start of clockwise operation n M change over control fu
88. such as flow rate pressure filling level or speed Configuration 630 Sensorless Field Orientated Control 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 Change over between variable speed control and torque dependent control is done jerk free during operation Operating I nstructions ACU 06 13 v Bonfig In the table you will find a list of functions which are available in the different configurations lioli V f Character field oriented control istic Sensorless Sensorless Sensor 36x Servo Servo sen lxx Axx 5XX sorless 6xx 110 112 410 412 430 210 211 230 510 530 610 611 630 Speed control 154 x x x x x x x x x x Torque control u52 x xr x x C e TTT ETT TL PTT torque control cere pe BE control Intelligent current limits Nl x x x fx xi xix x x X Voltage controller H e p a X Technology controller a173 x x Ix 1 kx presuecnrol 173 x x tx fx Volume flow control azs x pL ob l x Contents level control 323 Dx E Ex T pp qob TL oj Speed control 173 x txt txt fx Slip compensation pirat x j j tt Curre
89. the Warning Limit Heat Sink Temp 407 Heat sink temperature reached Max inside temperature T of 65 C minus the Inside temperature Warning Limit Inside Temp 408 reached Warning behavior according to parameterized motor temperature T prc ings 269 The selected limit values Warning Limit Heat Sink Temp 407 Warning limit Inside Temp 408 or the maximum motor temperature has been exceeded Failure of the mains voltage and power regula 13 Mains Failure tion active according to Operation Mode 670 for the voltage controller Warning Motor Protect Parameterized Operation Mode 571 for the mo 14 5 A Switch tor protection switch has triggered 15 Warning Current Limitation A controller or the Operation Mode 573 of the intelligent current limits limits the output current Long Term Ixt and the output current is being limited Short Term Ixt and the output current is being limited Max heat sink temperature TK reached intelli 18 Controller Current Limit TK gent current limits of Operation mode 573 ac tive Motor Temp rent limits of Operation Mode 573 active 12 Warning overtemperature 20 Comparator 1 The comparison according to the selected Op P eration mode Comparator 1 540 is true The comparison according to the selected Op oh Comparator eration mode Comparator 2 543 is true 180 Operating I nstructions ACU 06 13 vv Bonfiglioli Warning V belt rdg of Operation Mode 581 of V belt moni f The selec
90. the speed control The torque control is usable above the Frequency Limit 624 Below the Frequency Limit 624 the current impres sion is active with the current reference frequency as reference value In this case the torque is not controlled but results depending on the load and the Starting cur rent 623 To achieve a starting in torque control the reference frequency should be set higher than Frequency Limit 624 This is guaranteed in example by setting Min imum frequency 418 gt Frequency Limit 624 f Frequency Limit 624 Current impression f 2 Frequency Limit 624 Direct Torque Control The Frequency Limit 624 is set automatically during the motor setup 06 13 Operating I nstructions ACU 229 Go Bonfiglioli 17 5 3 1 Torque Reference The reference torque can be specified as follows Set parameter n T Control Change Over 164 to 6 On or link it to a digital signal and switch this on Via parameter Reference Percentage Source 1 476 or Reference Percentage Source 2 494 select a source for the reference torque For example The reference torque can be set via the arrow keys of the operator panel if the following setting is selected Reference Percentage Source 2 494 5 keypad motorpoti factory setting The reference torque can be set via multifunction input 1 MFI1A if the following setting is selected Reference Percentage Source 1 476 1 analog value MFI1A factory setting 100 Tor
91. the timer can be assigned to an inverter function or to a digital output By default Data Set Change Over 1 is linked to Timer 1 and Timer 2 is not linked Note The factory setting is Time 2 Timer 1 792 0 Signals at digital input SAIND are transmitted to the Data Set Change Over 1 without time delay Function Parameter for Operation mode Time constant Function output input signal signal Operation Mode Time 1 Timer 1 791 158 Tier d inert ga Timer 1 790 Time 2 Timer 1 792 23 2 Tels Operation Mode Time 1 Timer 2 794 159 _ TIRE 2 iene et Timer 2 793 Time 2 Timer 2 795 24 2 Tee For linking with inverter functions 2 For digital output Operating I nstructions ACU 201 Goo Bonfiglioli 15 5 1 1 Timer Time Constant 202 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 Select operation mode for Set time constants in Operation Mode Timer 1 790 Time I Timer 1 791 Time 2 Timer 1 792 Operation Mode Timer 2 793 Time I Timer 2 794 Time 2 Timer 2 795 signal delay signal duration signal delay signal duration No DESEDIDHON X Fact sett 791 0 00 s m h 792 0 0
92. tion Warnings 274 in which the respective feedback can be readout as a hexadecimal code and without text Please refer to the Communication manuals The actual values can be read out and monitored in the VAL menu branch of the oper ating unit The parameter Operation level 28 in the PARA menu branch defines the selection of the actual value parameters The digital inputs may seem deactivated in the actual value display 243 250 con stant 0 This can be caused by the used configuration or used functions in example encoder or frequency input S2IND PWM Rep freq input S4I ND Track B Encoder 1 S5 ND Track A Encoder 1 S6IND Track Z Encoder 1 or PWM Rep freq input MFI1 Analog input Settings For Encoder 1 check Parameter Operation mode 490 For PWM Rep Freq input check Parameter Operation mode 496 For MFI1 check Parameter Operation mode 452 Actual value Encoder 1 Frequency is displayed in 217 speed in 218 PWM Rep freq input PWM is displayed in 258 frequency in 252 Operating I nstructions ACU 06 13 vv Bonfiglioli 19 1 1 STO Status 06 13 Parameter STO Status 277 can be used for an extended diagnosis of the two digital inputs STOA and STOB The states of the inputs are bit coded displayed 0 1 Input STOA is missing 1 2 Input STOB is missing 2 4 Switch off input STOA 3 8 Switch off input STOA 4 16 Timeout STOA 5 32 Timeout STOB 6 6
93. 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 No Description Min Max Fact sett 1193 EC1 Filter time constant 0 us 32000 us Operating I nstructions ACU 131 Go Bonfiglioli 10 5 Sensor evaluation 132 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 A division mark is defined as a pulse including the pause following the pulse the pulse duty factor is typically 1 1 i e with each revolution a track delivers the number of increments for evalua tion Depending on the characteristics of the sensor and the requirements in the machine different degrees of sensor evaluation accuracy are possible Typical eval uation accuracy levels include Single evaluation One edge of a pulse of a track is counted and evaluated Double evaluation Two edges the positive and the negative edge of a pulse of a track are counted and evaluated Quadruple evaluation A second offset track delivers additional edges which can be evaluated Any status change of the two tracks is registered and evaluat ed Thanks to the offset arrangement of the tracks the direction of rota
94. up are stored Complete Setup w o 1 in data set 3 Extended motor data are not meas Para Ident DS3 red Complete Set p wio The parameter values of the auto set up are stored 11 p p in data set 4 Extended motor data are not meas Para Ident DS4 ured The additional motor data also contain values of the current controller settings The individual steps of the auto set up routine can be monitored and checked via parameter SETUP Status 797 The setup routine via the communication interface continuously updates the status parameter which can be read out via the interface For the status message of the Auto set up comply with e Chapter 8 2 7 Status messages during commissioning SS e Chapter 8 2 8 Warnings during commissioning SA e Chapter 8 2 9 Error messages during commissioning SF 06 13 Operating I nstructions ACU 117 Goo Bonfiglioli 9 9 1 9 2 9 3 9 4 118 Inverter Data The series ACU frequency inverters are suited for a wide range of applications The modular hardware and software structure enables customer specific adaptation The available hardware functionality of the frequency inverter is displayed in the control unit and the optional control software VPlus The software parameters can be adjust ed to meet the requirements of the specific application Serial Number The Serial Number O is entered on the nameplate during the fabrication of the fre quency inverter Informat
95. used during the guided commissioning to set the limits for the Isq set value in the frequency inverter This serves the protection of the connected synchronous motor The value can be taken from the motor name plate or the motor data sheet Exceeding the values given by the motor manufacturer can lead to damages in the motor Operating Instructions ACU 06 13 vv Bonfiglioli No Description Min Max Fact sett 0 1192 Peak current 0 01 Trin ie 6 10096 len FIN len Nominal value of Frequency inverter 0 Overload capability of Frequency inverter 10 2 8 Change sense of rotation The parameter Change sense of rotation 1199 reverses the rotating direction of the motor 0 Off Motor rotates forward Motor rotates reverse clockwise anti clockwise Motor rotates reverse Motor rotates forward sii 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 The sense of rotation can only be changed while the output stage is inhibited With the parameter Change sense of rotation 1199 the sense of direction of the com plete system motor control and encoder evaluation is reversed Go G When the sense of direction is different betwee
96. values are set as 0 Hz The pulse pause relation is not 1 1 The repetition frequency output should be evalu ated therefore only with rising or falling edge in the evaluating device Description Min Max Fact sett SS Nens E 8192 1024 The frequency limit of fmax 150 kHz may not be exceeded in the calculation of the parameter Division marks 556 150000 Hz max 2d Frequency value 06 13 Operating I nstructions ACU 179 GW Bonfiglioli 15 3 Digital Outputs The Operation mode Digital output 1 530 and the relay output with the parameter Operation mode Digital output 3 532 link the digital outputs to various functions 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 ation mode 550 and linking via parameter Digital operation MFOI 554 0 Off Digital output is switched off 1 Ready or Standby Signal Frequency inverter is initialized and on stand by or in operation Signal enable STO S1IND STOA and 2 Run Signal S7IND STOB and a start command are present output frequency available Message is displayed via the parameter Current The Stator frequency 210 is higher than the reached reached the nternal reference frequency 228 Reached erence percentage 229 The Warning Limit Short Term Ixt 405 or Warn ing Limit Long Term Ixt 406 has been reached Max heat sink temperature T of 80 C minus 8
97. 0 596 the output frequency is guided to the Fixed frequency 441 This is done using the set Deceleration clockwise 421 The Fixed frequency 441 must be in the range between Minimum frequency 418 and Maximum frequency 419 If the Fixed frequency 441 is set to a value smaller than the Minimum frequency 418 the output frequency is guided to Minimum fre quency 418 The frequency will not drop below Minimum frequency 418 If the actual value is available again the controller continues operation automatically The Integral value is reset when the Actual value returns o e G YT o vt ia gt gt o o 9 9 E eae ul oO 3 pas pus LL LL o eo e v g S E E S 0 SO Soc e zzi max P Compon 442 Integral Time 445 Derivative Time 618 gt 0 5096 Amplification 444 x o o o 9 R g fe Q To x e S a VI gt MI 17HE o9 ew y gt 9g aN Y oN g YSS uc o O Y Y g 5 995 gt p ogge sete 0 5 929 o uid EREE EEEE RSS 5 06 13 Operating I nstructions ACU 221 Goo Bonfiglioli 222 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 0 596 the output frequency is guided to the Fixed frequency 441 This is done using the set Deceleration clockwise 421 If there is no contr
98. 0 s m h 794 0 00 s m h 795 0 00 s m h Examples of the timer function depending on the selected operation mode and the input signal Parameter Operation Mode Timer 1 790 or Operation Mode Timer 2 793 1 Input Factory sering Time 2 0 Output As soon as the positive signal edge is received at the input time 1 signal delay starts After the expiry of time 1 signal delay the output signal is switched on for time 2 signal duration In the settings of signal duration Time 2 Timer 1 792 0 and Time 2 Timer 2 795 0 the timer does not reset the output signal Parameter Operation Mode Timer 1 790 or Operation Mode Timer 2 793 2 Input dL Time 1 Time 2 Ub setting Time 2 0 Output As soon as the positive signal edge is received at the input time 1 signal delay is started If a positive signal edge is detected within time 1 signal delay time 1 starts again After the expiry of time 1 signal delay the output signal is switched on for time 2 signal duration In the settings of signal duration Time 2 Timer 1 792 0 and Time 2 Timer 2 795 0 the timer does not reset the output signal qooque Time not run out completely 29 Time run out completely Operating Instructions ACU 06 13 vv Bonfiglioli Parameter Operation Mode Timer 1 790 or Operation Mode Timer 2 793 3 Input Time 1 Timel Time 2 Output 1 As soon as the positive signal edge is received
99. 10 2 7 1193 EC1 Filter time constant us 0 32000 10 4 4 1199 Change Sense of Rotation Selection 10 2 8 06 13 Operating I nstructions ACU 285 G Bonfiglioli No Description Unit Setting range Chapter f EEPROM 0 16 1250 Mux Input Index write RAM 1733 15 5 4 EEPROM 0 16 1251 Mux Input Index read Di 1251 Mux Input Index read RAM 17 33 15 5 4 1252 Mux input Selection 15 5 4 1253 DeMux input Selection 15 5 4 1363 User warning 1 Selection 15 4 11 1364 User warning 2 Selection 15 4 11 1370 In F PDP word 1 Selection 18 9 1371 In F PDP word 2 Selection 18 9 1372 In F intern long 1 Selection 18 9 1373 In F intern long 2 Selection 18 9 1374 In F Convert Reference Hz 0 01 999 99 18 9 leading digit 999 A00 B5 C66 286 Operating I nstructions ACU At the control unit KP500 parameter numbers gt 999 are displayed hexadecimal at the 06 13 Index A Acceleration sess 163 Acceleration pre control ss 236 Actual value memory ree 261 Actual values of the frequency inverter 257 of the machine eere 260 of the system cese tes 262 Application warning mask 190 Axle positioning 147 B Block frequencies s e 166 Brake Control via digital output 186 DC braking nue etes 140 Brake Chopper 243 Brake release
100. 10A 5 X210A 6 X210A 7 Digital input STOB 2 shutdown 10 V 4 mA path of safety function STO MFI1A Run Signal GND 10 V Analog signal of actual frequenc 06 13 Operating I nstructions ACU 77 G Bonfiglioli 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 Change over between variable speed control and torque dependent control is done jerk free during operation X210A 1 Voltage output 20 V or input for external power supply DC 24 V 10 GND 20 V GND 24 V ext Digital input STOA 1st shutdown ath of safety function STO Start of clockwise operation n M change over control function Data set change over 1 Data set change over 2 X210A 2 X210A 3 X210A 4 X210A 5 X210A 6 X210A 7 X210B 1 Motor thermal contact X210B 2 Digital input STOB 2 shutdown ath of safety function STO Run Signal Analog signal of actual frequenc Supply voltage 10 V for reference value potentiometer Reference speed 0 10 V or ref erence torque as percentage value X210B 7 Ground 10 V X210B 3 X210B 4 X210B 5 X210B 6 78 Operating Instructions ACU 06 13 vv Bonfiglioli
101. 19 Winding temperature 226 gt tempera Temp Follow Up ture 100 C 9 DC Link Voltage DC Link Voltage 222 gt Direct voltage 1000 V 10 Abs isq Isq 216 gt Rated Current 371 11 Abs Filtered Active Current Active current 214 gt Rated current 371 12 Abs Internal Ref Frequency Internal Reference Frequency 228 gt Maximum Frequency 419 Reference Percentage Value 229 gt Maximum 13 Abs Ref Percentage Value Reference Percentage 819 14 Abs Actual Percentage Val Actual Percentage Value 230 gt Maximum ue Reference Percentage 519 15 Abs Analog Input MFI1A Analog Input MFIIA 251 gt input signal 100 96 100 to 107 111 112 Operation modes with signs The switch on and switch off thresholds for compactors 1 and 2 are set by the para meters Comparator on above 541 544 and Comparator off below 542 545 The percentage limits of the corresponding reference values are indicated No Description Min Max Fact sett 541 Comparator 1 On above 300 00 300 00 100 00 542 Comparator 1 Off below 300 00 300 00 50 00 544 Comparator 2 On above 300 00 300 00 100 00 545 Comparator 2 Off below 300 00 300 00 50 00 204 Operating I nstructions ACU 06 13 tv Bonfiglioli 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 1
102. 20 to 423 are maintained regardless of the selected ramp times Operating Instructions ACU 06 13 06 13 vv Bonfiglioli 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 With this method exceeding the reference values is avoided and a data set change over between extremely deviating values becomes possible No Desenpuon x Fact sett 430 0 ms 431 0 ms 432 Ramp rise time anticlockwise 0 ms 433 0 ms Ramp Fall Time Clockwise 431 Ramp Rise Time Clockwise 430 N Rotary field clockwise Rotary field anticlockwise Ramp Rise Time Anticlockwise 432 Ramp Rise Time Anticlockwise 433 Example Calculation of the acceleration time in clockwise rotation at an accel eration from 20 Hz to 50 Hz fmax and an acceleration ramp of 2 Hz s for parameter Acceleration clockwise 420 The Ramp rise time clockwise 430 is set to 100 ms Af tur acceleration time hu PUE clockwise rotary field r Af change of frequency 50 Hz 20 Hz acceleration ramp La 15s 2 Hz s ar Acceleration clockwise tat T baut t ty ty Ramp rise time
103. 3 Operating I nstructions ACU 241 Goo Bonfiglioli The parameter Local Remote 412 defines the operating behavior and enables a change between the control via contacts or the control unit and or the interface The Start and Stop commands as well as the direction 0 Control via Contacts Es of rotation are controlled via digital signals The Start and Stop commands as well as the direction of rotation are controlled via the DRIVECOM Statema chine of the communication interface The Start and Stop commands as well as the direction Control via remote s b 2 of rotation are controlled via logic signals through the contacts ee communication protocol Control via keypad The Start and Stop commands are controlled from the 3 dir of rot via con control unit and the direction of rotation is controlled tacts via digital signals Control via KP or The Start and Stop commands are controlled from the cont control unit or via digital signals The statement of the dir of rot via con direction of rotation only with the help of the digital tacts signals rot via contacts control 87 via contacts dir of rot via keypad of rotation are controlled via the control unit Control via KP or The Start and Stop commands are controlled from the cont control unit or via digital signals The statement of the dir of rot via con direction of rotation only with the help of the operating tacts unit The Start and Stop commands are controlled
104. 4 0 V 0 0 V Analog Operation 553 with abs act Analog operation 553 with signs value With the parameters Voltage 100 551 and Voltage 0 552 the voltage range at 100 and 096 of the output parameter is set If the output value exceeds the refer ence value the output voltage also exceeds the value of the parameter Voltage 100 551 up to the maximum value of 24V 178 Operating Instructions ACU 06 13 vv Bonfiglioli 15 2 2 Frequency Output MFO1F The multifunctional output MFO1 can be used as a frequency output in the setting of Operation Mode 550 z 3 Repetition Frequency The DC 24V output signal is as signed to the abs value of the speed or frequency via the parameter Repetition Freq Operation 555 The selection of the operation modes depends on the expan sion modules installed as an option 0 Off Repetition frequency operation MFO1 switched off l Actual Frequency Abs value of the Actual frequency 241 2 Stator Frequency Abs value of the Stator frequency 210 3 Frequency Speed Sensor 1 Abs value of the Encoder 1 Frequency 217 5 Repetition Frequency Input Abs value of the Repetition freq input 252 15 2 2 1 Scaling The repetition frequency mode for the multifunction output corresponds to the map ping of an incremental sensor The parameter Division marks 556 must be parame terized according to the frequency to be output The minimum frequency of the repe tition frequency operation is 30 Hz Lower
105. 4 Diagnosis error 7 128 Frequency inverter error Fault The signal statuses at the digital inputs STOA and STOB can be linked with inverter functions 292 STOA Signal status at digital input STOA 284 STOA inverted Inverted signal status at digital input STOA 293 STOB Signal status at digital input STOB 285 STOB inverted Inverted signal status at digital input STOB For further instructions refer to the application manual STO Safe torque off Operating Instructions ACU 259 G Bonfiglioli 19 2 Actual Values of the Machine 260 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 No Description Function The output voltage motor voltage of the frequency inverter Calculated effective output current motor current of the frequency inverter Calculated R m s figure of the phase to phase volt age motor voltage of the frequency inverter Active power calculated from the voltage the current and the control variables Active current calculated from the rated motor pa rameters the control variables and the current Current component of the field orientated control forming the magnetic flux Torque forming current component of field orientated control 21
106. 506 Trigger threshold V 425 1000 0 401 18 4 f 225 1000 0 201 3U Irigger thresnola JL 507 Trigger threshold V 425 1000 0 401 18 7 1 E3 510 Setting Frequency Hz 0 00 999 99 1532 511 EC1 Gear Factor Numerator 300 00 300 00 10 4 3 512 EC1 Gear Factor Denominator 0 01 300 00 10 4 3 515 Integral Time Speedtracking ms 1 60000 17 5 4 3 517 Setting Frequency Off Delta Hz 0 00 999 99 15 3 2 518 Minimum Reference Percentage 96 0 00 300 00 14 3 519 Maximum Reference Percentage 96 0 00 300 00 14 3 Fixed percentage 1 n 14 6 3 521 Fixed percentage 2 14 6 3 Fixed percentage 3 iss 14 6 3 Fixed percentage 4 14 6 3 530 Operation mode digital output 1 Selection 15 3 532 Operation mode digital output 3 Selection 15 3 535 Op Mode ext Error Selection 15 4 12 536 Create Warning Mask Selection 15 3 8 540 Operation mode comparator 1 Selection 15 5 2 541 Comparator On above 96 300 00 300 00 15 5 2 06 13 Operating I nstructions ACU 281 Goo Bonfiglioli No Description Unit Setting range Chapter 542 Comp
107. 7 Frequency Speed Sen Calculated from the data on speed sensor 1 the No sor 1 of pole pairs 373 and the speed sensor signal 218 Speed sensor 1 speed Calculation from speed sensor 1 frequency Difference from the synchronous frequency calculated from the rated motor parameters the control varia bles and the current Torque at the current output frequency calculated 224 Torque from the voltage the current and the control varia bles 225 Rotor flux Current magnetic flux relative to the rated motor parameters Measured temperature of the motor winding ac cording to Operation mode 465 for temperature ad justment Time constant calculated for the operating point of 227 Act rotor time constant the machine from the rated motor parameters the rated and control variables Voltage component of the field orientated control 235 Flux forming voltage forming the magnetic flux Voltage component of the field orientated control Totguesiprmind voltage forming the torque 238 Flux value Magnetic flux calculated according to the rated values and the operating point of the motor Reactive current calculated from the rated motor 239 Reactive current parameters the control variables and the current 240 Actual speed Measured or calculated speed of drive 241 Actual frequency Measured or calculated frequency of drive The actual values can be read out and monitored in the VAL menu branch of the oper ating un
108. 755 or the product of Rated magnetizing current 716 and Reference flux 717 The magnetizing current parameter forming the upper limit is to be set to the rated figure of the machine For the lower limit select a value which also builds up an adequate flux in the machine in the field weakening area The limitation of the control deviation at the output of the modulation controller prevents a possible oscil lation of the control loop in the case of load surges The parameter Control deviation limitation 756 is stated as an absolute value and acts both as a positive and a nega tive limit Description Min Max Fact sett FUN No i Reference I mr lower limit 0 0 ru 0 01 1 juu Control deviation limitation 0 00 96 100 00 96 10 00 96 Operating Instructions ACU 239 69 Bonfiglioli 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 240 The motor noises can be reduced by changing over the parameter Switching fre quency 400 A reduction of the switching frequency should be up to a maximum ratio of 1 10 to the frequency of the output signal for a sine shaped output signal The maximum possible switching frequency depends on the drive output and the ambient conditions For the required technical data refer to the corresponding table and th
109. 9 or 100 10096 of Maximum frequency 419 3 E 3 S2IND Repetition frequency input on terminal X210A 4 21 Single evaluation pos One edge of the frequency signal is evaluated with positive sign S2IND Repetition frequency input on terminal X210A 4 2 Double evaluation pos Both edges of the frequency signal are evaluated with a positive sign il S3IND Repetition frequency input on terminal X210A 5 3 Double evaluation pos Both edges of the frequency signal are evaluated with a positive sign S6IND Repetition frequency input on terminal X210B 1 61 Single evaluation pos One edge of the frequency signal is evaluated with positive sign S6IND Repetition frequency input on terminal X210B 1 62 Double evaluation pos Both edges of the frequency signal are evaluated with a positive sign Repetition Frequency Input Operation modes 21 121 to 162 to 62 with evaluation of the frequency signal but with a negative sign If a digital input is configured as a PWM or repetition frequency input this input cannot be used for other functions Check the link of the digital inputs to other functions 2 2 S3IND Repetition frequency input on terminal X210A 5 3 Sinale evaluati n nos One edge of the frequency signal is evaluated with g pos positive sign 2 170 Operating Instructions ACU 06 13 vv Bonfiglioli The signal frequency at the selected repetition frequency input can be scaled via the parameter Divider 497 Th
110. A 8LS eDejueojed 92U919J91 UIJAI uni o anjea aBejusoiad B eouaJeJed Sm ES 4 umop ezz enje eDejueojed spun eBejuao1eg nodioyo eBejuaojog eoueJejeH u01 8 01 jo uonosjes dois ueis einjsqy L6 J9pIAIq 96p opoui uonejedo I amp QNI9S wma lt QNIES NMa amp QN IZS INMd ouenboJj uonnedeu 94 p pow uornejodo 92unos oDejueo2Jed o2uo1J9J9H Operating I nstructions ACU 160 vv Bonfiglioli 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 source 475 or Reference percentage source 476 is parameterized to an operation mode with sign The direction of rotation can also be stated with the digital signal sources assigned to the parameters Start clockwise 68 and Start anti clockwise 69 The fixed reference values are to be parameterized in four data sets and are assigned to further sources via the reference value channel The use of the functions Data set change over 1 70 and Data set change over 2 71 thus enables the setting of 16 fixed reference values 14 6 1 Fixed Freq
111. AL csscsscsscsscnsccnccnsensensensensecssensensensensensensensensensenss 89 Parameter Menu PARA csscsscssccsscnsenseneensensecsensensensensensensensenssensensensens 90 Copy Menu CPY 1 ee erreur nennen nne n nnn n nnn n anna annua hana aane AEAEE 91 Reading the Stored Information sssssssssssee eem 91 Men StEUCtUE eus erdt eo rna e ue Ree pai ea Rd ERROR ER E E Nd 92 Selecting the SOUICE cece tenet etter tree rere t emen nennen enne enne 92 Selecting the Destination aiccein i cite nian AM 93 Copy Operators TEES 93 Eror i e po i e EI 94 Reading Data from Control Unit 1 eeee cessisse ee eeeeeee ener 95 Ded mem 95 Data tra STON Tor Tm 96 Resetting to Normal Operation et cette tt att dati o i ree deu a 97 Control Menu CTRL csccsscscccscnscnsccssonsensensensensensenssensensensensensensenssensensenses 97 Controlling the Motor via the Control Unit eeneeeeeerne 98 8 Commissioning 8 1 8 2 8 2 1 8 2 2 8 2 3 8 2 4 8 2 5 8 2 6 8 2 7 8 2 8 8 2 9 8 2 10 8 2 10 1 8 2 10 2 8 2 11 8 2 12 8 3 8 4 8 4 1 8 4 2 06 13 Switching on Mains Voltage e eeseeeee e ceei eene ener anna nana naa 101 Setup Using the Control Unit eeee sessi esee nennen nnn 101 CONTIGUPALON EET 102 Data SOT sch nace nanana aiaa aD a aA AE EA AAEE AEA 104 Motor ro ii eaa ae eda aiias 104 Machin
112. AXXXX 15 3 9 797 SET UP Status OK NOK 8 5 22 2 Parameter Menu PARA No Description Unit Setting range Chapter 0 Serial Number Characters 9 1 1 Optional Modules Characters 9 2 12 Inverter Software Version Characters 9 3 15 Copyright Characters 9 3 27 Set password 0 999 9 4 28 Control level Lead 9 5 29 User Name 32 characters 9 6 69 30 Configuration Selection 9 7 33 Language Selection 9 8 69 34 Program ming 0 9999 9 9 37 Start Positioning of Axle Selection 12 6 2 39 Switch on temperature deg C 0 60 18 2 amp 48 Reference frequency Selection 18 8 49 Handshake Traverse Function Selection 15 4 10 58 Technology Controller Release Selection 17 3 62 Frequency Motorpoti Up Selection 15 4 9 63 Frequency Motorpoti Down Selection 15 4 9 66 Fixed frequency change over 1 Selection 15 4 8 67 Fixed frequency change over 2 Selection 15 4 8 68 Start clockwise Selection 15 4 1 Start anticlockwise Selection 15 4 1 Data set change over 1 Selection 15 4 7 Data set change over 2 Selection 15 4 7 Percent Motorpoti Up Selection 15 4 9 Percent Motorpoti Down Selection 15 4 9 Fixed perc value change over 1 Selection 15 4 8 Fixed perc value change over 2 Selection 15 4 8 83 Timer 1 Selection 15 4 4 84 Timer 2 Selection 15 4 4 87 Start 3 wire control Selection 15 4 2 Error Acknowledgment Selection 15 4 3 164 n M Control Change Over Selection 15 4 6 183 External error Selection 15 4 12 204
113. Convert Reference 1374 in Hz The Profibus Notation is limited to values from 200 96 0x8000 to 200 96 Fact sett Selection Selection 1374 50 00 Hz Ox7FFF 0x4000 100 In F Convert Reference 1374 Ox7FFF 200 2x In F Convert Reference 1374 0x8000 200 2x In F Convert Reference 1374 0xC000 100 In F Convert Reference 1374 The values converted this way can be used as internal source 774 Out F PDP Conv1 long1 as output of In F PDP word 1 1370 Profibus Not gt Frequency 775 Out F PDP Conv1 long2 as output of In F PDP word 2 1371 Profibus Not gt Frequency 776 Out F PDP Conv1 word1 as output of In F PDP long 1 1372 Frequency gt Profibus Not 777 Out F PDP Conv2 word2 as output of In F PDP long 2 1373 Frequency gt Profibus Not 256 Operating I nstructions ACU 06 13 vv Bonfiglioli 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 19 1 Actual Values of the Frequency I nverter 06 13 The modular hardware of the frequency inverter enables application specific adapta tion Further actual value parameters can be displayed as a function of the selection configuration and the installed
114. E 3ph 400V AC 66 Operating I nstructions ACU 06 13 WwW Bonfiglioli Vectron 37 0 kW 65 0 kW threaded bolt M8x25 wire cross section up to 70 mm 8Nm 70 8 Ib in Star connection Delta connection C 37 0 kW 65 0 kW x2 threaded bolt M8x25 uuaa Wire cross section up to 70 mm 70 8 Ib in I 8Nm Rb1 4J Rb2 T1 ees T2 E Optional the inverters in this size can be purchased without brake chopper and are 1 then not provided with the terminal Rb2 for a brake resistor connection 06 13 Operating I nstructions ACU 67 I Bonfiglioli 6 5 5 ACU 401 75 0 to 132 0 kW 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 When the frequency inverter is disconnected from power supply the mains DC link voltage and motor terminals may still be live for some time Switch off power supply before connecting or disconnecting the mains cable to from terminal X1 the motor cables and the brake resistor to from terminal X2
115. ERE E in Gre e ew eR ER ERBEN ER eee 162 Fixed Perceritages i iced Derictedtp e Gad eee e bad Fera PR uU Mg 162 Frequency ramps 11 een eeee nanus nun uuu aa uaa u aua uu anu R RR R4 RR RR RR a RR Rau 163 Percentage Value Ramps e eeeieee ee eeee eene ina aun a nau a nua uana aaa 166 Block Frequencies 1 ee e eeeieee ee eei seen nna au nnn a aaa n uaa aaa a aaa aa annua aua ua 166 Motor Potentiometer e eeeeeeeeeeieieee eee ei annua na runs nada naa a aa anna na 167 Motorpoti MP essssssssseseee mmn nennen nnne nnns 168 MOCOND OLIN GAP LEE 168 Controlling the Motor via the Control Unit eee eet eeee e 169 PWM repetition frequency input ee cessisse eee eene nennen nnn 170 15 1 15 1 1 15 1 1 1 15 1 1 2 15 1 1 3 15 1 1 4 15 1 1 5 15 2 15 2 1 15 2 11 15 2 2 15 2 2 1 15 3 15 3 1 15 3 2 15 3 3 15 3 4 06 13 Multi Function I nput MFI 1 11nseeeeeeeeeeee e eeeiee enne nnn nnn nnn nnn 172 Analog input MP LA 1 aie Le e se cic Re Da ce et eir e ed e Pp nda 172 euricaii mE 172 sees 174 Tolerance Band and Hysteresis ssssssssssseeenne emen 174 Filter Time Constant scrcas eu barba esie Xe cin vae ig aeria ure Dunes sey 175 Error and warning DellaVIQFl uu iciieace donasse Tercia ed ette eda e doen Dag ed 176 Multi Function Output MFO 1 essere eeeee e
116. FU rated current Abs value of flux forming current component ata eee 0 0 A FU rated current 22 Abs Is Abs value of torque forming current component Veg 0 0 A FU rated current Abs value of current active power Pactive a0 AHS Paciive 0 0 kW Rated mech power 376 Abs value of calculated torque M 0 0 Nm Rated torque 31 Abs M Abs Inside Tempera Abs value of measured inside temperature ture 0 C 100 C C 32 Abs Heat Sink Temper Abs value of measured heat sink temperature 33 o o ature 0 C 100 C 40 Abs Analog Input Abs signal value on analog input 1 MFI1A 0 0 V 10 0 V 50 Abs Abs current value of measured output currents 0 0 A FU rated current DC link voltage du BOW LOD Output voltage U foe aoe Abs value of calculated volume flow 0 0 m h Nominal volumetric flow 397 Abs value of calculated pressure 0 0 kPa Reference pressure 398 101 to 133 Operation modes in analog operation with signs 06 13 Operating I nstructions ACU 177 G Bonfiglioli 15 2 1 1 Output Characteristic The voltage range of the output signal at multifunction output 1 can be adjusted The value range of the actual value selected via parameter Analog operation 553 is assigned to the value range of the output signal which is adjusted via the parameters Voltage 100 551 and Voltage 0 552 Description x Fact sett Voltage 10096 a E V 10 0 V Voltage 096 2
117. For safe motor protection it is generally sufficient using one of the available possibili ties A combination of the two groups and their simultaneous operation is possible 18 5 1 Motor Protection Switch 06 13 Motor protection switches are used for protecting a motor and its supply cable against overheating by overload Depending on the overload level they disconnect the motor from power supply immediately in the case of a short circuit or they dis connect the motor if an overload has occurred for some time Conventional motor protection switches are commercially available for various applica tions with different trigger characteristics L G U R and K as shown in the diagram on 40 the right As frequency inverters in most 9 cases are used for supplying motors which 3 10 are classified as operating equipment with very high starting currents exclusively the K characteristic was realized in this function 40 Unlike the operation of a conventional motor 2 20 protection switch which disconnects the lt 10 SS equipment to be protected immediately if g 5 12 the trigger threshold is reached this func 9 A lt tion provides the possibility of issuing a 1 AN warning instead of disconnecting the equip 7 S A ment immediately om A N 7 E Fg The rated current of the motor protection 9 SHE Wd KK switch refers to the rated motor current NI LA WN Z stated via parameter Rated current 371 of S 20 AAA
118. H the corresponding data set SSA The rated values of the frequency inverter are to be considered accordingly when it comes to dimensioning the application 1523 5 10 30 x nominal current 39 E E y ael The function of the motor protection switch can be linked to different data sets In this way it is possible to operate different motors via one frequency inverter Thus each motor can be equipped with its own motor protection switch Operating I nstructions ACU 245 G Bonfiglioli 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 tiated by selecting the parameter Operation mode 571 for single motor operation or multiple motor operation K Char Mul Motor In each of the four data sets the rated values are 1 Op Err ew Off monitored Overloading the drive is prevented by the Ter T fault switch off F0401 K Char The rated values in the first data set are used inde 2 Sing Motor Err Sw Off pendently of the active data set Overloading the drive pid is prevented by the fault switch off F0401 K Char Multi Motor In each of the four data sets the rated values are 11 Op Warning monitored Overloading the drive mechanism is sig li naled by a warning message A0200 f The rated values in t
119. I nputs 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 15 1 Multi Function Input MFI 1 Multifunction input MFI1 can be configured as a voltage a current or a digital input Depending on the selected Operation mode 452 for the multifunction input a link to various functions of the software is possible The unused operation modes are as signed the signal value 0 LOW 1 Voltage Input voltage signal MFI1A OV 10 V 2 Current Input current signal MFI 1A 0 mA 20 mA 3 Digital Input digital signal MFI 1D OV 24 V The sampling rate of multi function input MFI1D is slower than that of digital signals S1IND STOA S2IND etc For this reason this input should only be used for signals which are not time critical 15 1 1 Analog input MFI 1A Multifunction input MFI1 is configured by default for an analog reference value source with a voltage signal of 0 V to 10 V Alternatively you can select the operation mode for an analog current signal of 0 mA to 20 mA The current signal is continuously monitored and the fault message F1407 displayed if the maximum figure is exceeded 15 1 1 1 Characteristic Mapping of the analog input signal onto a r
120. INA FF Combination of the operation modes 10 1 and 2 Reference value source is the function Frequency Mo eur dee ane CHO DOMI torpoti Up 62 and Frequency Motorpoti Down 63 21 Abs value MFI 1A MP Combination of the operation modes 20 and 1 22 Abs Value EM S1INA MP Combination of the operation modes 20 and 2 24 Abs Value MFI1A EM S1INA MP Combination of the operation modes 20 1 and 2 30 Abs Val Speed Sensor 1 F1 Wd dud bor E mode 490 are eval 31 Abs value MFI1A F1 Combination of the operation modes 30 and 1 The frequency signal on the digital input according to Abs vae Tepe mooie em IPM Operation mode 496 for the PWM repetition frequen input F3 cy input 33 Abs value MFI1A F3 Combination of operation modes 1 and 32 34 Abs Val Speed Sensor 2 F2 ee mode 490 are eval 35 Abs Value MFI1A F2 Combination of operation modes 1 and 34 KP 500 is the reference value source with keys A for 40 Abs value Motorpoti KP increasing the frequency and W for reducing the fre quency Combination of operation modes 40 and 1 42 Abs Value EM S1INA KP Combination of operation modes 40 and 2 44 Abs Value MFI1A EM S1INA KP Combination of operation modes 40 1 and 2 Combination of the operation modes 1 10 40 32 EM S1INA 1 and 2 Combination of the operation modes 1 10 40 30 32 F3 EM S1INA and 2 82 Abs value MFI1A FF KP F3 Combination of
121. LC compatible response time approx 2 ms Digital input S4IND Umax 30 V 10 mA at DC 24 V Input resistance 2 3 kO PLC compatible uency signal 0 30 V 10 mA at 24 V fmax 150 kHz Digital input S5IND Umax 30 V 10 mA at DC 24 V Input resistance 2 3 kQ PLC compatible uency signal 0 30 V 10 mA at 24 V fmax 150 kHz Digital input S6IND Umax 30 V 10 mA at 24 V input resistance 2 3 kQ PLC compatible response time approx 2 ms Digital input STOB 2nd shutdown path for function Safe Torque Off Umax 30 V 10 mA at 24 V input resistance 2 3 kQ PLC compatible response time approx 10 ms Multi Function Input MFI1 Analog signal resolution 12 Bit 0 10 V Ri 70 kQ 0 20 mA Ri 500 Digital signal response time approx 4 ms Umax 30 V 4 mA at 24 V PLC compatible 7 Ground GND 10 V 1 The power output on terminal X210A 1 may be loaded with a maximum current of Imax 180 mA The maximum current available is reduced by the digital output S10UT and multifunctional output MFO1 Level Low 0 V 3 V High 12 V 30V Digital inputs X210A 3 X210B 2 Digital output X210B 3 06 13 Operating I nstructions ACU 71 G6 Bonfiglioli 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
122. M ENC The connection of SinCos encoders or Absolute encoders requires an expansion module type EM ABS Operating Instructions ACU 06 13 vv Bonfiglioli 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 Actual system value factor 389 can be used if the drive is monitored via the actual value Actual system value 242 The Actual frequency 241 to be monitored is multiplied by the Actual system value factor 389 and can be read out via the parameter Actual system value 242 i e Ac tual frequency 241 x Actual system value factor 389 Actual system value 242 No Description Min Max Fact sett Factor Actual Value System 100 000 100 000 1 000 11 2 Volume Flow and Pressure The parameterization of the factors Nominal Volumetric Flow 397 and Nominal Pressure 398 is necessary if the matching actual values Volumetric Flow 285 and Pressure 286 are used to monitor the drive The conversion is done using the elec trical control parameters Volume flow 285 and Pressure 286 are referred to the Effective current 214 in the case of the sensorless control methods In the case of the field oriented control methods they are referred to the torque forming current component 7 sq 216 Description
123. Mains frequency UL type 600 VAC RK5 Dimensions 250 x 60 x 175 Weight approx 1 6 Degree of protection P20 EN60529 Terminals 0 2 1 5 Form of assembly vertical 2 kHz switching frequency Coolant temperature 3K3 DIN IEC 721 3 3 Storage temperature 25 55 Transport temperature 25 70 Rel air humidity 9 15 85 not condensing If required by the customer the switching frequency may be increased if the output current is reduced at the same time Comply with the applicable standards and regulations for this operating point Switching frequency iini hace ele EHE D iege 1 85 kW 2 2 kW 3 0 kW 4 0 kW D Three phase connection requires a commutating choke 2 Mains current with relative mains impedance 1 see chapter Electrical installation 3 Reduction of switching frequency in thermal limit range 4 Maximum current in continuous operation 36 Operating I nstructions ACU 06 13 j Bonfiglioli 4 8 ACU 401 5 5 to 15 0 kW 400 V ACU 401 Construction Size Recommended motor shaft power P kW 5 5 7 5 9 2 11 0 15 0 Output current faf 140 180 220 250 320 Long term overload curent 60s a 210 263 303 375 445 Short time overload current 1s faf 280 330 330 500 640 Output voltage u v Maximum input voltage three TEES Protection o 9 e Short circuit earth fault proof Rotary field frequency 0
124. Max Control Deviation 549 Set value 96 Reference frequency Internal Reference Frequency 228 or Actual Frequency 241 Reference percentage or Reference Percentage Value 229 Actual Percentage Value 230 x Max Control Deviation 549 t Digital output 1 163 Reference Frequency reached 178 Reference Percentage reached A e i 06 13 Example Max Control Deviation Hz Af x Max Control Deviation 549 96 Maximum Frequency 419 Minimum Frequency 418 x Max Control Deviation 549 50 Hz 3 5Hz x 596 2 325 Hz Actual frequency Maximum frequency 50 Hz gt 2 325 Hz Reference frequency 30 Hz 46 5 Hz Minimum frequency 3 5 Hz IZ serpentine 3 Digital output 163 Reference Frequency reached Operating Instructions ACU 185 Goo Bonfiglioli 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 The magnetizing can be defined via the starting behavior and is influ enced by the amount of the set starting current 15 3 5 Brake release The Open brake function in operation mode 41 enables the activation of a corre sponding unit via the digital control output The function uses both the control com mands via the contact i
125. O Prin 19 3 297 Average value active power kW 0 0 O Prin 19 3 301 Energy positive kWh 10 99999 19 3 302 Energy negative kWh 0 99999 19 3 Operating I nstructions ACU 06 13 06 13 vv Bonfiglioli Operating I nstructions ACU No Description Unit Display range Chapter 310 Last error h m F 00000 00 FXXXX 20 1 311 Last error but one h m F 00000 00 FXXXX 20 1 312 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 F 00000 00 FXXXX 20 1 315 Error 6 h m F 00000 00 FXXXX 20 1 316 Error 7 h m F 100000 00 FXXXX 20 1 317 Error 8 h m F 00000 00 FXXXX 20 1 318 Error 9 h m F 00000 00 FXXXX 20 1 319 Error 10 h m F 00000 00 FXXXX 20 1 320 Error 11 h m F 100000 00 FXXXX 20 1 321 Error 12 h m F 00000 00 FXXXX 20 1 322 Error 13 h m F 00000 00 FXXXX 20 1 323 Error 14 h m F 00000 00 FXXXX 20 1 324 Error 15 h m F 00000 00 FXXXX 20 1 325 Error 16 h m F 00000 00 FXXXX 20 1 330 DC Link Voltage V 0 0 Ugmax 20 2 331 Output voltage V 0 0 Urun 20 2 332 Stator frequency Hz 0 00 999 99 20 2 333 Enco
126. One and two phase connection requires a commutating choke 3 Mains current with relative mains impedance gt 1 see chapter Electrical installation Three phase connection permissible only 5 Reduction of switching frequency in thermal limit range 9 Maximum current in continuous operation 7 The device for single phase connection is not listed in the product catalogue and only available on request 34 Operating I nstructions ACU 06 13 j Bonfiglioli 4 6 ACU 401 0 25 to 1 5 kW 400 V ACU 401 Construction Size Recommended motor shaft power P kw 0 25 0 37 0 55 0 75 1 1 1 5 Output current Jaj 10 16 18 24 32 38 Long term overload current 60s a 20 32 27 36 48 57 Short time overload curent 1s A 20 32 36 48 64 76 Output voltage Maximum input voltage three phase Protection o e Short circuit earth fault proof Rotary field frequency 0 1000 depending on switching frequency Switching frequency 2 4 8 12 16 Min brake resistance 300 Recommended brake resistor R a 930 930 930 634 462 300 Uagc 770 V Mains current 3ph PE af 10 16 18 24 28 33 Mains voltage 320 528 Mains frequency 45 66 Fuses 1 Al 6 UL type 600 VAC RK5 A 6 Dimensions 190 x 60 x 175 Weight approx 1 2 Degree of protection P20 EN60529 Terminals 0 2 1 5 Form of assembly vertical 2 kHz switchin
127. Operation Mode Timer 1 790 and Operation Mode Timer 2 793 de fine the evaluation of the digital input signals and the unit of time of the time func tion 0 Off Signal output is switched off Positive signal edge starts timer trigger 1 Normal Rising Edge Sec time 1 delays the output signal time 2 defines the signal period Positive signal edge starts timer trigger next positive signal edge within time 1 starts the delay in time again Retrigger time 2 defines the signal period Positive signal edge starts timer trigger if no input signal is received within time 1 the delay starts again Retrigger if no input signal is received within time 2 the signal period is terminated 11 to 13 Operation modes 1 3 negative signal edge starts timer 101 to 113 Operation modes 1 3 in minutes 201 to 213 Operation modes 1 3 in hours By default the functions are linked according to the following illustration Timer 1 83 73 S4IND ETT 3 158 Timer 1 gt P83 1 4 Data Set Change Over 1 70 Timer 2 84 7 Aus pedo Timer 2 Retrigger Rising Edge Sec _ AND Connect Rising Edge Sec 4P 84 No function linked The sources of the digital signals e g 73 S4IND are selected via the parameters Timer 1 83 and Timer 2 84 n the factory setting Timer 1 is linked to digital input 4 and Timer 2 is switched off The output signal of
128. Otherwise components may be damaged EN ei int b CTRL RUN UO UU When the RUN key was pressed the drive was in operation already 98 Operating I nstructions ACU 06 13 tv Bonfiglioli The CTRL menu branch can be accessed via the navigation eme within the menu structure The CtrL function contains sub functions which are displayed according to the operating point Eel of the frequency inverter Pressing the RUN key leads to a direct change from anywhere g E cm within the menu structure to the motorpoti function PotF for QEF clockwise rotation or Potr for anticlockwise rotation HEF V IZ If the drive is already running the display reads intF forward EE em clockwise intr reverse anticlockwise for the function in a ternal reference value or inPF forward clockwise inPr HHE 9 reverse anticlockwise for the function Motorpoti KP The function Motorpoti KP enables linking to other refer cm RUN ence sources in the reference frequency channel The function ne J is described in chapter Reference values Motorpoti KP HHH V Z Motor potentiometer function Pot Fabr eme Using the arrow keys you can adjust the output frequency of a the frequency inverter from the minimum frequency 418 to HHE Hz 9 the ma
129. Output percentage 1 101 to 199 Operation modes with signs 1 The reference value source is only available if an optional expansion module with analog input is connected For information refer to the expansion module operating instructions 158 Operating Instructions ACU 06 13 vv Bonfiglioli 14 5 1 Block diagram The following table describes the software switches shown in the circuit diagram as a function of the selected Reference percentage source 476 Operation Fiza rp MP F3 EM Sign mode S1IN 0 1 fs vate 2 Ts value 4 1 DD D0Dp ft Abs value i0 1 X 24d Abs vale u 1 1 J Abs vale 2 1 J AHd 1 J Absvalhe 14 1 1 1 Abs vale 20 1 Abs valve a 1 J 1 J bs value 22 1 1 Abs vale 24 1 1 1 Abs vale 3 P 1 J Abs vale 3 1 J 1 J Abs vale 90 1 1 1 1 Abs vale 95 Abs value 96 Abs value 99 Abs value 101 199 Operation modes 1 99 with signs 06 13 Operating I nstructions ACU 159 f percent reference value channel iagram o ircuit di Bonfigliol C WUE 94 z JaA0 a6ueyy 4 06 13 cS y oDejueojed pexiJ ZG eDejueojed pexiJ lt lt lt IzS z ebejuaded paxi4 lt ozs eBejueojed pexiJ on BEEBE e cme co o SHEE 69 S8IWoop 61g ebejusdied ljue ues 92U919J91 Xe
130. STOA and S7IND STOB are connected in series If the same signal is used for the digital inputs S1IND STOA and S2IND safe discon nection of power supply to the motor according to safety function STO Safe Torque Off is not guaranteed Operating I nstructions ACU 73 GW Bonfiglioli 6 7 74 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 Configurations Standard 110 410 210 510 610 Technology Controller 111 411 211 611 Electronic gear with 115 415 215 515 position controller Electronic gear 1 116 216 516 index controller Torque control 430 230 530 630 Positioning 440 240 540 640 Brake control 160 460 260 560 Please also comply with the following manuals 1 Application Manual Electronic Gear Position Control and Index Control 2 Application Manual Positioning 3 Application Manual Lifting Gear Drives and Load Estimation Note The control methods 2xx can be used with HTL sensors with or with out reference track connected to the basic device or to an expansion module The control methods 2xx with TTL sensors r
131. Switch off Stopping behavior 2 Stop Hold Stopping behavior 3 Stop DC brakes Stopping behavior 4 Emergency stop switch off Stopping behavior 5 Emergency stop Hold Stopping behavior 6 Emergency stop Brake Stopping behavior 7 Direct current brake vv Bonfiglioli The inverter is disabled immediately The drive deener gized immediately and coasts freely The drive is brought to a standstill at the set decelera tion As soon as the drive is at a standstill the inverter is disabled after a after a holding time The holding time can be set via the parameter Holding time 638 Depending on the setting of the parameter Starting func tion 620 the Starting current 623 is impressed or the Starting voltage 600 is applied for the duration of the holding time The drive is brought to a standstill at the set deceleration and remains permanently supplied with current Depending on the setting of the parameter Starting func tion 620 the Starting current 623 is impressed as from standstill or the Starting voltage 600 is applied In configurations 2xx the magnetizing current is used instead of the Starting current 623 The magnetizing current results from Rated magnetizing current 716 and Reduction Factor Flux 778 The drive is brought to a standstill at the set decelera tion As from standstill the DC set via parameter Braking current 631 is impressed for the Braking time 632 Comply with the notes in chapt
132. 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 errr ZEEE EL er ae 3 XESS e ea 12 fixing pak t bes fixing braket bottom fixing with screws M5x20 fixing with screws M5x20 Assembly is done by screwing the two fixing brackets to the heat sink of the frequen Cy inverter and the assembly panel The frequency inverters are provided with fixing brackets which are fitted using four thread cutting screws The dimensions of the device and the installation dimensions are those of the standard device without optional components and are given in milli meters ACU S Hosskr E Pai 401 37 65kW 400 275 425 445 470 20 160 Operating I nstructions ACU 06 13 vv Bonfiglioli 5 5 06 13 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 C cl X 2300 mm b S c2 C I F D l P I o b1 b2 tb al The diameter of the fixing holes is 9 mm Assembly is done by screwing the bac
133. The manufacturer shall not be held liable for any damage resulting from such misuse The sole risk shall be borne by the operator 2 3 1 Explosion protection The frequency inverter is an IP 20 protection class device For this reason use of the device in explo sive atmospheres is not permitted 06 13 Operating I nstructions ACU 15 Goo Bonfiglioli 2 4 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 proper working on electrical equipment Danger of contact with energized components inside of the frequency inverter if no external discon nection device was installed by the operator Electrostatic charging Touching electronic components bears the risk of electrostatic discharges Thermal hazards Risk of accidents by hot machine plant surfaces e g heat sink transformer fuse or sine filter Charged capacitors in DC link The DC link may have dangerous voltage levels even up to three minutes after shutdown Danger of equipment falling down over e g during transport Center of gravity is not the middle of the electric cabinet modules 2 5 Safety and wa
134. Trigger Threshold 506 Nys t Brake chopper ON OFF l gt 4 E t 125 us Operating I nstructions ACU 243 GO Bonfiglioli 18 4 1 Dimensioning of Brake Resistor 244 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 peak in W Resistance Ry in Q Operation Time OT in 96 e Calculation of peak braking power P peak Pb peak Peak braking power in W J Moment of inertia of drive system kgm Speed of drive system before the braking oper Pope ation in min 182 t n2 Speed of drive system after the braking opera tion in min th Braking time ins e Calculation of resistance R iL Rp Resistance in Q R Ua gc Switch on threshold in V P peak Pb peak Peak braking power in W The switch on threshold Uy ac is the DC link voltage at which the brake resistor is switched on The switch on threshold can be set as described above via parameter Trigger threshold 506 The resistance of the brake resistor must not be less than the minimum value Rb min 10 The values for R min are listed in chapter 4 Technical Data If the calculated resistance R of the brake resistor is between two standard series values the lower resistance is to be selected e Calculation of operation time OT
135. U 201 up to 3 0 kW and 401 up to 4 0 kW 25 ACU 201 4 0 to 9 2 kW and 401 5 5 to 15 0 KW 26 ACU 401 18 5 to 30 0 kW eeeeeeeee ee eieeeeee enne nnne nnn nnn nnn 27 ACU 401 37 0 to 65 0 kW 1 1 eeeeeeeeeeeee ee eieeeeiennnn nennt nnn annu nnn 28 ACU 401 75 0 to 132 0 kW eeeeeeeeee eee eeeeein eheu nennen nnn nhan nnn 29 Operating I nstructions ACU 3 GG Bonfiglioli 4 Technical Data 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 4 10 4 11 4 12 General technical data eee eeeeee ecciesie essei ee nnne annnm 30 Technical Data Control Electronic Equipment e 31 ACU 201 0 25 to 1 1 kW 230 V eeeeeeeeeeeeeeee nennen nana nnn 32 ACU 201 1 5 to 3 0 kW 230 V eeeeeeeeeeeeeeeee ener nn enne n anna ananas 33 ACU 201 4 0 to 9 2 kW 230 V eeeeeeeeeeeeeeeieee ener anna nna nnnaaaaa nanus 34 ACU 401 0 25 to 1 5 kW 400 V eeneeeeeeeeeeee nennen nnn nnn 35 ACU 401 1 85 to 4 0 kW 400 V eeeeeeeer rennen rennen nnn nnn 36 ACU 401 5 5 to 15 0 kW 400 V 1 1neeeeeeneeeee rennen nnne nnn nnn 37 ACU 401 18 5 to 30 0 kW 400 V eeeeeeeeeee eene eene nennen nnn nanus 38 ACU 401 37 0 to 65 0 KW 400 V
136. V 2 mA according to Analog Input MFI 1A the operation mode Error Warning Behavior 453 Warning The input signal on the analog input of an expansion Analog Input EM S1INA module is lower than 1V 2mA according to the oper ation mode Error Warning Behavior 453 23 Warning A slave on the system bus reports a fault System bus warning is only relevant with the EM SYS option 17 20 Warning Fmax 21 Warning Udc The DC link voltage has reached the type dependent minimum value 24 25 Application Warning A warning application is signaled 30 Controller Controller is active according to the Operation Mode Udc Dynamic Operation 670 for the voltage controller The output frequency in the case of a power failure a gt controller SRUEHQNR is below the Shutdown threshold 675 Failure of the mains voltage and power regulation 32 Controller Mains Failure active according to Operation Mode 670 for the voltage controller 06 13 Operating I nstructions ACU 187 G Bonfiglioli 33 Controller Udc Limita The DC link voltage has exceeded the Reference UD tion limitation 680 Controller The Dyn Voltage Pre Control 605 accelerates the 34 fg Voltage Pre Control control characteristics 35 Controller abs The output current is limited Controller The output power or the torque is limited by the 36 ee Torque Limitation speed controller Controller Switch over of field orientated control between 37 Torque Control speed
137. a iaaa a A AA EE a a aia 197 n M Control Change Over sisira sonansa aaia aaa 197 Data Set Change OVer iei oaa cecidi Due teneo e ax bas ERE MR Pa ep E SR NERA HER SEE 198 Fixed Value Change OVE 5 tei tasted eut eta Hc a E D aid 199 Motor PotentioMeter cccccccccccccc cece emen nennen rennen rens 199 Handshake Traverse Function seems 200 User Ctr M 200 External error socaac ciao mea ra e de tcd pad tede ea tasa usw aa be has GENE A de Rr gud 200 Function Modules 1 eese annua uunuunnunuuuuunuuuuuuu uuu sua auos Ras R a Ran aun 201 Unseee PU or c 201 Timer TIME Constant 2 7 axi pesados ta cab eater estas tiae iaa rye diy dw ad ga ibd Pad ag 202 epe prp 204 Function table tinc inui Ga dua da ud dd aaa iod sad a RR ad caue 2M aa dad irn dA 205 Multiplexer Demultiplexer siririna aana iaaa 206 16 V f Characteristic 16 1 Dynamic Voltage Pre Control esses eeeseee eese ee nnn nn nnn 209 17 Control Functions 17 1 17 2 17 3 17 4 17 4 1 17 4 2 17 5 17 5 1 17 5 2 17 5 3 17 5 3 1 17 5 3 2 17 5 3 3 17 5 3 4 17 5 4 17 5 4 1 17 5 4 2 17 5 4 3 17 5 5 17 5 6 17 5 6 1 17 5 7 17 5 7 1 Intelligent current limits eee eee eere erre enne nenne 210 Voltage controller 11111eeeeeeeeieeeeeeei esee nea anna annm anna annua 211 Technology Control
138. accelerated in the previous direction of rotation The drive is held for the Waiting time 464 after 5 Reversal by time control the waiting time it is accelerated in the opposite direction of rotation The position reached can be maintained for the Waiting time 464 then the drive is accelerated according to operation mode 4 or 5 Description Min Max Fact sett 3600 000 ms The diagram shows how the positioning to the set positioning distance is affected The positioning distance remains constant at different frequency values At the refer ence point the position signal Sposi is generated Starting from frequency fmax the positioning is affected at the set Deceleration clockwise 421 At a lower frequency value f the frequency remains constant for some time before the drive is stopped at the set deceleration If during acceleration or deceleration of the machine positioning is started by the signal Sposi the frequency at the time of the positioning signal is maintained fA Fina f Deceleration Clockwise 421 Unin U ent Digital Input 6 T gt t Operating Instructions ACU 06 13 Bonfiglioli Vectron Examples of reference positioning as a function of the parameter settings selected The reference point is registered according to the Signal sources 459 parameter in operation mode 16 S6IND pos edge by a signal on digital input 6 The Positioning distance 460 with
139. ack triggered a warn A00 80 Userl oe set on digital input User Warning 1 1363 is AOL 00 User2 oo set on digital input User Warning 2 1364 is Output signals The output of an application warning message is signaled 1 2 216 Application Warning 26 Warning Application The output of a warning message in Application Warnings 273 is signaled 1 For linking with inverter functions 2 For digital output 274 Operating I nstructions ACU 06 13 22 Parameter List vv Bonfiglioli 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 E V The parameter is available in the four data sets The parameter value is set by the SETUP routine 9 This parameter cannot be written when the frequency inverter is in operation I riu Urin Pein rated values of the frequency inverter o overload capacity of frequency inverter 201 value for ACU201 devices 401 value for ACU401 devices ACU201 devices Ugmax 387 5 V ACU401 devices Ugmax 770 V At the control unit KP500 parameter numbers 999 are displayed hexadecimal at the leading digit 999 AOO B5 C66 22 1 Actual Value Menu VAL 06 13
140. aeeene 17 Prohibition SIQfis 2 rcd tete E open E ipt ee cen Pag da aa epu eu oo edad ade 17 Personal safety EQUIPMENT eee nens 18 sse eli EE 18 Grounding Symbol aunt tr tnis tape a t obe Lt tot eeu 18 sejpx3unce Cr 18 I nformation silgmsiroi iode e deua E etu tee blu sd td e acp da 18 Directives and guidelines to be adhered to by the operator 19 Operator s general plant documentation ener 19 Operator s operating staff s responsibilities 19 Selection and qualification of staff sssssssssssseee mee 19 General work safety ssssssessssssssseeeene emen ener enne 19 Organizational measures 1 ee ee eeei eene eese nana na auum nnmnnn nnmnnn 20 re m 20 Use in combination with third party products sssse 20 Transport and Storage rese cnt La pui eir ke Eu CERES ERE RAE DS 20 Handling and installation eee 20 Electrical CONNECTIONS 22 oa e reete rr prepa pir re Rat aln iaa i eb udi 20 The five safety rules iret ed edente eade addu tear pede o edoa te R 21 Sale operatio e mt TET 21 Maintenance and service troubleshooting ssss e 22 Final decommissioning ssssssseee mee n ens 22 Safety Instructions on Function Safe Torque Off STO 23 3 1 3 2 3 3 3 4 3 5 06 13 AC
141. al edges are evaluated per division mark 101 Single evaluation Same as in operation mode 1 The actual speed value is inverted inverted Alternative to exchanging the track signals tion inverted inverted Alternative to exchanging the track signals negative negative negative negative One channel speed sensor via track signal A The actual speed value is negative for signal Low and positive for signal High at digital input S4IND One signal edge is evaluated per division mark One channel speed sensor via track signal A The actual speed value is negative for signal Low and positive for signal High at digital input S4IND Two signal edges are evaluated per division mark Quadruple evalua 75 tion Single evaluation 31 sense of rot via contact Double evaluation 32 sense of rot via contact Single evaluation 131 sense of rot via contact inverted Double evaluation 132 sense of rot via contact inverted 128 Operating I nstructions ACU 06 13 06 13 vv Bonfiglioli Two channel speed sensor with recognition of direc Single evaluation tion of rotation via track signals A and B reference 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 with reference track track via digital input S6IND Two signal edges are
142. al frequency should be observed for the modification of the flux forming component The upper limit is to be estimated from the product of the set magnetizing current and the correction factor Reference flux 717 although the limit must not exceed the overload current of the drive 238 Operating Instructions ACU 06 13 vv Bonfiglioli 17 5 7 Modulation Controller The modulation controller which is designed as an 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 parameter Reference modulation 750 the field forming current component and thus the flux in the machine are reduced In order to make the best possible use of the voltage available the figure selected via parameter Operation mode 753 is put into proportion to the DC link voltage That means that with a high mains voltage there is also a high output voltage available the drive only reaches the field weakening area later and produces a higher torque 0 Usa Control The modulation is calculated from the ratio of torque i forming voltage component U to the DC link voltage V Absolute Value The modulation is calculated from the abs voltage value 1 Control DC link voltage ratio The integrating part of the modulation controller is to be set via parameter Integral time 752 No Description Min Max Re
143. alue source is the multifunctional in MFI 1A put 1 in analog Operation mode 452 i 1 Reference value source is the Analog value of 2 Abs Analog Value EM S1INA EM S1INA 4 a ee ore Combination of the operation modes 1 and 2 The percentage according to Fixed percent Abs value fixed percentage h 175 Fixed h value FP cnange over y Ixe percent cnange over 2 76 and the current data set 11 Abs value MFI1A FP Combination of the operation modes 1 and 10 12 Abs Value EM S1INA FP Combination of the operation modes 2 and 10 4 E D 1 Abs Value MFI1A EM Combination of the operation modes 1 2 and S1INA FP 10 Reference value source is the function Percent 20 Abs value Motorpoti MP Motorpoti Up 72 and Percent Motorpoti Down 73 21 Abs value MFI1A MP Combination of the operation modes 1 and 20 22 Abs Value EM S1INA MP Combination of the operation modes 2 and 20 24 Abs Value MFI1A EM Combination of the operation modes 1 2 and S1lINA MP 20 The frequency signal on the digital input ac cording to Operation mode 496 for the PWM repetition frequency input 33 Abs value MFI1A F3 F3 EM S1INA P 32 4 analog input of an expansion module Torque 0x6071 6 Abs Val Rep Freq PWM Es Input F3 9 9 B Frofibus DUT Reference value source is Profibus OUT PZD3 99 Abs Val FT Output Percent Reference value source is the output of the agel function table FT
144. an be adapted to the application in question Depending on the Configuration 30 selected the default assignment or the selection of the operation mode differ In addition to the available digital control inputs further internal logic signals are available as sources Each of the individual software functions is assigned to the various signal sources via parameterizable inputs This enables a flexible use of the digital control signals Signal input is switched on Signal input is switched off _ Technology Controller Start command technology controller configura Start tion 111 211 or 411 Signal on digital input S1IND STOA X210A 3 70 Inverter Release and S7IND STOB X210B 2 the safety function STO is linked permanently Signal on digital input S21 ND X210A 4 or re mote operation via communication interface Signal on digital input S31 ND X210A 5 or re mote operation via communication interface Signal on digital input S4I ND X210A 6 or re mote operation via communication interface 71 72 73 S4IND Refer to the application manual Safe Torque Off for further details 06 13 Operating I nstructions ACU 191 G Bonfiglioli Signal on digital input S5IND X210A 7 or re mote operation via communication interface Signal on digital input S6I ND X210B 1 or re mote operation via communication interface Signal at multifunction input MFI1 X210B 6 in 76 MFI1D Operation Mode 452 3 digital inpu
145. and torque controlled The Operation mode 620 selected in starting be 38 Ramp Stop Nut havior limits the output current Contr Intel Curr Lim Overload limit of the long term Ixt 60s reached 9 n LT Ixt intelligent current limits active 0 39 40 Contr Intel Curr Lim Overload limit of the short term Ixt 1s reached ST Ixt intelligent current limits active Max heat sink temperature T reached Operation Tc Mode 573 for the intelligent current limits active Max motor temperature Tprc reached Operation Motor Temp Mode 573 for the intelligent current limits active The reference frequency has reached the Maximum Freq Limitation Frequency 419 The frequency limitation is active 101 to 143 Removal or deactivation of the operation mode with in the warning mask The selected warning mask can be read out via the parameter Actual Warning Mask 537 The above operation modes of parameter Create Warning Mask 536 are en coded in the Actual Warning Mask 537 The code results from hexadecimal addition of the individual operation modes and the matching abbreviation 188 Operating Instructions ACU 06 13 06 13 vv Bonfiglioli A 0000 0010 Ti A 0000 0200 PMS 0000 1000 A2 A 0000 2000 Sysbus A 0000 8000 WARN2 A 0001 0000 UDdyn A 0002 0000 UDstop A 0004 0000 UDctr 0008 0000 UDlim 36 Controller Torque Limitation The selected warning mask can be read out via parameter Actual W
146. aracteristic re sults 3588 us 400 0 V 5 0 V J T FC 0 50 00 Hz 0 00 Hz The Rise frequency 602 FK is entered as a percentage of the Cut off frequency 604 FC the default value is f 10 Hz The output voltage for the default Voltage rise 601 UK is calculated as U 92 4V u SES rk Fe vs as ur ASY 2 50 v 14 s24v FC 0 50Hz 0Hz 16 1 Dynamic Voltage Pre Control 06 13 The Dyn voltage pre control 605 accelerates the control behavior of the current limit controller parameter Operation mode 610 and the voltage controller parame ter Operation mode 670 The output voltage value resulting from the V f character istic is changed by addition of the calculated voltage pre control No Description Min Max Fact sett Dyn voltage pre control 200 100 Operating I nstructions ACU 209 I Bonfiglioli 17 Control Functions The frequency inverters provide a selection of established control methods in Config uration 30 The selected control structure can be parameterized as required and 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 The func tion extends the current controller available in the control system The overload re serve of the frequency inverter can be used optimally by means of the i
147. arameter figure is calculated from the linear V f char acteristic Via the parameters Minimum frequency 418 and Maximum frequency 419 the working range of the machine or the V f characteristic is defined U f 418 FMIN 419 FMAX Working range 603 UC 601 UK 600 US 602 FK 604 FC f MIN Minimum frequency 418 FMAX Maximum frequency 419 S Starting voltage 600 Voltage rise 601 FK Rise frequency 602 F U UK UC Cut off voltage 603 FC Cut off frequency 604 No Description x Fact sett 600 5 0 V 601 10 602 20 603 400 0 V 604 Cut off frequency 0 00 Hz 999 99 Hz 50 00 Hz The guided commissioning takes the parameterized rated motor values and reference data of the frequency inverter into account when it comes to pre setting the V f characteristic In the case of three phase machines the speed can be increased at a constant torque if the motor winding can be switched over from star to delta connec tion If the data for delta connection indicated on the rating plate of the three phase motor were entered the cut off frequency is increased automatically by the square root of three Operating Instructions ACU 06 13 vv Bonfiglioli The default Cut off voltage 603 UC and Cut off frequency 604 FC are derived from the motor data Rated voltage 370 and Rated frequency 375 With the parame terized Starting voltage 600 US the linear equation of the V f ch
148. arator Off below 96 300 00 300 00 15 5 2 543 Operation mode comparator 2 Selection 15 5 2 544 Comparator On above 96 300 00 300 00 15 5 2 545 Comparator Off below 96 300 00 300 00 15 5 2 549 Max Control Deviation 96 0 01 20 00 15 3 3 550 Operation mode Selection 15 2 551 Voltage 100 V 0 0 22 0 15 2 1 1 552 Voltage 0 V 0 0 24 0 15 2 1 1 553 Analog operation Selection 15 2 1 554 Digital operation Selection 15 3 555 Repetition frequency operation Selection 15 2 2 556 Division Marks 30 8192 15 2 2 1 570 Motor Temp Operation Mode Selection 13 6 571 Operation mode Selection 18 5 572 Frequency Limit 96 0 300 18 5 573 Operation mode Selection 17 1 574 Power Limit 40 00 95 00 17 1 575 Limitation time min 5 300 17 1 amp i 576 Phase supervision Selection 13 7 578 Allowed no of auto acknowl 0 20 13 8 579 Restart delay ms 0 1000 13 8 580 Reduction Limit Ti Tc deg C 25 0 18 1 581 Operation mode Selection 18 5 2 582 Trigger limit l active 96 0 1 100 0 18 5 2 583 Delay time S 0 1 600 0 18 5 2 V 600 Starting voltage V 0 0 100 0 16 Vi EE 601 Voltage rise 100 200 16 V 602 Rise frequency 0 100 16 V 603 Cut off voltage V 60 0 560 0 16 V amp 604 Cut off frequency Hz 0 00 999 99 16 605 Dyn voltage pre control 0 200 16 1 610 Operation mode Selection 17 4 2 611 Amplificat
149. are they intended to supplement or replace such agreements assurances or legal relationships The manufacturer s obligations are exclu sively specified in the relevant purchase contract This contract also contains all and any warranty regulations which may apply to the relevant scope of supply These contractual warranty provisions are neither extended nor limited by the specifications contained in this documentation The manufacturer reserves the right to correct or amend the specifications product information and omissions in these operating instructions without notice The manufacturer shall not be liable for any damage injuries or costs which may be caused by the aforementioned reasons This documentation was written in german language Other language versions are translated 06 13 Operating I nstructions ACU 11 GG Bonfiglioli 1 2 This document The present documentation describes the frequency inverters of the ACT VE Cube series The modular hardware and software structure enables customer specific adaptation of the frequency inverter se ries Applications with high functionality and dynamism can be realized easily The user manual contains important information on the installation and use of the in its specified ap plication range Compliance with this user manual contributes to avoiding risks minimizing repair cost and downtimes and increasing the reliability and service live of the frequency inverter For this reason make sure
150. arning Mask 537 The above operation modes of parameter Create Warning Mask 536 are en coded in the Actual Warning Mask 537 The code is calculated by hexadecimal addi tion of the individual operation modes and the corresponding abbreviation Output signals The output of a warning message is signaled 157 Warning Mask 1 Output of a warning message which is activated in Create 25 g 2 Warning Mask 536 For linking with inverter functions 2 For digital output Parameter Warning 269 and Warning 356 error environment show the warnings independent from the created Warning mask Parameter Controller Status 275 and Controller Status 355 error environment show the Controller Status independent from the created Warning mask Operating Instructions ACU 189 G Bonfiglioli 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 ate Appl Warning Mask 626 As soon as limit switches are reached or contouring error limits are exceeded a warning can be issued The warnings refer to the parameter values set in er ror warning behavior Depending on the application any number of warnings can be configured This enables internal and or external control using a common output signal The display of Warning Application 273 is not affected by the Warning mask 0 no chan
151. ary If an adjustment is necessary please remember that the rotor time constant is calculated by the guided commis sioning via the machine data The Adjusting temperature 467 is to be set to the temperature at which the optimization of the extended machine data was carried out The temperature can be read out via the actual value parameter Winding tempera ture 226 and can be used in the optimization for the parameter 18 7 3 Speed Sensor Monitoring Failures of the speed sensor lead to a faulty behavior of the drive as the measured speed forms the foundation of the control system By default the speed sensor moni toring system continuously monitors the speed sensor signal the track signals If an expansion module EM is connected the number of division marks is monitored addi tionally If while the frequency inverter is released a faulty signal is recognized for longer than the timeout a fault switch off is affected If the parameter Operation mode 760 is set to zero the monitoring function is deactivated 0 Off The function is deactivated A fault message is displayed according to the timeouts set The speed sensor monitoring is to be parameterized in the part functions according to the application The monitoring function becomes active with the release of the frequency inverter and the start command The timeout defines a monitoring time in which the condition for the fault switch off must be fulfilled without interruption If one of
152. ary speed sensor feedback results in a precise speed and torque performance Configuration 530 field oriented control of synchronous machine with speed torque control 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 The switch over between variable speed control and torque dependent control is done without jerk in operation Configuration 610 Sensorless Field Oriented Control of Synchronous Ma chine 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 Configuration 611 Sensorless Field Orientated Control 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 Configuration 630 Sensorless Field Orientated Control of a Synchronous Machine Speed and Torque Con
153. at Sink Temp 407 or 169 General Warning 170 Warning Overtemperature 65 C minus Warning Limit Inside Temp 408 is attained The comparison according to the selected Op Hide QUIpUESOmparetor 1 eration mode Comparator 1 540 is true Negated Output Compara Operation mode 171 with inverted logic LOW tor 1 active The comparison according to the selected Op eration mode Comparator 2 543 is true 174 Negated Output Compara Operation mode 173 with inverted logic LOW tor 2 active 172 173 Output Comparator 2 Signal according to parameter Operation mode 15e Digital Signal 1 digital output 1 530 f Signal according to parameter Digital Opera abu cL E tion 554 on multifunctional output MFO1 E Signal according to parameter Operation mode pit Digital endis digital output 3 532 178 Reference Percentage Signal when the Actual percentage 230 has reached reached the reference percentage 229 192 Operating Instructions ACU 06 13 vv Bonfiglioli Failure of the mains voltage and power regulation Mains Failure active according to Operation Mode 670 for the voltage controller Switch protection switch has triggered Module output of an expansion module Module output of an expansion module The defined warning mask of parameter Create Warning Mask Application Appl Warning Mask 626 signals a critical oper ating point All warnings application are activated Display is
154. at the input time 1 signal delay is started 2 If a positive signal edge is detected within time 1 signal delay time 1 starts again retrigger 3 After the expiry of time 1 signal delay the output signal is switched on for the time 2 signal duration 4 Within the time 2 signal duration the output is switched off by the input signal AND connection 5 If the input signal is present during the whole time 2 signal duration the output signal remains on in this time e Time not run out completely Time run out completely Factory settings Time 12 0 Time 2 0 Input Output In the factory settings the output signal follows the input signal 06 13 Operating I nstructions ACU 203 G Bonfiglioli 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 parameters Op Mode Comparator 1 540 and Op Mode Comparator 2 543 If an expansion module is connected further operation modes are available Comparator is switched off 1 Absolute current R m s Current 211 Rated Current 371 2 Abs Active Current Active current 214 Rated current 371 cy 419 fais acl sped Speed Sensor 2 Speed 220 gt maximum speed 4 Abs Actual Speed 1 calculated from Maximum Frequency 419 and No of Pole Pairs 373 frequency 4
155. ating staff s responsibilities 2 9 1 Selection and qualification of staff e Any work on the frequency inverter may only be carried out by qualified technical staff The staff must not be under the influence of any drugs Note the minimum age required by law Define the staff s responsibility in connection with all work on the frequency inverter clearly e Work on the electrical components may only be performed by a qualified electrician according to the applicable rules of electrical engineering e The operating staff must be trained for the relevant work to be performed 2 9 2 General work safety e In addition to the user manual of the machine plant any applicable legal or other regulations relating to accident prevention and environmental protection must be complied with The staff must be instructed accordingly Such regulations and or requirements may include for example handling of hazardous media and materials or provision use of personal protective equipment e In addition to this user manual issue any additional directives that may be required to meet spe cific operating requirements including supervision and reporting requirements e g directives re lating to work organization workflow and employed staff e Unless approved of expressly by the manufacturer do not modify the frequency inverter in any way including addition of attachments or retrofits e Only use the frequency inverter if the rated connection and setup valu
156. ation according to UL508c the in chapter 4 Technical Data described maximum temper atures must not be exceeded For an installation according to UL508c only 60 75 C copper conductors are allowed to be used For an installation according to UL508c the devices are only allowed to be used in environments ac cording to Pollution Degree 2 According to UL508c Warn or Marking labels are not allowed to be removed 86 Operating I nstructions ACU 06 13 vv Bonfiglioli 7 Control Unit KP500 06 13 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 Cod V TRL C FAUL 3 l B PARA CPY CWARN REM F SM Mmm bes a a B kHz s C RUN Used for starting the drive and opening the CTRL menu Press the RUN key to open the motor potentiometer function Used for opening the CTRL menu stopping the drive and acknowledg ing faults ET Used for navigating in the menu structure and selecting parameters ncreasing decreasing of parameter values ENT Used for opening parameters or switching to another menu within the menu structure Confirmation of the selected function or the set parameter ESC Used for aborting parameters
157. ation of the electronic gear is reached 624 In Gear The slave drive is engaged and operates at a synchronous angle with the master i ai Process data for Profibus communication Module 655 Out PZD18Boolean CM PDP V1 with Profibus interface is necessary 691 Index Contr Warn The phase error of the index control exceeded Phase Error the Warning limit 597 692 Index Contr Warning Index signal period too short during index con Period trol 700 RxPDO1 Booleanl Signal if an optional expansion module EM with system bus is used 701 RxPDO1 Boolean2 Signal if an optional expansion module EM with system bus is used 702 RxPDO1 Boolean3 Signal if an optional expansion module EM with system bus is used 703 RxPDO1 Boolean4 10 Signal if an optional expansion module EM with system bus is used Operation modes 700 to 703 for RxPDO2 with an 710 to 713 expansion module EM with system bus Operation modes 700 to 703 for RxPDO3 with an 720 to 723 expansion module EM with system bus 730 Sysbus Emergency Signal if an optional expansion module EM with system bus is used 616 Phasing Done The digital signal is independent of the configuration of the parameter Local Remote 412 Refer to the application manual Positioning for further details 7 Refer to the application manuals Positioning and Electronic gear for further details Refer to the operating instructions of the expansion modules with Profibus interface
158. ation to the customer s requirements in different applica tions The Technology Controller enables flow rate pressure level or speed control Configuration 410 sensorless field oriented control Configuration 410 contains 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 In this configuration parallel connection of several 3 phase motors is possible to a limited extent only Configuration 411 sensorless field oriented control with technology controller Configuration 411 extends the functionality 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 Configuration 430 sensorless field oriented control with speed torque control Configuration 430 extends the functionality of Configuration 410 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 The switch over between variable speed control is done without jerk in operation 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 formi
159. be installed separate from the control data and motor cables DClink connection The frequency inverters are to be connected to the same mains potential or a common direct voltage source Cables longer than 300 mm are to be shielded The shield must be connected to the mounting panel on both sides 9 Control Connection Keep control and signal cables physically sepa rate from the power cables Analog signal lines are to be connected to the shield potential on one side Install sensor cables separate from motor cables Motor and brake resistor The shield of the motor cable is to be connected to ground potential properly on both sides On the motor side use a metal compression gland On the frequency inverter side an appropriate shield clamp is to be used The signal cable used for monitoring the motor temperature must be kept separate from the motor cable Connect the shield of this line on both sides If a brake resis tor is used the connection cable must also be shielded and the shield is to be connected to earth potential on both sides Line choke Line chokes reduce mains harmonics and reactive power Additional the increase of product life is possible Consider the reduction of the maximum output voltage if a line choke is installed The line choke must be installed between mains connection and input filter Input filter Input filters reduce the conducted radio frequency interference voltage The input filter
160. by the ratio of the currents mentioned should be done in the motor supply line by means of a measuring current transformer of a sufficient bandwidth The internally calculated actual value for the flux forming current component cannot be output via the analog output for this measurement as the time resolution of the measurement is not sufficient To set the parameters of the PI controller the Amplification 700 is increased first until the actual value overshoots distinctly during the control process Now the am plification is reduced to about fifty percent again and then the ntegral time 701 is synchronized until actual value overshoots slightly during the control process The settings of the current controllers should not be too dynamic in order to ensure a sufficient reserve range The control tends to increased oscillations if the reverse range is reduced The dimensioning of the current controller parameters by calculation of the time con stant is to be done for a switching frequency of 2 kHz For other switching frequen cies the values are adapted internally so that the setting can remain unchanged for all switching frequencies The dynamic properties of the current controller improve if the switching and scanning frequency increases The fixed time interval for the modulation results in the following scanning frequen cies of the current controller via parameter Switching frequency 400 Switching frequency Scanning frequency 12
161. c Jono ebueup anjer lt c G ANIES uogeedo asipopnuy yas SEAP uomuny ON JeAO BHueYD o43u02 enbauo peeds N v aues uoneJedo esWepop Pes T 4vo ebueup enje ebeyusojed pox uoneJado esWwepop areis s E NIIS qd uuebpepwoupe Jou3A7O1S qi uuebpajvoupe Jou3A7O1S puau pamowpe Jou3A O1S a ano oO 5 I ul A tzoa m OA0Z 2d p jo 7uo02 p ds Jo o quoo A60jJouupe L Jo o ebuerp 041uo2 enbuo peeds suoneJn6yuoo pJepuejs y ui sjeu jo43uo2 9u3 Jo SUCH UN 289 Operating I nstructions ACU 06 13 C Bonfiglioli Bonfiglioli worldwide network Bonfiglioli Australia 2 Cox Place Glendenning NSW 2761 Locked Bag 1000 Plumpton NSW 2761 Tel 61 2 8811 8000 Fax 61 2 9675 6605 www bonfiglioli com au sales bonfiglioli com au Bonfiglioli Brazil Travessa Cl udio Armando 171 Bloco 3 CEP 09861 730 Bairro Assun o S o Bernardo do Campo S o Paulo Tel 55 11 4344 1900 Fax 55 11 4344 1906 www bonfigliolidobrasil com br bonfigliolidobrasil bonfiglioli com Bonfiglioli Canada 2 7941 Jane Street Concord Ontario L4K 4L6 Tel 1 905 7384466 Fax 1 905 7389833 www bonfigliolicanada com sales bonfigliolicanada com Bonfiglioli China 19D No 360 Pu Dong Nan Road New Shanghai International Tower 200120 Shanghai Tel 86 21 5054 3357 Fax 86 21 5970 2957 www bonfiglioli cn bdssales bonfiglioli com cn Bonfiglioli Deutschland Sperb
162. cess takes a few seconds When the process is f complete the message rdY is displayed 5 m w ig 3 e Confirm the message by pressing the ENT key Now you can select the copy function as described in the fol lowing zi pec E ated wo 06 13 Operating I nstructions ACU 1 69 Bonfiglioli 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 Function FOr Hm Use the function For to format and delete the memory in the ui control unit This may be necessary if a new control unit is Pir used for the first time Function ALL All readable and writable parameter values are transferred e Confirm this selection by pressing the ENT key and contin ue by selecting the source Function Act The active parameter values of the frequency inverter are cop ied to the control unit only The number of active parameter values depends in the current or selected configuration of the frequency inverter When copying the data from the control unit to the frequency inverter all stored parameter values are transmitted like in the case of the ALL function e Confirm the selection Act by pressing the ENT key and continue by selecting the source plo ae p
163. ch the reference output of the frequency inverter pcc X Fact sett e555 mi Rev 1190 0 0019 100 0000 10 0000 1 Available in configurations 1xx 2xx 4xx Parameter Configuration 30 Available in configurations 5xx and 6xx Parameter Configuration 30 Stator resistance asynchronous motor The value of the stator resistance can be optimized while the machine is in no load operation At the stationary operating point the torque forming current sq 216 and or the estimated Active current 214 should be zero Due to the temperature dependent of the stator resistance the adjustment should be done at a winding tem perature which is also reached during normal operation A correct measurement will optimize the control functions Stator resistance asynchronous motor The value of the stator resistance of the synchronous motor is entered during the guided commissioning The value of the stator resistance is used for adjustments of the current controller and should be therefore entered as exact as possible The sta tor resistance 1190 is the value between two motor phases and can be taken usually from the data sheet of the motor 10 2 2 Leakage Coefficient 124 The leakage coefficient of the machine defines the ratio of the leakage inductivity to the main inductivity The torque and flux forming current components are thus cou pled via the leakage coefficient Optimization of the leakage coefficient within the field orientat
164. chieved actuating the W key displays the highest parameter number In the current data set the data set related actual value parameters are dis played including the corresponding data set number The seven segment dis play shows data record 0 if the actual values in the four data sets are identical Display the actual value parameter upon switch on FUN A Display last actual value parameter highest number FUN V Display first actual value parameter lowest number 3 Use the ENT key to select the actual value The parameter is displayed includ ing its current value unit and the active data set 9 During commissioning operation and error analysis it is possible to monitor each actual value parameter specifically Some of the actual value parameters are arranged in the four available data sets If the parameter values in the four data records are identical the actual value is displayed in data record 0 If the actual values in the four data sets are different diFF is displayed in data set 0 Switch to another of the data set in the case of related actual values Determine minimum value and display it permanently Determine and display minimum actual value permanently Display of mean value of the actual value during the monitoring period FUN ENT Use the ENT key to save the selected actual value as a parameter displayed at switch on The message SEt with parameter number
165. choke 2 Mains current with relative mains impedance gt 1 see chapter Electrical installation 3 Reduction of switching frequency in thermal limit range Maximum current in continuous operation 5 Optional the frequency inverter of this size is purchasable without brake transistor Frequency inverter nominal power 06 13 Operating I nstructions ACU 39 Goo Bonfiglioli 4 11 ACU 401 75 0 to 132 0 kW 400 V ACU 401 eses 45 j w 49 Construction Size a ee Recommended motor shaft P KW 75 90 110 132 Output current 1 faf 150 180 210 250 Long term overload current 60 s 315 332 I fA A Short time overload current 1 s Output voltage Protection Rotary field frequenc fi cee Short circuit earth fault proof 0 1000 depending on switching frequenc Min brake resistance Recommended brake resistor Uagc 770 V Mains current 3ph PE Mains voltage Mains frequenc Fuses 3ph Fuses according to UL Cooper Bussmann I a 339 1 72 208 249 V 320 528 Dimensions Degree of protection Bae 1P20 EN60529 Terminals up to 2 x 95 Form of assembl Po 5 vetial jJ Energy Coolant temperature Om 95 0 40 3K3 DIN IEC 721 3 3 Storage temperature 25 55 Transport temperature Tt lec 25 70 96 15 85 not condensing If req
166. ck motor and cabling increase limit if necessary 10 Minimum current monitoring check motor and wiring Reference value on multifunctional input 1 faulty check signal Reference value EM S1INA faulty check signal Overcurrent on multifunctional input 1 check signal Resolver fault Check resolver connection and speed One track of the speed sensor signal is missing check connections Encoder 1 Division Marks Fault Correct Division Marks 491 of encod er 1 refer to chapter 10 4 2 Division marks speed sensor 1 The encoder is disabled In configurations 210 211 and 230 an encoder must be activated Set parameter Operation Mode 490 to an evalua tion mode not to 0 off If an expansion module is installed and parameter Actual Speed source 766 is set to 2 Speed Sensor 2 parameter Operation Mode 493 speed sensor 2 must be set to an evaluation mode KTY Temperature Measurement Failure Check KTY connection External error drive responded according to parameter setting for Op 54 eration mode ext error 535 Error was triggered via the logic signal or digital input signal assigned to parameter External error 183 5n 6n 7n 8n Fault with Absolute encoder evaluation Please check EM ABS 01 manu On Jal Table Fault Messages continued on next page Positioning function fault Please check Application manual Positioning F14 266 Operating I nstructions ACU 06 13 vv Bonfiglioli Code M
167. clockwise 422 and Deceleration anticlockwise 423 if these have been parameterized to the factory setting of 0 01 Hz s The parameter value of 0 00 Hz s for the acceleration blocks the corresponding di rection of rotation No Description x Fact sett 420 Acceleration clockwise 0 Pr Ex Hz s 5 00 Hz s 421 Deceleration clockwise 0 01 Hz s 9999 99 Hz s 5 00 Hz s 422 Acceleration anticlockwise 0 01 Hz s 9999 99 Hz s 0 01 Hz s 423 Deceleration anticlockwise 0 01 Hz s 9999 99 Hz s 0 01 Hz s Value 0 01 Hz s means Acceleration Clockwise 420 is applied Value 0 01 Hz s means Deceleration Clockwise 421 is applied The setting 0 00 Hz s won t accelerate or decelerate the drive due to the limitation of the ramp The ramps for the Emergency stop clockwise 424 and Emergency stop anticlockwise 425 of the drive mechanism to be activated via Operation mode 630 for the stop ping behavior must be selected according to the application The non linear S shaped course of the ramps is not active in the case of an emergency stop of the drive No Description X Fact sett Emergency stop clockwise 0 a TET T x Hz s 5 00 Hz s Emergency stop anti clockwise 0 01 Hz s 9999 99 Hz s 5 00 Hz s A Hus Rotary field clockwise Acceleration Deceleration Clockwise 421 Clockwise 420 or Emergency Stop Clockwise 424 t Acceleration Deceleration anticlockwise 423 Rotary field a
168. ction limit Ti Tk The limit for the switching frequency reduction is influenced by the intelligent current limits depending on the selected Operation mode 573 and the output current If they have been switched off or provide the full overload current the switching frequency is reduced when the output current exceeds the limit of 87 596 of the long term overload current 60s The switching frequency is increased if the output current drops below the reference current of the next highest switching frequency Operating Instructions ACU 06 13 vv Bonfiglioli 18 2 Fan The switch on temperature of the heat sink fan can be set with the parameter Switch on temperature 39 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 Switch on temperature 39 the heat sink fan will be switched on as soon as the frequency inverter is switched on and enabled and the start signal is received To protect the device a device fault is triggered when reaching an internal switching off temperature threshold If the heat sink temperature drops below the set temperature by 5 C or if the con troller enable signal is inhibited the heat sink fan is switched off when the minimum ON time has elapsed The minimum ON time of the heat sink fan is set internally to 1 minute When the temperature drops below the Switch on temperature 39 durin
169. cy of the drive via a search run in operation modes 1 to 5 The synchronization in operation modes 10 to 15 is accelerated by short test im pulses Rotary frequencies of up to 175 Hz are determined within 100 ms to 300 ms For higher frequencies a wrong frequency is determined and the synchronization fails In the Quick synchronization operation modes the search run cannot deter mine whether a synchronization attempt has failed For operation of a synchronous motor the flux direction can be determined in order to prevent alignment of the motor shaft jerking during start up Determining the flux direction takes approx 20 ms In this process there are short torque pulses This method is not suitable for very dynamic drives since the torque pulses result in a rotation of the drive and consequently in wrong measurements Once the flux direc tion was determined the flux is formed Parameter Minimum flux formation time 779 Maximum flux formation time 780 Current during flux formation 781 in order to improve the starting behavior 0 Off The synchronization to a rotating drive is deactivated The search direction is defined by the sign in front of the reference value If a positive reference value clockwise field of rotation is entered the search is in a positive di rection clockwise field of rotation with a negative refer ence value the search is in a negative direction anti clockwise field of rotation The first attemp
170. d and the parameter val ues are saved in data set 1 Additional motor data are measured dependent 32 Calc and para ident DS2 parameters are calculated and the parameter val ues are saved in data set 2 Operating I nstructions ACU 06 13 vv Bonfiglioli Additional motor data are measured dependent parameters are calculated and the parameter val ues are saved in data set 3 Additional motor data are measured dependent parameters are calculated and the parameter val ues are saved in data set 4 Data only DSO all of the four data sets Data only DS1 data set 1 Data only DS2 data set 2 _ Calc and para ident DS3 _ Calc and para ident DS4 43 Para Ident Machine Additional motor data are measured and saved in Data only DS3 data set 3 Para Ident Machine Additional motor data are measured and saved in Data only DS4 data set 4 The auto set up routine is performed in data set 0 Complete Setup w o and the parameter values are stored in all of the Para Ident DSO four data sets identically Extended motor data are not measured CaninisteSetupawia The parameter values of the auto set up are stored 111 p p in data set 1 Extended motor data are not meas Para Ident DS1 tired Complete Setupew a The parameter values of the auto set up are stored 12 p p in data set 2 Extended motor data are not meas Para Ident DS2 ured 13 i 4 44 110 1 The parameter values of the auto set
171. d operates at a synchronous angle with the master The current actual value is in the range between Switch on position 1243 and Switch off position 58 Position comparator 1244 of the position comparator The adjusted value of the parameter Hysteresis 1245 is con sidered Homing Done Em i reference position for positioning was set Reference orientation 469 of axle positioning was reached or Target position Distance 1202 of a position 60 Target Position Reached ing operation was reached the current act position is within the range set in parameter Target window 1165 for a minimum period of Target window time 1166 tion Threshold 1105 was exceeded Message on status of a travel order during a positioning operation The conditions set for pa rameter Digital Signal 1 1218 were fulfilled Start Reference value reached and End of a travel order were evaluated 29 41 Brake release 56 Phasing Done Motion Block Digital Sig BE nal 1 06 13 Operating I nstructions ACU 181 I Bonfiglioli Motion Block Digital Sig nal 2 Motion Block Digital Sig nal 3 Motion Block Digital Sig nal 4 FT Output Buffer 1 FT Output Buffer 2 FT Output Buffer 3 FT Output Buffer 4 90 Obj 0x3003 DigOut 1 a to to 94 Obj 0x3003 DigOut 5 100 to 194 Message on status of a travel order during a positioning operation The conditions set for pa rameter Digital Signal 2 1219 w
172. d values have been entered correctly Aborting the guided commissioning procedure by pressing ESC key should only be done by expert users because it may be possible that rated values have not been entered or determined correctly Operating Instructions ACU 06 13 vv Bonfiglioli Vectron 8 2 6 Parameter identification H CTRL RUN T PH ide Liq E3 rv Eg 2 gt i a m lc g 06 13 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 The machine data are measured while the drive is at a standstill The measured values are entered in the parameter automatically either directly or after the calculation The procedure and the duration of the parameter identification de pend on the type of machine connected and the device After checking the machine data entered the guided commissioning switches to the parameter identification Confirm the display PAidE by pressing the ENT key During the parameter identification the connected load is measured For the setting of parameter Motor type 369 to operation mode 10 Transformer no parameter identification is affected The safety functions o
173. de 1 Operation mode 2 anticlockwise clockwise anticlockwise clockwise generator motor generator motor motor generator E Current limit 728 E Current limit generator op 729 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 to be set via the parameters Amplification 1 721 Integral time 1 722 For the sec ond speed range the parameters can be set via the parameters Amplification 2 723 Integral time 2 724 The distinction between the speed ranges is done by the pa rameter Speed control switch over limit 738 The parameters Amplification 1 721 and Integral time 1 722 are taken into account with the parameter Speed control switch over limit f parameter Speed control switch over limit 738 is set to a value higher than 0 00 Hz parameters Amplification 1 721 Integral time 1 722 are active below the limit and parameters Amplification 2 723 Integral time 2 724 are active above the limit The control deviation can be filtered with the filter time constant 754 if necessary Therefore the operation with static control deviation with occasional undesired devia tions can be stabilized while at the same time the dynamic behavior in load change operation speed change or changing torque demand suffers The parameterized amplification at the current operating point can additionally be as sessed via the parameter Backlash damp
174. de Digital Out 177 Digital Signal 3 put 3 532 With expansion module Signal at digital output 1 of an expansion module Digital Signal 4 The signal which is selected via Op Mode EM mus EM Module SIOUTD 533 Signal at digital output 2 of an expansion module 182 Digital Signal 5 The signal which is selected via Op Mode EM EM Module S20UTD 534 Operating Instructions ACU 183 x Bonfiglioli 15 3 2 Setting Frequency If operation mode 4 Setting Frequency is selected for a digital output the corre sponding output becomes active if the actual value Stator Frequency 210 exceeds the value of Setting Frequency 510 The relevant output is switched over again as soon as the Stator Frequency 210 falls below the value of Setting Frequency 510 minus Setting Frequency Off Delta 517 If the output stage is switched off in example via STO the digital signal Setting frequency is set to zero independent of the actual frequency Signal source 164 Setting Frequency can be linked with inverter functions Description x Fact sett Setting Frequency 0 s uz TN 56 Hz 3 00 Hz Setting Frequency Off Delta 0 00 Hz 999 99 Hz 2 00 Hz Setting Frequency 510 Stator Frequency 210 Setting Frequency Off Delta 517 1 Digital output 164 Setting Frequency i a If Setting Frequency Switch Off Delta 517 gt Setting Frequency 510 the output is nev 1 er reset after the fir
175. der 1 Frequency Hz 0 00 999 99 20 2 335 Phase current la A 0 0 Imax 20 2 336 Phase current Ib A 0 0 Imax 20 2 337 Phase current Ic A 0 0 lax 20 2 R m s current A 0 0 1 20 2 Isd reactive current A 0 0 20 2 sq active current A 0 0 1 20 2 Rotor magnetizing current A 0 0 I max 20 2 Torque 9999 9 20 2 Analog input MFI1A 100 00 20 2 Analog output MFO1A 0 0 24 0 20 2 349 Repetition frequency output 0 00 999 99 20 2 Status of digital inputs 00 255 21 2 Status of digital outputs 00 255 21 2 Time since release 00000 00 00 000 20 2 Heat sink temperature 0 T nax 20 2 354 Inside temperature deg C 0 Timax 20 2 355 Controller Status C0000 CFFFF 21 3 356 Warning Status A0000 AFFFF 21 4 357 Int value 1 32768 20 2 358 Int value 2 32768 20 2 359 Long value 1 2147483647 20 2 360 Long value 2 2147483647 20 2 361 Checksum OK NOK 20 2 362 No of errors 0 32767 20 1 363 No of self acknowledged errors 0 32767 20 1 277 Goo Bonfiglioli No Description Unit Display range Chapter 367 Application Warning Status A0000 AFFFF 21 4 470 Rotations u 0 000 110 12 6 537 Actual warning mask AXXXXXXXX 15 3 8 627 Actual Appl Warning Mask
176. di Calderara di Reno bonfiglioli bonfiglioli com Bologna Italy www bonfiglioli com
177. direction of rota tion can be changed via parameter Change Sense of Rotation 1199 Refer to chapter 10 2 8 Change sense of rotation Operating I nstructions ACU 219 Sg Bonfiglioli 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 If the actual value is missing lt 0 596 the output frequency is guided to the Mini mum frequency 418 This is done using the set Deceleration clockwise 421 If the actual value is available again the controller continues operation automatically a c v A o t bg E gt gt 6 5 5 E 2 a 9c9 us x ra iL Difference Hysteresis 443 I Component Frequency 418 Frequency 419 Max Integral Time 445 Derivative Time 618 max P Compon 442 gt 0 50 X 9 S 0 Bs ES A E 6 a VI gt Y Bye G re 9g segs Pg 9 c 9557 eco 3s Sg Eg E o S glg 5 w8 5 EREL 9ouo Bas Peres es 220 Operating I nstructions ACU 06 13 vv Bonfiglioli 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 If the actual value is missing
178. djusted is saved as the JOG frequency 489 e Release the FUN key to stop the drive e The display returns to the previous function Pot or int or inP if function Motorpoti KP is activated 06 13 Operating I nstructions ACU 99 G Bonfiglioli 100 ENT Reversal of the sense of rotation independent of the control signal on the terminals Clockwise S21 ND or Anticlockwise S3I ND Cancel function and return to the menu structure Switch from internal set point int or motor potentiometer function Pot to JOG frequency the drive starts Release the key to switch to the sub function and stop the drive Start drive alternative to control signal S21 ND or S3IND Stop drive alternative to control signal S2IND or S3IND ESC FUN RUN STOP If you press the ENT key the sense of rotation is changed independent of the signal on the terminals Clockwise S21 ND or Anticlockwise S3I ND If the minimum frequency 418 has been set to 0 00 Hz the sense of rotation of the motor changes as soon as the sign of the reference frequency value changes Operating Instructions ACU 06 13 Bonfiglioli Vectron 8 Commissioning of the Frequency I nverter 8 1 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
179. dshake Traverse Function 49 06 13 Operating I nstructions ACU 255 G Bonfiglioli 18 9 Converter Profibus from to I nternal 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 Through the routing of the Profibus Word via the Systembus Tunneling the necessary bandwidth can be reduced and the parame terization of the Gateway Systembus Master with Profibus Slave communication be simplified The converter is used in this case in a device without Profibus module to convert the Profibus Notation into an internal reference value No Description Selection Selection In F Convert Reference 0 01 Hz 999 99 Hz A similar procedure can be used to convert in example the Actual Frequency into a value according to Profibus notation The converter can also be used for other purposes in example when using the inter nal PLC programming In F PDP word 1 1370 and In F PDP word 2 1371 convert the Profibus Notation into the internal Frequency 0x4000 in Profibus Notation 2100 96 refers to In F Convert Reference 1374 in Hz In F intern long 1 1372 and In F intern long 2 1373 convert an internal frequency value into Profibus Notation 0x4000 in Profibus Notation 2100 96 refers to In F
180. e 680 Ud 421 or 423 The overvoltage controller prevents a switch off of the frequency inverter in genera tor operation The reduction of the drive speed by a ramp gradient selected via the parameter Deceleration Clockwise 421 or Deceleration Anticlockwise 423 can lead to an overvoltage in the DC link If the voltage exceeds the figure set by the parame ter Reference DC link limitation 680 the deceleration is reduced in such a way that the DC link voltage is regulated to the set value If the DC link voltage cannot be regulated to the set reference value by the reduction of the deceleration the decel eration is stopped and the output frequency raised The output frequency is calculat ed by addition of the parameter value Max Frequency Rise 681 to the frequency at the operating point of the controller intervention Description i Max Fact sett 387 5 380 V Reference DC link limitation 775 760 V Max Frequency Rise 201 401 0 00 Hz 999 99 Hz 10 00 Hz When an operation mode with motor chopper is selected set the Trigger Threshold 507 Reference DC Link Limitation 680 10 V See chapter 18 7 1 Motor Chop n per 212 Operating Instructions ACU 06 13 tv Bonfiglioli Operation mode power failure regulation Voltage controller Parameter Operation mode 670 2 Ud f nm Gradient limited Standard ramp by P683 FOC SERVO or P674 Mains voltage Po
181. e 101 inverted 210 Inv fixed limit value Operation mode 110 inverted 17 5 3 4 Switching over between speed control and torque control Via the signal assigned to parameter n T Control Change Over 164 you can switch between speed control and torque control See chapter 15 4 6 n M Control Change Over 06 13 Operating I nstructions ACU 231 Goo Bonfiglioli 17 5 4 Speed controller The source of the actual speed value is selected via parameter Actual Speed Source 766 By default speed sensor 1 is used as the actual speed source If speed 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 Alternatively the speed controller can derive the actual speed value from the machine model in configura tions 4xx and 6xx Parameter Configuration 30 1 Speed Sensor 1 The actual speed source is speed sensor 1 of the basic device factory setting 2 Speed Sensor 2 D speed source is speed sensor 2 of an expansion The speed controller receives the calculated actual speed 3 Machine Model value from the machine model Can be set in configura tions 4xx and 6xx Speed synchronization by comparison between the calcu lated machine model and speed sensor 1 to increase speed 4 Speedtracking EC 1 accuracy Can be set in configurations 4xx and 6xx Ad justment for parameter Integral Time Speedtracking 515 is considered Speed synchronization
182. e D atte ET 105 Plausibility check i i ci ire d E t c ein RR EET uA 106 Parameter identification cc mmm 107 Status messages during commissioning SS sssssseee 108 Warnings during commissioning SA sssssse ee ee eee eeee ena aaeeeeees 108 Error messages during commissioning SF sss 110 Application data c te eee eei ec T UR Eae RE He eH Ee RT RA DOR 111 Acceleration and deceleration ssssssee eem 111 Set points at multi functional input mH 111 Quitting COMMISSIONING meme ens 112 Selection of an actual value for display sssssssse ee 112 Check direction of rotation 1 esseeeeeeeieeee essei eene anneau 113 Speed 1 114 Speed sensor I e De aa narar HER EV REEL EE Re EE a eae DART Eus an 115 Speed Sens r 2 3 edu ere EH HEEL EE a EXTR Fe EAR ERA 115 Operating I nstructions ACU 5 G6 Bonfiglioli 8 5 Set up via the Communication Interface esee 116 9 Inverter Data 9 1 9 2 9 3 9 4 9 5 9 6 9 7 9 8 9 9 Serial Number 118 Optional Modules ccccsesseeeeeenseeueennaeeesennageeeeenaaseesennuseesenonaseesennasensenoas 118 Inverter Software Version 111 eeeeeeceei esee enean nnn n na ua nna nnmnnn nna 118 Set PASSWOP PE E E E 118 Control Level 119 User NaMe sssssssssssnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn
183. e ENT key Use the arrow keys to set value 110 Normal operation and confirm your selec tion by pressing the ENT key The control unit is set to normal operation Resetting via communication module CM and or using control software VPlus Resetting of the control unit through a communication connection is possible only if the frequency inverter is fitted with an optional communication module CM and communi cation takes place via this module Establish connection to frequency inverter Start communication and select parameter Program ming 34 via the communi cation connection Via the communication connection enter value 110 in parameter Program ming 34 and confirm this value Via the communication connection enter value 123 in parameter Program ming 34 and confirm this value by pressing Enter The frequency inverter is reset The display of the control unit reads rESEt After resetting the control unit is available again with full functionality 7 7 Control Menu CTRL A 06 13 In order to be able to control the drive via the control unit the digital inputs S1IND STOA and S7IND STOB must be connected for enabling the output The unit may only be connected with the power supply switched off Verify that the frequency inverter is discharged Switch off power supply before connecting or disconnecting the control inputs and outputs Verify that the keyed control inputs and outputs are deenergized before connect
184. e can be used for further logic instructions and digital out puts The logic instructions can be linked with each other for any complex intercon nections Up to 32 logic instructions allow flexible adoption of various input signals Example A drive should start when the enable signal AND the S5IND signal are set OR the enable signal AND the S6IND signal are set Refer to the application manual Function table for a more detailed description Operating Instructions ACU 205 I Bonfiglioli 15 5 4 Multiplexer Demultiplexer 206 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 Multiplexer The multiplexer features 16 inputs for logic signals or digital input signals On the output the logic signal 927 Output MUX for the inputs of the TxPDO process data of the system bus or for PZDx IN process data of the Profibus can be used 1252 Mux inputs The parameters Mux input index write 1250 and Mux input index read 1251 for the input signals of the multiplexer enable parameterization via the control unit KP500 or the application VTable in VPlus No Description Min Max Fact se
185. e device type diagrams No Description X Fact sett 400 Switching frequen 2 kHz 16kHz kHz PRU ES ue The factory setting of parameter Switching frequency 400 depends on the setting of param eter Configuration 30 D configurations 1xx 2 configurations 2xx 4xx 5xx The heat losses increase proportionally to the load point of the frequency inverter and the switching frequency The automatic reduction adjusts the switching frequen cy to the current operating state of the frequency inverter in order to provide the output performance required for the drive task at the greatest possible dynamics and a low noise level The switching frequency is adapted between the limits which can be set with the pa rameters Switching frequency 400 and Min switching frequency 401 If the Min switching frequency 401 is larger than or equal to the Switching frequency 400 the automatic reduction is deactivated Descrip ion Min Max Fact sett 16 kHz The change of the switching frequency depends on the heat sink temperature switch off limit and the output current The temperature limit to be exceeded so that the switching frequency is reduced can be set via parameter Reduction limit heat sink temp 580 If the heat sink temperature falls below the threshold set via parameter Reduction limit heat sink temp Ti Tk 580 by 5 C the switching frequency is in creased again step by step No Description Min mex Fact sett Redu
186. e heat sink or brake resistor may be hot even some time after the ma chine plant was shut down Don t touch any surfaces directly after shutdown Wear safety gloves where necessary The frequency inverter may hold dangerous voltage levels until the capacitor in the DC link is dis charged Wait for at least 3 minutes after shutdown before starting electrical or mechanical work on the frequency inverter Even after this waiting time make sure that the equipment is deener gized in accordance with the safety rules before starting the work In order to avoid accidents or damage only qualified staff and electricians may carry out the work such as installation commissioning or setup In the case of a defect of terminals and or cables immediately disconnect the frequency inverter from mains supply Persons not familiar with the operation of frequency inverters must not have access to the fre quency inverter Do not bypass nor decommission any protective facilities The frequency inverter may be connected to power supply every 60 s This must be considered when operating a mains contactor in jog operation mode For commissioning or after an emer gency stop a non recurrent direct restart is permissible After a failure and restoration of the power supply the motor may start unexpectedly if the Auto Start function is activated If staff is endangered a restart of the motor must be prevented by means of external circuitry Before commissionin
187. e pa rameter description is displayed by the PC control software e g VPlus in the select ed Language 33 0 Deutsch Parameter description in German 1 English Parameter description in English 2 Italiano Parameter description in Italian 100 The language is defined via VPlus ACU firmware 5 2 0 or higher Up to ACU firmware 5 1 11 the language is set via Language 33 0 1 2 Starting with d ACU firmware 5 2 0 the texts of the parameters is administered by the PC software VPlus When Language 33 is set to 100 the settings 0 1 and 2 are not selectable Firmware version 5 2 0 or higher requires a compatible VPlus version VPlus 7 38 or higher 9 9 Programming The parameter Program ming 34 enables acknowledgment of a fault message and resetting to the factory settings The display of the control unit reads dEFLt or rE SEt and the LEDs indicate the status of the frequency inverter Parameter tage Control unit P 500 is prepared for parameter transmis lll sion A connected frequency inverter can receive data mission from the control unit 110 Standard opera Resetting of control unit KP 500 to standard operation tion mode The current error message can be acknowledged via 123 Reset digital input S1IND STOA or the software parameter The display of the control unit reads rESEt The parameters of the selected configuration except for 4444 Default a few exceptions are reset to the default settings
188. e parameter figure is comparable with the division marks 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 No Desenpulon Min Max Fact sett 497 Divider o 1 819 1024 The reference value specification within the different functions enables the use of the repetition frequency signal as a percentage figure A signal frequency of 100 Hz at the repetition frequency input corresponds to 10096 1 Hz corresponds to 196 The param eter Divider 497 is to be used in a way comparable with the speed sensor simulation Via parameters Offset 652 and Amplification 653 the PWM input signal can be adjusted for the application No Description X Fact sett w G0 ooo 000 Amplification 1000 0 100 0 PWM Signal PWM Value Offset 652 E ges x Amplification esa Set the reference value via one the following modes For reference frequency values Reference Frequency Source 475 32 Rep Frequency Input F3 The PWM value is related to Maximum Frequency 419 For reference percentage values Reference Percentage Source 476 32 Rep Frequency Input F3 The PWM value is related to Maximum Reference Percentage 519 Parameter PWM Input 258 shows the actual value of the PWM input 06 13 Operating I nstructions ACU 171 GG Bonfiglioli 15 Control
189. e parameterized control behavior The distance between the reference point and the required position is to be defined in motor revolutions The calculation of the distance covered is done with the select ed Positioning distance 460 according to the application The setting 0 000 U for the Positioning distance 460 causes an immediate stop of the drive according to the selected stopping behavior for Operation mode 630 No Description Min Max Fact sett 0 000U 1000000 000U 0 000 U The actual value parameter Revolutions 470 facilitates the setting and optimization of the function The revolutions of the motor displayed should correspond to the Po sitioning distance 460 at the required position Operating Instructions ACU 06 13 vv Bonfiglioli The minimum number of revolutions needed until the required position is reached depends on the Actual frequency 241 and Deceleration clockwise 421 or Decel eration anticlockwise 423 as well as the No of pole pairs 373 of the motor f2 Umn min number of rotations U f Actual frequency 241 mim 2 a p a Deceleration 421 423 p No of pole pairs 373 of motor Example f 20 Hz a 5 Hz s p 2 gt rpm 20 With an actual frequency of 20 Hz and a delay of 5 Hz s at least 20 rotations are needed until standstill at the required position This is the minimum value for the Positioning distance 460 a shorter positioning distance is not possible I
190. e selection in the copy menu Use the ESC key to switch to the target selection menu Operating Instructions ACU 93 I Bonfiglioli 7 5 6 Error Messages 94 The copy function archives all parameters regardless of the g off access control and the value range Some of the parameters are only writable if the frequency inverter is not in operation GEN The controller enable input S1IND STOA S7IND STOB may not be activated during the copy operation otherwise the data transmission is aborted The message StO and the number of the last parameter which was copied are displayed If the con troller enable input is deactivated again the aborted copy op eration is continued The data transmission from the selected source to the destina ali tion is continuously monitored by the copy function If an error occurs the copy operation is aborted and the message Err Err and an error code are displayed e 2 o Write error in memory of control unit repeat the copy operation If error message is displayed again format the memory Read error in memory of control unit repeat the copy operation If error message is displayed again format the memory The size of the memory of the control unit was not determined correct ly If this error occurs repeatedly replace the control unit Not enough memory the data are incomplete Delete the incomplete file and date no longer needed from the control unit The communicat
191. e temperature to an analog voltage or current signal in a range from 26 0 C to 207 8 C The resistance of the measuring resistor KTY84 130 to be used is 1000 at a temperature of 100 C The material used for the rotor winding of the motor is taken into account via the pa rameter Temperature coefficient 466 This value defines the change of the rotor re sistance as a function of the temperature for a certain material of the rotor winding Typical temperature coefficients are 39 100 C for copper and 36 100 C for aluminum at a temperature of 20 C The temperature characteristic within the software is calculated via the aforemen tioned temperature coefficient and the parameter Temperature adjustment 467 The adjustment temperature enables an additional optimization of the rotor time constant alongside the parameter Rated slip correction factor 718 No Description Min Max Fact sett 466 Temperature coefficient 0 00 100 C 300 0096 100 C 39 0096 100 C Adjusting temperature 300 C Operating Instructions ACU 06 13 vv Bonfiglioli 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 correction factor 718 nor an adjustment of the temperature synchronization via the parameter Temperature coefficient 466 is necess
192. e the direct current brake Depending on the setting of the stop function a direct current is impressed into the motor either directly or when it is at a standstill after the demagnetization time The impression of the Braking current 631 results in the motor heating up and should only be done for a short period in the case of internally ventilated motors Description Min Max Fact sett 0 00 A um len Nominal Output current of Frequency inverter The setting of the parameter Braking time 632 defines the time controlled stopping behavior Contact controlled operation of the direct current brake is activated by entering the value zero for the Braking time 632 Time controlled The direct current is controlled by the status of the signals Start clockwise and Start anticlockwise The current set by the parameter Braking current 631 flows until the time set by the parameter Braking time 632 has expired For the duration of the braking time the control signals Start clockwise and Start anticlockwise are logical 0 Low or 1 High Operating Instructions ACU 06 13 vv Bonfiglioli Contact controlled If the parameter Braking time 632 is set to the value 0 0 s the direct current brake is controlled by the Start clockwise and Start anticlockwise signals The time monitor ing and limitation by Braking time 632 are deactivated The braking current will be impressed until the controller enable control signal S1IND STOA and S7IND
193. e time of the last four faults No Description Function 330 DC Link Voltage Direct voltage in the DC link 331 Output voltage S output voltage motor voltage of the requency inverter 332 Stator frequency The output voltage motor voltage of the fre quency inverter Calculated from the data on speed sensor 1 the 29 FIRQHEncy Spend Sengon No of pole pairs 373 and the speed sensor signal 335 Phase current la Measured current in motor phase U 336 Phase current Ib Measured current in motor phase V 337 Phase current Ic Measured current in motor phase W Calculated effective output current motor current S28 Bonus damen of the frequency inverter Current component forming the magnetic flux or 339 Isd reactive current the calculated reactive current 340 Isq active current Current component forming the torque or the cal culated active current 341 Rotor magnetizing current Magnetizing current relative to the rated motor parameters and the operating point 342 Torque Torque calculated from the voltage the current and the control variables Input signal on multifunctional input 1 in analog Operation mode 452 Output signal on multifunctional input 1 in Op Sae Analog DULBHERTFORR eration mode 550 analog 349 Repetition frequency out Signal at repetition frequency output according to put Operation mode 550 repetition frequency Decimally coded status of the six digital
194. eanin F15 nn Positioning function fault Please check Application manual Positioning F17 nn Fault with Absolute encoder evaluation Please check EM ABS 01 manu al Communication error according to parameter CM VABus Watchdog F20 10 Timer 413 F20 F20 F23 F24 F25 F27 F28 dia of received bytes differs from map 2c CAN RxPDO3Timeout OSO 5x DeviceNet Fault Please check DeviceNet manual 6x PROFIBUS Fault Please check PROFIBUS manual Fault message on system bus master when a fault at system bus slave nn occurs nn node ID of slave hex Communication fault system bus timeout sync telegram Communication fault system bus timeout RxPDO1 Communication fault system bus timeout RxPDO2 Communication fault system bus timeout RxPDO3 Communication fault system bus bus off nn Heartbeat error nn triggering node nn Unknown CM module Check compatibility firmware and CM module nn Unknown CM module Check compatibility firmware and EM module Industrial Ethernet Fault Please check manual of used Ethernet Mod ule nn EtherCAT fault Table Fault Messages continued on next page Operating I nstructions ACU 267 G Bonfiglioli Meaning User triggered Error of Internal PLC Please check the application man ual VPLC 10 Data transmission from control unit KP 500 to the frequency inverter not possib
195. ed control systems demands acceleration to various operating points of the drive Unlike the torque forming current sq 216 the flow forming current Isd 215 should be largely independent of the load torque The flow forming current component is inversely proportional to the leakage coefficient If the leakage coeffi cient is increased the torque forming current increases and the flux forming compo nent drops The adjustment should result in a relatively constant actual current 7sd 215 matching the set Rated magnetizing current 716 regardless of the load on the drive The sensorless control system uses the parameter Leakage coefficient 378 in order to optimize the synchronization to one drive Description Min Max Fact sett imm Coefficient 20 0 7 0 Operating I nstructions ACU 06 13 vv Bonfiglioli 10 2 3 Magnetizing Current The Rated magnetizing current 716 is a measure of the flux in the motor and thus of 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 current 371 This current can be compared to the field current of an externally excit ed direct current machine In order to optimize the sensorless field oriented control system the machine must be operated without load at a rotational frequency which is below the Rated frequen cy 375 The accuracy of the optimization increases with the adjusted Switching f
196. ed warning mask is not modified T Activate everthi The warnings and controller status messages stated DM are linked in the warning mask 2 Activate all Warnings oa reports stated are linked in the warn 3 Activate all Controller The controller status reports stated are linked in the States warning mask 10 Warning Ixt The frequency inverter is overloaded Overload reserve for 1 s less the Warning limit Lis WamingShortTem Dt aterm Ixt 408 has been reached f Overload reserve for 60 s less the Warning limit vie Marni Cong her L long term Ixt 406 has been reached Warning Heat Sink Max heat sink temperature Tx of 80 C minus the 13 g Warning Limit Heat Sink Temp 407 has been Temperature reached 14 Warning Inside Tem Max inside temperature T of 65 C minus the perature Warning Limit Inside Temp 408 reached uu The controller stated in Controller status 355 limits 15 Warning Limit the reference value 16 Warning Init Frequency inverter is being initialized Warning behavior according to parameterized Oper Warning Motor Tem i ation mode Motor temperature 570 at max motor perature temperature Tprc Warning A f 18 Mains Fallufa Phase monitoring 576 reports a phase failure 19 Warning Motor Protec Operation Mode 571 for the motor protective tive Switch switch has triggered The Maximum frequency 419 has been exceeded The frequency limitation is active Warning The input signal is lower than 1
197. eeeeeeseeeeeneaseeseeeageeeeenaaseesenauseesenoeaseesnoaasenseaoas 151 IDC Compensation Limit e eeeeeeeeeeeeieee esee enne nhan nn nana nana 151 Frequency Switch Off Limit 1 uee ee eeeeeee ee ieei eene ne nane 152 Motor Temperature 111 eeeeeee eina eee na aun ana uuu a aaa a aaa uaa nua nananana 152 Phase Failure 1 111eeeeeeeeieee nanena opaan uann annua a aaa usua a Rana auda 153 Automatic Error Acknowledgment ecce eeeieee n nnnns 153 14 Reference Values 14 1 14 2 14 3 14 4 14 4 1 14 5 14 5 1 14 6 14 6 1 14 6 2 14 6 3 14 7 14 8 14 9 14 10 14 10 1 14 10 2 14 10 3 14 11 Frequency Limits e eeeeeee e eeeieee einen anna nana nnn a nau n nana uana asas annm auda 154 EJOgi ilile 154 Percentage Value Limits 11eeeeee e eeeieee eese eene nena un nana nnn 154 Frequency reference channel 11 ees eere cesse eene nana nnn nnn 154 Block Ca Grants uui cdd Ded veux pe Go eoa rc Pre tuin Dese Da 156 Reference percentage channel 1 ueeee cessere eren 158 isIlefe dio E Te is Tun EE c Em 159 Fixed reference values eese eeeieee e eieii eene nianu nana aka a a rna na 161 Fixed Frequencies 00 eee eer eee e nnnm ener nne 161 J OG frequenty itor nisiut pxcestum a
198. efer 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 setting of Operation Mode 630 22 06 13 Operating I nstructions ACU 139 G Bonfiglioli 12 2 1 Switch Off Threshold The Switch off threshold stop function 637 defines the frequency as from which a standstill of the drive is recognized This percentage parameter value is relative to the set Maximum frequency 419 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 Description X Fact sett Switch off threshold ini z 1 0 96 If the motor builds up a stopping torque it may be possible that the switch off threshold stop function is not reached due to the slip frequency and the standstill of the drive is not recognized In this case increase the value of the Switch off thresh old stop function 637 12 2 2 Holding Time The Holding time stop function 638 is considered in stopping behavior 1 3 4 and stopping behavior 6 Controlling to speed zero leads to a heating of the motor and should only be done for a short period in internally ventilated motors Description Min Max Fact sett Holding time stop function 200 0 s 1 0s 12 3 Direct current brake 140 Stopping behaviors 3 6 7 and the search run function includ
199. eference frequency value or a reference percentage value is possible for various requirements Parameterization can be done via two points of the linear characteristic of the reference value channel Point 1 with coordinates X1 and Y1 and point 2 with coordinates X2 and Y2 can be set in four data sets No Description x Fact sett soos Xo 200 100 00 100 00 0 00 0 00 100 00 98 00 457 Point Y2 100 00 96 100 00 96 100 00 96 The coordinates of the points relate as a percentage to the analog signal with 10 V or 20 mA and parameter Maximum Frequency 419 or parameter Maximum percent age reference 519 The direction of rotation can be changed via the digital inputs and or by selection of the points The monitoring of the analog input signal via the parameter Error Warning behavior 453 demands the examination of the parameter Characteristic point X1 454 172 Operating Instructions ACU 06 13 vv Bonfiglioli The following characteristic is set by default and can be adapted to the application via the parameters mentioned Y X2 98 Y2 100 Point 1 X122 0096 10V 2 0 20 V Y1 0 0096 50 00 Hz 0 00 Hz Point 2 X2 98 00 10 V 9 80 V Y2 100 00 50 00 Hz 50 00 Hz x 10 V 0 mA 02V 20 mA neg maximum value The freely configurable characteristic enables setting a tolerance at the ends as well as a reversal of the direction of rotation The following example sh
200. 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 After a few seconds the self test is complete the relay X10 picks up and signals no fault If the unit is in as delivered condition or after resetting the unit to the factory set tings the guided commissioning procedure is started automatically On the control unit the SetUP menu from the menu branch CTRL is displayed 8 2 Setup Using the Control Unit 06 13 The guided commissioning of the frequency inverter determines all parameter set tings relevant to the required application The available parameters were selected based on known standard drive applications This facilitates the selection of the im portant parameters After successful completion of the SETUP routine the actual value Actual frequency 241 from the VAL menu branch is displayed on the control unit Now the user should check whether further parameters are relevant for the application The guided commissioning contains the function for parameter identification The parameters are determined by way of measurement and set accordingly You must carry out the guided commissioning procedure with cool machine because part of the machine data depends on the operating temperature For control of a synchronous machine and successful setting of parameter Configura tion 30 to 510 FOR syn speed con
201. ency 0 Hz If shutting down or fault switch off are to be affected at an output frequency of 0 Hz the Point X1 must be adjusted e g X1 10 1 V 02V 1V 98v X 176 Operating Instructions ACU 06 13 vv Bonfiglioli 15 2 Multi Function Output MFO1 Multifunction output MFO1 can either be configured as a digital analog or a repeti tion frequency output Depending on the selected Operation mode 550 for the multi function output a link to various functions of the software is possible The operation modes not used are deactivated internally Output has the logic signal LOW Digital output 0 24 V 1 2 Analog Analog output 0 24 V 3 Repetition Frequency Repetition frequency output 0 24 V fmax 150 kHz 15 2 1 Analog output MFO1A By default the multifunction output MFO1 is configured for the output of a pulse width modulated output signal with a maximum voltage of DC 24 V The selected configuration determines which actual values can be selected for pa rameter Analog operation 553 of multifunction output 1 Abs value of the Stator Frequency 0 00 Hz Maximum frequency 419 Abs value of the Stator Frequency fmin fmax Minimum frequency 418 Maximum frequency 419 Abs value of speed sensor signal 1 isse ono din 0 00 Hz Minn S 419 Abs value of act frequency nies neal Frequency 0 00 Hz Maximum frequency 419 2 i Abs value of current effective current active 205 ANE aellye 0 0 A
202. ene n nnne 177 Analog output MFOTA scorre Sergeant Merion tua RR eu wa uo gu EE Rs 177 Output CharacteristiC 2 22 6 dace dre rd aa dps deba e a bua d 178 Frequency Output MFOTF iriure end ene ren rh hd e ER ek ewadene ii 179 Eel ii bie dead hie elec al dere ee ee 179 Digital OUtPUtS ccccceeseeeeeeseeeeeneaeeesenoaseeseeneaseeseooaseeseenaeesenoauseeesnogsenees 180 BITE E 183 Setting Frequency i uet ii tee de Ee c P REOR EH LEER eee RE TER A 184 Reference value reached sesssssssseesee eene nen 185 Flux Forming finished i ie Ee re x a E aa a 186 Operating I nstructions ACU 7 GJ Bonfiglioli 15 3 5 15 3 6 15 3 7 15 3 8 15 3 9 15 4 15 4 1 15 4 2 15 4 3 15 4 4 15 4 5 15 4 6 15 4 7 15 4 8 15 4 9 15 4 10 15 4 11 15 4 12 15 5 15 5 1 15 5 1 1 15 5 2 15 5 3 15 5 4 Brake release addita root aa i sese gs E cU ET DIR CK De MERE NEU ME dE 186 Current Limitation siii oe t nare d ra dde d aad la ra dest sra Rad a Po M ped rada dida 186 External PAM tiateiaadssaaneinnsdatatnastt aaa a decidat daa awe Rag rA a UnUM DM US 186 Warning Mask eiie er nete eter en e HE RR RE PARC od ee chi apa 187 Application warning mask sssese e emen 190 Duc 191 Start command iii ee eto E laver E aaa 196 3 Wire COntOl eU TUTTI 196 Error Acknowledgment eccinrnrnrcninncini aa aaa 197 TIME a E E a eats ast eeieetaueans 197 Thermo conta Ct TITEL ana
203. equire an expansion mod ule An expansion module EM RES for evaluation of resolver signals is re quired for operation of a synchronous machine control method 5xx 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 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 Operating Instructions ACU 06 13 vv Bonfiglioli 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 X210A 1 Voltage output 20 V or input for external power supply DC 24 V 10 GND 20 V GND 24 V ext Digital input STOA 1st shutdown ath of safety function STO Start of clockwise operation X210A 5 Start of anticlockwise operation X210A 6 Data set change over 1 X210A 7 Data set change over 2 X210A 2 X210A 3 X210A 4 X210B 1 Motor thermal contact X210B 2 Digital input STOB 2 shutdown ath of safety function STO Run Signal Analog signal of act
204. er 75 Operating I nstructions ACU 06 13 6 7 3 6 7 4 6 7 5 6 7 6 6 7 7 6 7 8 6 7 9 6 7 10 6 7 11 6 7 12 Controller 6 7 13 Controlled 6 7 14 tv Bonfiglioli Configuration 410 Sensorless Field Oriented Control 76 Configuration 411 Sensorless Field Oriented Control with Technology Controller 77 Configuration 430 Sensorless FOC Speed and Torque Controlled 78 Configuration 210 Field Oriented Control Speed Controlled 79 Configuration 211 Field Oriented Control with Technology Controller 80 Configuration 230 Field Orientated Control Speed and Torque Controlled 80 Configuration 510 FOC of Synchronous Machine Speed Controlled 81 Configuration 530 FOC of a Synchronous Machine Speed and Torque Controlled82 Configuration 610 Sensorless FOC of Synchronous Machine Speed Controlled 83 Configuration 611 Sensorless FOC of a Synchronous Machine with Technology 84 Configuration 630 Sensorless FOC of a Synchronous Machine Speed and Torque 85 Installation notes according to UL508C cece terre e 86 7 Control Unit KP500 7 1 7 2 7 3 7 4 7 5 7 5 1 7 5 2 7 5 3 7 5 4 7 5 5 7 5 6 7 6 7 6 1 7 6 2 7 6 3 7 7 7 8 Menu Structure 11eseieieee eiiis nena uuu auu aan uaa a anu a a Rana R4 Ra Sau RR a RR Rua uua maa 88 Main Menu E 88 Actual Value Menu V
205. er DC brake Stopping behaviors 3 6 and 7 are only available in the configurations for V f sensor less control 1xx The drive is brought to a standstill at the emergency stop deceleration As soon as the drive is at a standstill the inverter is disabled after a after a holding time The holding time can be set via the parameter Holding time 638 Depending on the setting of the parameter Starting function 620 the Starting current 623 is im pressed as from standstill or the Starting voltage 600 is applied The drive is brought to a standstill at the emergency stop deceleration and remains permanently supplied with cur rent Depending on the setting of the parameter Starting func tion 620 the Starting current 623 is impressed as from standstill or the Starting voltage 600 is applied The drive is brought to a standstill at the set emergency stop deceleration As from standstill the DC set via pa rameter Braking current 631 is impressed for the Brak ing time 632 Comply with the notes in chapter DC brake Stopping behaviors 3 6 and 7 are only available in the configurations for V f sensor less control 1xx Direct current braking is activated immediately The di rect current set with the parameter Braking current 631 is impressed for the die Braking time 632 Comply with the notes in chapter DC brake Stopping behaviors 3 6 and 7 are only available in the configurations for V f sensor less control 1xx Please r
206. er 12 2 Stopping Behavior In these operation modes the setting of Reduction Factor Flux 778 becomes effec tive after the time of parameter Holding Time 638 is elapsed The resulting standstill flux is calculated by multiplying Reference Flux 717 and Reduction Factor Flux 778 After a start command the drive starts immediately and the flux is increased up to the reference value during the movement Because of the reduced flux the initially required torque forming current component Isq is increased The time needed to achieve the reference flux can be influenced by parameter Ref Isd Upper Limit 743 which is set to the motor rated current after setup Description Min Max Fact sett Reduction Factor Flux 20 00 100 00 100 00 17 5 6 1 Limitation of field controller The output signal of the field controller the integrating and proportional components are limited via parameter Ref Isd upper limit 743 and parameter Ref Isd lower lim it 744 The guided commissioning has set the parameter Ref Isd upper limit 743 according to the parameter Rated current 371 Description X Fact sett Ref Isd upper limit Le ca Irun Ref Isd lower limit 0 0 The limits of the field controller define not only the maximum current occurring but also the dynamic properties of the controller The upper and lower limits restrict the modification speed of the machine flux and the torque resulting from it In particular the speed area above the nomin
207. er taking appropriate technical measures e g use of low capacitance cables and output filters The following table contains recom mended values for the use of output filters Frequency inverter unshielded cable shielded cable 0 25 kW 1 5 kW upon request upon request 1 85 kW 4 0 kW 150m 100m 5 5 kW 9 2 kW 200m 135 m 11 0 kW 15 0 kW 225m 150m 18 5 kW 30 0 kW 300m 200m 37 0 kW 65 0 kW 300m 200 m 75 0 kW 132 0 kW 300m 200 m 6 4 3 3 Motor cable length with sinus filter Motor cables can be much longer if sinus filters are used By conversion in sinus shaped currents high frequency portions which might limit the cable length are fil tered out Also consider the voltage drop across the cable length and the resulting voltage drop at the sinus 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 BONFIGLI OLI 06 13 Operating I nstructions ACU 57 G Bonfiglioli 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 mo
208. er to the control unit is also disabled Activation of the control unit KP 500 for parameter transfer is prepared via parameter Program ming 34 The control unit KP 500 must be connected to the frequency inverter Control unit P 500 is prepared for parameter trans mission A connected frequency inverter can receive data from the control unit Parameter transmis lll sion 110 Standard operation ii of control unit KP 500 to standard operation Parameter transmission mode can be activated on the control unit KP 500 only if at least 1 file is stored in the control unit Otherwise the error message FOA10 will be displayed as soon as activation is attempted 7 6 1 Activation 06 13 The control unit KP 500 can be configured both via the keys of the KP 500 and via any available CM communication module For configuration and activation of the KP 500 control unit proceed as follows Activation via keyboard of control unit e n the parameter menu PARA use the arrow keys to select parameter Pro gram ming 34 and confirm your selection by pressing the ENT key e Use the arrow keys to set value 111 Parameter transmission and confirm your selection by pressing the ENT key Now the control unit is ready for activation Before data transmission the control unit must be initialized e Unplug the control unit from the frequency inverter and connect again to the same or another frequency inverter The initialization is s
209. eration 673 until the frequency limit Shutdown threshold 675 is reached If the energy of the system for bridging the mains failure is not sufficient the delay is affected at maximum ramp gradient as from the Shutdown threshold 675 The time required until the motor has come to a standstill results from the regenera tive energy of the system which results in an increase in the DC link voltage The DC link voltage set with the parameter Reference shutdown value 676 is used by the voltage controller as a control figure and kept constant The voltage rise enables optimization of the braking behavior and the time until the drive has come to a standstill The behavior of the controller can be compared to stopping behavior 2 Shutdown Stop as the voltage controller brings the drive to a standstill at the maximum deceleration ramp and supplies it with the remaining DC link voltage If the DC link voltage is restored before the shutdown of the drive but after falling below Shutdown Threshold 675 the drive is still decelerated to standstill If the mains voltage is restored after the shutdown of the drive but before the un dervoltage switch off has been reached the frequency inverter signals a fault The control unit displays the fault message F0702 If the mains failure without shutdown Shutdown threshold 675 0 Hz takes so long that the frequency has been reduced to 0 Hz the drive is accelerated to the reference frequency when the mains sup
210. eration of positioning con troller Message anticlockwise operation of positioning controller Message on status of a travel order during a posi tioning operation The conditions set for parame ter Digital Signal 1 1218 were fulfilled Start Reference value reached and End of a travel order were evaluated Message on status of a travel order during a posi tioning operation The conditions set for parame ter Digital Signal 2 1219 were fulfilled Start Reference value reached and End of a travel order were evaluated Message on status of a travel order during a posi tioning operation The conditions set for parame ter Digital Signal 3 1247 were fulfilled Start Reference value reached and End of a travel order were evaluated Message on status of a travel order during a posi tioning operation The conditions set for parame ter Digital Signal 4 1248 were fulfilled Start Reference value reached and End of a travel order were evaluated 895 to 898 Operation modes 891 to 894 inverted LOW ac tive 910 Output DeMux Bit 0 to to 925 Output DeMux Bit 15 Bit 0 to Bit 15 on output of de multiplexer de multiplexed process data signal via system bus or Profibus on input of multiplexers parameter DeMux Input 1253 2401 FT Output Buffer 1 to to 2416 FT Output Buffer 16 Output signals from FT instructions of the func tion table Refer to the operating
211. ere fulfilled Start Reference value reached and End of a travel order were evaluated Message on status of a travel order during a positioning operation The conditions set for pa rameter Digital Signal 3 1247 were fulfilled Start Reference value reached and End of a travel order were evaluated Message on status of a travel order during a positioning operation The conditions set for pa rameter Digital Signal 4 1248 were fulfilled Start Reference value reached and End of a travel order were evaluated The output signal of a function table instruction The output signal is the signal source 2401 FT Output buffer 1 The signal source contains the value of the FT instruction output which is as signed to the signal source 2401 The assignment is done by parameter FT target output 1 1350 or FT target output 2 1351 The output signal of a function table instruction The output signal is the signal source 2402 FT Output buffer 2 The signal source contains the value of the FT instruction output which is as signed to the signal source 2402 The assignment is done by parameter FT target output 1 1350 or FT target output 2 1351 The output signal of a function table instruction The output signal is the signal source 2403 FT Output buffer 3 The signal source contains the value of the FT instruction output which is as signed to the signal source 2403 The assignment
212. error envi ronment all warnings present at the time of the error are always displayed AXXXX ABCDE Warning code Abbreviation for the warning Meaning of code displayed by parameter Warning status 356 A 00 00 No warning message present A 00 01 Ixt Frequency inverter overloaded A0002 or A0004 A 00 02 Ixtst Overload for 60 s relative to the nominal output of the frequen cy inverter A 00 04 IxtLt Short time overload for 1 s relative to the nominal output of the frequency inverter A 00 08 Tc Max heat sink temperature T of 80 C less the Warning Limit Heat Sink Temp 407 reached A 00 10 Ti Max inside temperature T of 65 C less the Warning Limit Inside Temp 408 reached a The controller stated in Controller status 275 limits the refer A 00 20 Lim ence value A 00 40 INIT Frequency inverter is being initialized A 00 80 PTC Warning behavior according to parameterized Operation mode Motor temp 570 at max motor temperature T motor A 01 00 Mains Phase monitoring 576 reports a phase failure A 02 00 PMS pee switch parameterized in Operation mode 571 A 04 00 Flim The Maximum frequency 419 was exceeded The frequency limitation is active A 08 00 Al The input signal MFI1A is lower than 1 V 2 mA according to the operation mode for the Error warning behavior 453 A 10 00 A2 The input signal is lower than 1 V 2 mA according to the op eration mode for the Error warning behavior 453 A slave on the system bus re
213. ers and the ambient conditions The selected Switching frequency 400 defines the rated current and the available overload for one second and sixty seconds respectively The Warning Limit Short Term Ixt 405 and Warning Limit Long Term Ixt 406 are to be parameterized ac cordingly Description X Fact sett Warning Limit Short Term Ixt o 96 Warning Limit Long Term Ixt 100 96 Exceeding of warning limit is signaled by 165 Warning Ixt Output signals Digital signals indicate the attainment of warning limits 165 Warning Ixt 7 Warning Limit Short Term Ixt 405 or Warning Limit 7 Ixt Warning Long Term Ixt 406 is attained 1 For linking with inverter functions For digital output 13 2 Temperature 150 The ambient conditions and the energy dissipation at the current operating point result in the frequency inverter heating up In order to avoid a fault switch off of the frequency inverter the Warning Limit Heat Sink Temp 407 for the heat sink temper ature limit and the Warning Limit Inside Temp 408 as an internal temperature limit are to be parameterized The temperature value at which a warning message is out put is calculated from the type dependent temperature limit minus the adjusted warning limit The switch off limit of the frequency inverter for the maximum temperature is an internal temperature of 65 C and a heat sink temperature of 80 C 90 C No Description Min Max Fact
214. ers staff who is assigned special tasks by the Operator of the frequency inverter e g installation maintenance and service repair and troubleshooting Based on their qualifi cation and or know how qualified staff must be capable of identifying defects and assessing func tions Qualified electrician The term Qualified Electrician covers qualified and trained staff who has special technical know how and experience with electrical installations In addition Qualified Electricians must be familiar with the applicable standards and regulations they must be able to assess the assigned tasks properly and identify and eliminate potential hazards Instructed person The term Instructed Person covers staff who was instructed and trained about in the assigned tasks and the potential hazards that might result from inappropriate behavior In addition instructed per sons must have been instructed in the required protection provisions protective measures the appli cable directives accident prevention regulations as well as the operating conditions and verified their qualification Expert The term Expert covers qualified and trained staff who has special technical know how and experience relating to frequency inverter Experts must be familiar with the applicable government work safety directives accident prevention regulations guidelines and generally accepted rules of technology in order to assess the operationally safe condition of the frequency inv
215. erter 14 Operating I nstructions ACU 06 13 vv Bonfiglioli 2 2 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 The frequency inverters meet the requirements of the low voltage directive 2006 95 EEC and DIN EN 61800 5 1 CE labeling is based on these standards Responsibility for compliance with the EMC Directive 2004 108 EC lies with the operator Frequency inverters are only available at specialized dealers and are exclusively intended for commercial use as per EN 61000 3 2 No capacitive loads may be connected to the frequency inverter The technical data connection specifications and information on ambient conditions are indicated on the rating plate and in the documentation and must be complied with in any case 2 3 Misuse Any use other than that described in Designated use shall not be permissible and shall be consid ered as misuse For example the machine plant must not be operated e byuninstructed staff e while it is not in perfect condition e without protection enclosure e g covers e without safety equipment or with safety equipment deactivated
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217. es 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 with good conductivity on both sides The control mains and motor lines must be kept physically separate from one another The user must comply with the applicable limits stipulated in the relevant national and international directives as regards the application the length of the motor cable and the switching frequency 56 Operating I nstructions ACU 06 13 vv Bonfiglioli 6 4 3 1 Length of motor cables without filter Frequency inverter unshielded cable shielded cable 0 25 kW 1 5 kW 50m 25m 1 85 kW 4 0 kW 100 m 50m 5 5 kW 9 2 kW 100 m 50m 11 0 kW 15 0 kW 100 m 50m 18 5 kW 30 0 kW 150m 100m 37 0 kW 65 0 kW 150m 100m 75 0 kW 132 0 kW 150m 100m The specified lengths of the motor cables must not be exceeded if no output filter is installed The frequency inverters x 9 2 kW with integrated EMC filter comply with the emission limits of the product standard EN 61800 3 up to a motor cable length of 10 m The frequency inverters lt 9 2 kW with integrated EMC filter comply with the emission limits stipulated in EN 61800 3 if the motor cable is not longer than 20 m Customer specific requirements can be met by means of an optional filter 6 4 3 2 Motor cable length with output filter dU dt Longer motor cables can be used aft
218. es specified by the manu facturer are met e Provide appropriate tools as may be required for performing all work on the frequency inverter properly 06 13 Operating I nstructions ACU 19 Goo Bonfiglioli 2 10 Organizational measures 2 10 1 General e Train your staff in the handling and use of the frequency inverter and the machine plant as well as the risks involved e Use of any individual parts or components of the frequency inverter in other parts of the opera tor s machine plant is prohibited e Optional components for the frequency inverter must be used in accordance with their designated use and in compliance with the relevant documentation 2 10 2 Use in combination with third party products e Please note that BONFIGLIOLI VECTRON GmbH will not accept any responsibility for compatibility with third party products e g motors cables or filters e In order to enable optimum system compatibility BONFIGLIOLI VECTRON GmbH office compo nents facilitating commissioning and providing optimum synchronization of the machine plant parts in operation e f you use the frequency inverter in combination with third party products you do this at your own risk 2 10 3 Transport and Storage e The frequency inverters must be transported and stored in an appropriate way During transport and storage the devices must remain in their original packaging e The units may only be stored in dry rooms which are protected against dust and mo
219. ets to the heat sink of the frequen cy inverter and the assembly panel The frequency inverters are provided with fixing brackets which are fitted using four thread cutting screws The dimensions of the device and the installation dimensions are those of the standard device without optional components and are given in milli meters ACU aba a tadaa 201 40 5 5 KW 250 100 200 270 290 315 12 133 401 9 5 9 2 KW 250 100 200 270 290 315 12 133 110 15 0KkW 250 125 200 270 290 315 17 5 133 Operating I nstructions ACU 06 13 vv Bonfiglioli 5 3 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 fixing bracket top fixing bracket bottom fixing with screws M4x20 fixing with screws M4x70 Assembly is done by screwing the two fixing brackets to the heat sink of the frequen cy inverter and the assembly panel The frequency inverters are provided with fixing brackets which are fitted using four thread cutting screws The dimensions of the device and the installation dimensions are those of the standard device without optional components and are given in milli meters ACU a ce e a od 18 5 30 0 kW 06 13 Operating Instructions ACU 45 GO Bonfiglioli 5 4 46 ACU 401 37 0 to 65 0 kW
220. etta tt eb ral t en rb az 54 WE Tnaereunzeshe P m 56 Motor Conne ctlo eT ih wid viverettesaseetaene ERN 56 Length of motor cables without filter reren 57 Motor cable length with output filter dU dt 0 rerer eres 57 Motor cable length with sinus filter 57 ejerce EE 58 Speed sensor Connector aeter bet Lt t ot a etd art 58 Connection of a Brake Resistor ssssssssssseeee memes 59 Connection of types 1eiseeeeeeieeieeeeeiei aene aua auam a aduana aaa R anas usan nna u 4 60 ACU 201 up to 3 0 kW and 401 up to 4 0 kW HH 60 ACU 201 4 0 to 9 2 kW and 401 5 5 to 15 0 kW 62 ACU 401 18 5 to 30 0 kW disent retro rt raritas eee o Peur do P dau dun 64 ACU 401 37 0 to 65 0 KW ooo eee 66 ACU 401 75 0 t0 132 0 KW iiec ua Rie eas tinea ERE ETERNA RENE 68 Control Terminals ee eee eeeie eee i eiie enean a aun nnmnnn nnmnnn na 70 External DC 24 V power SUPDIY cece eem 72 Relay OUtp t ied de ER E HER E Pe ean Mox ue er e M GERE Ex Ex ce Bains 72 Motor Thermo Contact sssssssssseeeee emen nennen nennen 73 Control terminals Connection diagrams of configurations eee 73 Configurations overview ee eeeeee eee eei eene nen annua na aan nnmnnn nnmnnn nna 74 Configuration 110 Sensorless Control cece cece eee eect eee reese nea eneeees 75 Configuration 111 Sensorless Control with Technology Controll
221. ety function STO X210B 3 Run Signal X210B 4 Analog signal of actual frequenc X210B 5 Supply voltage 10V for reference value potentiometer X210B 6 Reference speed 0 10 V X210B 7 Ground 10 V 06 13 Operating I nstructions ACU 83 G Bonfiglioli 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 X210A 1 Voltage output 20 V or input for il external power supply DC 24 V 10 20 V 180 mA Digital input STOA 1st shutdown path of safety function STO 2 seta 6 over 1 sea X210A 6 X210A 7 Digital input STOB 2 shutdown path of safety function STO Run Signal Analog signal of actual frequenc 84 Operating I nstructions ACU 06 13 vv Bonfiglioli 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 Change over between variable speed control and torque dependent control is done jerk free d
222. evaluated per division mark Two channel speed sensor with recognition of direc tion of rotation via track signals A and B reference track via digital input S6IND Four signal edges are evaluated per division mark One channel speed sensor via track signal A the ac tual speed value is positive The reference track is connected to digital input S6IND One signal edge is evaluated per division mark The digital input S4IND is available for further functions One channel speed sensor via track signal A the ac tual speed value is positive The reference track is connected to digital input S6IND Two signal edges are evaluated per division mark The digital input SAIND is available for further functions One channel speed sensor via track signal A The actual speed value is positive for signal Low and negative for signal High at digital input S4IND One signal edge is evaluated per division mark The refer ence track is connected to digital input S6IND One channel speed sensor via track signal A The actual speed value is positive for signal Low and negative for signal High at digital input S4IND Two signal edges are evaluated per division mark The reference track is connected to digital input S6I ND 1001 1002 Quadruple evalua 1004 tion with reference track Single evaluation with sense of rot without sign with ref track 1011 Double evaluation with sense of rot without sign with ref track 1012
223. f EN 61800 3 please comply with the installation instructions in these operating instructions The frequency inverters ACU meet the requirements of EN 61800 3 for use in industrial environments The frequency inverters marked with the UL label according to UL508c also meet the requirements of the CSA Standard C22 2 No 14 UL approved are the device series ACU401 in sizes 1 to 7 and ACU201 devices in sizes 1 and 2 The function is described in the application manual Safe Torque Off Operation 0 55 C as from 40 C power reduction has to be considered Operation 3K3 EN60721 3 3 Relative humidity 15 85 no water condensation IP20 if covers and connection terminals are used properly Up to 1000 m at rated specifications Up to 4000 m at reduced power 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 Continuous Operation 100 96 ly Up to 150 Iy for 60 s Devices 01 03 Up to 200 Iy for 60 s Up to 200 Iy for1s 0 25 amp 0 37 kW Up to 200 Infor 1s The overload capability can be used once in a time cycle of 10 minutes Control methods adjusted to motors and application configuration Adjustable speed torque control Various control functions for motor and frequency inverter Positioning absolute or relative to a reference point Search Run Special brake control and
224. f an error occurs in a frequency inverter the error signal can be transmitted via a bus system and the required reaction can be triggered in another frequency inverter Parameter External error 183 can be assigned the logic signal or digital input signal which is to trigger the external error Via parameter Operation mode ext error 535 the response to an external error can be configured 0 Disabled No response to external errors The drive is switched off and the error message F1454 l Error Switch Off External Error is output if the logic signal or digital input signal for parameter External Error 183 is present The drive is stopped at the current deceleration ramp and the error message F1454 External Error is output if the Aea LOW ENO logic signal or digital input signal for parameter External Error 183 is present The drive is stopped at the current emergency stop ramp Emergency Stop and the error message F1454 External Error is output if Error the logic signal or digital input signal for parameter Exter nal Error 183 is present 3 For setting up external warnings parameters User Warning 1 1363 and User Warn ing 2 1364 can be used Check chapter 15 3 9 Application warning mask for fur ther details Operating Instructions ACU 06 13 vv Bonfiglioli 15 5 Function Modules 15 5 1 Timer 06 13 The timer function can be linked to various functions for time control of digital sig nals The parameters
225. f the frequency inverter avoid enabling of the power unit if no signal is present at digital input S1IND STOA terminal X210A 3 and S7IND STOB terminal X210B 2 If signals were already applied at the beginning of the guided commissioning the StO message is not displayed In order to be able to control the drive via the control unit the digital inputs S1IND STOA terminal X210A 3 and S7IND STOB terminal X210B 2 must be con nected for enabling the output 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 Do not touch the terminals because the capacitors may still be charged Only connect suitable voltage sources The nominal voltage of the frequency invert er must correspond to the supply voltage The frequency inverter must be connected to ground potential If voltage supply is switched on no covers of the frequency inverter may be re moved Confirm the final rEAdY message by pressing the ENT key Canceling the operation with the ESC key or withdrawing the enable signal S1IND STOA and S7IND STOB results in an incomplete take over of the values You must carry out the guided commissioning procedure with c
226. f the num ber of rotations until the required position is reached is to be lower the frequency must be reduced the deceleration increased or the reference point must be shifted The digital signal for registration of the reference point and the logical assignment are to be chosen from a selection of Signal source 459 The link of the digital inputs S21 ND S3IND and S6IND to further functions is to be checked according to selected Configuration 30 e g in configurations 110 and 210 digital input S2IND is linked to the function Start of clockwise operation The signals for positioning and a stopping behavior should not be assigned to the same digital input 2 S2IND neg edge The positioning starts with the change of the 3 S3IND neg edge logic signal from 1 HI GH to 0 LOW at the 6 S6IND neg edge reference point The positioning starts with the change of the logic signal from 0 LOW to 1 HIGH The positioning begins with the change of the logic signal 1x SxIND pos edge 2x SxIND pos neg edge The registration of the reference position via a digital signal can be influenced by a variable dead time while the control command is read and processed The signal running time is compensated by a positive figure for the Signal correction 461 The setting of a negative signal correction decelerates the processing of the digital signal Desenption Min Max Fact sett 327 68 ms 32167
227. ference modulator 3 00 105 00 96 102 00 96 1000 0 ms The percentage setting of the Reference modulation 750 is basically a function of the leakage inductivity of the machine The default value was selected such that in most cases the remaining deviation of 596 is sufficient as a reserve range for the current controller For the optimization of the controller parameters the drive is accelerated with a flat ramp into the area of field weakening so that the modulation controller intervenes The limit is set via parameter Reference modulation 750 Then the con trol loop can be excited with a unit step function by modifying the reference modula tion change over between 9596 and 5096 By means of an oscillographed meas urement of the flux forming current component on the analog output of the frequen cy inverter the controlling process of the modulation controller can be assessed The course of the signal of the flux forming current lsa should reach the stationary value after overshooting without oscillation An oscillating of the course of the current can be damped by increasing the integral time The parameter Integral time 752 should roughly correspond to the actual value Act rotor time constant 227 17 5 7 1 Limitation of Modulation Controller 06 13 The output signal of the modulation controller is the internal reference flux The con troller output and the integrating part are limited via the parameter Reference Imr lower limit
228. fine adjustment or a check of the rotor time constant proceed as follows Load the machine at fifty percent of the Rated frequency 375 As a result the voltage must be approximately fifty percent of the Rated voltage 370 with a maximum toler ance of 5 96 If this is not the case the correction factor must be changed according ly The larger the correction factor is set the stronger the voltage drop when the ma chine is loaded The value calculated by the rotor time constants can be read out via the actual value Current rotor time constant 227 The adjustment should be done at a winding temperature which is also reached during normal operation of the motor Description Min Max Fact sett Rated slip correction factor 0 01 300 0096 100 00 06 13 Operating I nstructions ACU 125 Goo Bonfiglioli 10 2 5 Voltage constant In configuration 5xx and 6xx for the control of synchronous machines the control behavior can be improved for high dynamic requirements by the settings of the pa rameter Voltage constant 383 For the voltage constant refer to the motor data sheet In the motor data sheet the value may be indicated in V This value can be taken over for parameter 1000 rpm Voltage constant 383 Description Min Max Fact Se 850 0 mvmin If the guided commissioning Setup is not carried out the auto setup should be carried out via parameter SETUP selection 796 in order to improve the drive behav
229. following procedure e Set the output frequency in a way i e via the frequency reference value that the actual value Modulation 223 80 90 Reference Modulation 750 e Now change the Flux Reference Value 717 from 100 96 to 90 96 Oscillo graph the actuating variable Isa The course of the signal of the flux forming current Isa should reach the stationary value after overshooting without oscil lation e Change the parameters Amplification 741 and Integral Time 742 according to the application requirements e Change the Flux Reference Value 717 back to 100 96 und repeat the flux reference step while you can analyze the changes with the oscillograph Re peat these steps if necessary If a quick transition into field weakening is necessary for the application the integral time should be reduced Increase the Amplification 741 in order to achieve a good dynamism of the controller An increased overshoot is necessary for a good control behavior in controlling of a load with low pass behavior e g an asynchronous motor Operating I nstructions ACU 237 G Bonfiglioli Parameter Reduction Factor Flux 778 reduces the standstill current if a stopping behavior with the function R gt 0 Stop is selected This stopping behavior is select ed if parameter Operation Mode 630 is set to 2x 20 27 R gt 0 Stop or x2 2 12 22 32 42 52 62 72 R gt 0 Stop The stopping behavior is de scribed in chapt
230. for access to the parameters The previous password is deleted No Description Min Max Fact sett 27 Setpassword 0 999 0 Operating Instructions ACU 06 13 9 5 9 6 9 7 06 13 vv Bonfiglioli Control Level The Control level 28 defines the scope of the functions to be parameterized The op erating instructions describe the parameters on the third control level These parame ters should only be set by qualified users Description Min Max Fact sett No i Control level User Name The User name 29 can be entered via the optional control software VPlus The plant or machine designation cannot be displayed completely via the control unit 32 alphanumeric characters Configuration The Configuration 30 determines the assignment and basic function of the control inputs and outputs as well as the software functions The software of the frequency inverters offers various configuration options These differ with respect to the way in which the drive is controlled Analog and digital inputs can be combined and com plemented by optional communication protocols The operating instructions describe the following configurations and the relevant parameters in the third Control level 28 adjustment of parameter Control level 28 to value 3 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 a
231. for some time Switch off power supply before connecting or disconnecting the keyed plug in terminals X1 and X2 x1 Phoenix ZEC 1 5 ST7 5 C L3 092 15mm AWG 24 16 Sf 02 15mm AWG 24 16 t3 0 25 1 5 mm AWG 22 16 CI C 9025 15mm AWG 22 16 250 W 1 1 kW L1 NPE Li L2PE L1 L2 L3 PE 1ph 230V AC 2ph 230V AC 3ph 230V AC D 3ph 400V AC 15kW 30kW BB 1 5kW 3 0kW DB 1 5kW 4 0 kW iif ii L1 N PE L1 L2 PE L1 L2 L3 PE 1ph 230V AC 2ph 230V AC 3ph 230V AC 3ph 400V AC With a mains current above 10 A the mains power connection 230 V 1ph N PE and the mains power connection 230 V 2ph N PE are to be done on two termi nals Loenen 60 Operating Instructions ACU 06 13 vv Bonfiglioli Phoenix ZEC 1 5 ST7 5 C ta 02 15mm AWG 24 16 f a 02 15mm AWG 24 16 Co B 0 25 1 5 mnt AWG 22 16 C3 025 1 5 mm AWG 22 16 U VLW UL VLW p Delta connection Star connection X2 X2 Phoenix ZEC 1 5 ST7 5 I EN St 0902 15mm E AWG 24 16 aq f Gp 02 15mnr m AWG 24 16 Bet 025 15mnt R AWG 22 16 i ee CCo 0 25 1 5mn Ti nh AWG 22 16 06 13 Operating I nstructions ACU 61 Go Bonfiglioli 6 5 2 ACU 201 4 0 to 9 2 kW and 401 5 5 to 15 0 kW Disconnect the frequency inverter from mains voltage and protect it against being energized uninten
232. frequency inverter e non compliance with the instructions warnings and prohibitions contained in the documentation e unauthorized modifications of the solar inverter e insufficient monitoring of parts of the machine plant which are subject to wear e repair work at the machine plant not carried out properly or in time e catastrophes by external impact and Force Majeure 12 Operating I nstructions ACU 06 13 vv Bonfiglioli 1 4 Obligation This user manual must be read before commissioning and complied with Anybody entrusted with tasks in connection with the e transport e assembly e installation of the frequency inverter and e operation of the frequency inverter must have read and understood the user manual and in particular the safety instructions in order to prevent personal and material losses 1 5 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 Any non compliance will constitute an offense against the copyright law dated 09 September 1965 the law against unfair competition and the Civil Code and
233. frequency limit The machine stops with the se lected stopping behavior at the entered position angle To ensure the correct function of the axle positioning the speed controller should be optimized after the guided commissioning This is described in the chapter Speed controller Via the parameter Reference orientation 469 the angle between the reference point and the required position is entered If this value is changed while the machine is at a standstill the positioning operation is carried out again at a frequency of 0 5 Hz For this a stopping behavior must be selected for the parameter Operation mode 630 which impresses a starting current either permanently when the drive is at a standstill or for the stopping time refer to chapter Stopping Behavior Description Min Max Fact sett No E i 469 Reference orientation 0 0 359 9 0 0 During the positioning operation the direction of rotation of the drive may change regardless of whether the command Start clockwise or Start anticlockwise was acti vated Make sure that the change of the direction of rotation cannot result in any personal or material damage Operating I nstructions ACU 147 G Bonfiglioli The positioning is started by a start command from a signal source e g digital input which must be assigned to the parameter Start Positioning of Axle 37 The signal source can be selected from the operation modes for digi
234. g and the start of the operation make sure to fix all covers and check the terminals Check the additional monitoring and protective devices according to EN 60204 and ap plicable the safety directives e g Working Machines Act or Accident Prevention Directives 06 13 Operating I nstructions ACU 21 Goo Bonfiglioli 2 10 7 Maintenance and service troubleshooting e Visually inspect the frequency inverter when carrying out the required maintenance work and inspections at the machine plant e Perform the maintenance work and inspections prescribed for the machine carefully including the specifications on parts equipment replacement e Work on the electrical components may only be performed by a qualified electrician according to the applicable rules of electrical engineering Only use original spare parts e Unauthorized opening and improper interventions in the machine plant can lead to personal injury or material damage Repairs on the frequency inverters may only be carried out by the manufac turer or persons authorized by the manufacturer Check protective equipment regularly e Before performing any maintenance work the machine plant must be disconnected from mains supply and secured against restarting The five safety rules must be complied with 2 10 8 Final decommissioning Unless separate return or disposal agreements were made recycle the disassembled frequency in verter components e Scrap metal materials e Recycle plastic
235. g frequency Coolant temperature 3K3 DIN IEC 721 3 3 Storage temperature E 25 55 Transport temperature 25 70 Rel air humidity 9 15 85 not condensing If required by the customer the switching frequency may be increased if the output current is reduced at the same time Comply with the applicable standards and regulations for this operating point Switching frequency diii Doha Em ise 0 25 kW 0 37 kW 0 55 kW 0 75 kW 1 1kW 1 5 kw 9 1 Three phase connection requires a commutating choke 2 Mains current with relative mains impedance 1 see chapter Electrical installation 3 Reduction of switching frequency in thermal limit range Maximum current in continuous operation 06 13 Operating I nstructions ACU 35 Goo Bonfiglioli 4 7 ACU 401 1 85 to 4 0 kW 400 V ACU 401 ee s qo d qo 8 oj 2 Construction Size Recommended motor shaft power P W 185 22 30 4 0 Output current 1 TAT 42 58 78 90 Long term overload curent 60s 1 A 63 87 117 135 Short time overload current 1 s Ld a 84 1388 5 3156 18 0 Output voltage V Maximum input voltage three phase Protection o e Short circuit earth fault proof Rotary field frequency 0 1000 depending on switching frequency Switching frequency 2 4 8 12 16 Min brake resistance 92 Recommended brake resistor R Q 300 220 148 106 Uagc 770 V Mains current 2 3ph PE Mains voltage
236. g this time since start ing the fan will continue to operate until the running ON time is reached Operation mode 43 for digital outputs additionally enables the control of an ex ternal fan Via the digital output the fan is switched on if the controller is released and Start clockwise or Start anticlockwise are switched on or if the Switch on tem perature 39 for the internal fan was reached Like in the case of the internal heat sink fan the minimum ON time of the external fan is 1 minute Description Max Fact sett 18 3 Bus controller Disconnect the frequency inverter from mains voltage and protect it against being energized unintentionally Verify that the frequency inverter is discharged A Wait for 3 minutes until the DC link capacitors have discharged before starting to work at the unit When the frequency inverter is disconnected from power supply the mains DC link voltage and motor terminals may still be live for some time In order to be able to control the drive the digital controller inputs SIIND STOA and S7IND STOB must be connected and set to High Signal in order to enable the out ut stage The frequency inverters can be extended by different options for data communication and can be integrate in an automation and control system in this way Parameteriza tion and commissioning can be done via the optional communication card the oper ating unit or the interface adapter 06 1
237. ge The configured warning mask is not changed 2 Activate all Warnings The warnings reports stated are linked in the warning mask 10 Waming V belt The Operation mode 581 for V belt monitoring signals no load operation of the application Warning message indicating that the positive SW limit switch has been reached parameter Positive SW limit switch 1145 T Warning message indicating that the negative UE meg SUW Limit SW limit switch has been reached parameter Negative SW limit switch 1146 Switch HW limit switch has been reached Switch HW limit switch has been reached Warning message indicating that the contour ing error monitoring range adjusted with pa rameter Warning Threshold 1105 has been left An encoder with data track can trigger a warn 16 Warning Encoder ing Selection is not effective with encoders without data track The signal set on digital input User Warning 1 He arning Veeri 1363 is active The signal set on digital input User Warning 2 ie Maring User 1364 is active 102 Deactivate all Warnings All warnings are deactivated 110 Deactivate Warning V Belt___ Warning 10 is deactivated Deactivate Warning pos 111 SW Limit Switch Warning 11 is deactivated Deactivate Warning neg 112 SW Limit Switch Warning 12 is deactivated Warning pos SW Limit l Switch 12 15 Warning Contouring Error Deactivate Warning pos 113 HW Limit Switch Warning
238. glioli 8 2 5 Plausibility check L LE 106 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 Verification of the machine data should only be skipped by experienced users The configurations contain complex control processes which depend to a large degree on the correctness of the machine parameters entered The warning and error messages displayed during the verification process have to be observed If a critical condition is detected during the guided commissioning it is dis played by the control unit Depending on the deviation from the expected parameter value either a warning or an error message is displayed To ignore the warning or error messages press the ENT key The guided commis sioning is continued However it is recommended that the data be checked and corrected if necessary To correct the entered parameter values after the warning or error message press the ESC key Use the arrow keys to switch to the parameter value which is to be corrected If an error message is displayed the rated values must be checked and corrected The guided commissioning procedure is repeated until the rate
239. gnals Please check incoming goods for quality quantity and nature without delay Obvious defects such as exterior damage of the packing and or the unit must be notified to the sender within seven days for insurance reasons Operating I nstructions ACU 06 13 vv Bonfiglioli 3 5 ACU 401 75 0 to 132 0 kW E Frequency inverter Terminal strip X10 Phoenix ZEC 1 5 3ST5 0 Plug in terminals for the relay output Plug in terminal for connection of the control signals Brief Instructions and Operating Instructions on CD ROM Control terminals X210A X210B Wieland DST85 RM3 5 Please check incoming goods for quality quantity and nature without delay Obvious defects such as exterior damage of the packing and or the unit must be notified to the sender within seven days for insurance reasons 06 13 Operating I nstructions ACU 29 I Bonfiglioli 4 Technical Data 4 1 CE conformity EMC directive Interference immunity UL Approval Safety function Ambient temperature Environmental class Degree of protection Altitude of installation Storage Overload capability Functions Parameterization 30 General technical data The frequency inverters ACU meet the requirements of the low voltage directive 2006 95 EEC and EN 61800 5 1 For proper installation of the frequency inverter in order to meet the require ments o
240. hange or a start stop or brake command No Description Min Max Fact sett x 420 Acceleration clockwise 0 00 Hz s 999 99 Hz s 5 00 Hz s 421 Deceleration clockwise 0 00 Hz s 999 99 Hz s 5 00 Hz s NOTE The deceleration of the drive is monitored in the default parameter setting Voltage controller operation mode 670 The deceleration ramp can be extended in the case of an increase in the DC link voltage during regenerative operation and or during the braking process 8 2 10 2 Set points at multi functional input The multi functional input MFI1 can be parameterized for a reference value signal in Operation mode 452 Operation mode 3 should only be selected by expert users for drive control via Fixed frequency 1 480 and Fixed frequency 2 481 l Voltage Input voltage signal MFI1A OV 10 V 2 Current Input current signal MFI 1A 0 mA 20 mA 3 Digital Input digital signal MFI 1D OV 24 V Use multifunction input MFI1 as digital input for slow signals For rapidly and regularly changing signals a digital input S2IND S6IND or a digital input of an expansion module EM should be used 06 13 Operating I nstructions ACU 111 G3 Bonfiglioli 8 2 11 Quitting commissioning End em 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
241. he first data set are used inde K Char Single pendently of the active data set Overloading the drive i mechanism is signaled by a warning message A0200 I t Single Motor I t Multi Motor Opera 61 tion Warning and Er See chapter 18 5 2 ror Switch Off I t Single Motor I t Single Motor 62 Warning and Error See chapter 18 5 2 Switch Off K Char Mul Motor m Op Err Sw Off Latching K Char oe Sing Motor Err Sw Off Latching 111 K Char Multi Motor Op Warning Latching K Char Single He Motor Warning Latching Like Operation modes 1 2 11 or 22 Additionally the integrated current over the time is stored when the device is switched odd and set to the stored value when switched on again 246 Operating Instructions ACU 06 13 06 13 vv Bonfiglioli Parameter Operation Mode 571 1 11 101 or 111 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 In this operation mode the rated values of the active data set are monitored The current output current of the frequency inverter is only taken into account in the motor protection switch activated by the data set In the motor pro tection switches of the other data sets zero current is expected with the result that the thermal decay functions are taken into account In combination with the data set change ove
242. he flux forming and torque forming current components Upon startup the machine is magnetized and a current is impressed first With the parameter Current during flux formation 781 the magnetization current is set with the parameter Maximum Flux Formation Time 780 the maximum time for the current impression is set The current impression is done until the reference value of the rated magnetizing current is reached or the Maximum Flux Formation Time 780 is exceeded No Description Min Max Fact sett 780 Maximum Flux Formation Time 1 ms 10000 ms 1000 ms 50 ms Current during flux formation The factory setting of parameter Maximum Flux Formation Time 780 depends on the setting of parameter Configuration 30 D configurations 1xx 2 configurations 2xx 4xx 3 configurations 6xx The magnetizing current changes according to the rotor time constant of the motor By setting the parameters Max Flux Formation Time 780 and Min Flux Formation Time 779 a constant flux formation time can be achieved With parameter Min Flux Formation Time 779 the minimum time for flux forming current can be set This enables a defined time between start signal and run up of the drive For an optimum setting of the parameters the rotor time constant the required starting torque and Current during Flux Formation 781 have to be considered No Description Min Max Fact sett l es 10 ms 779 Min Flux Formation Time 1 ms 10000 ms D 50
243. he value for parameter Rated Current 371 is too high referred to pa rameters Rated Power 376 and Rated Voltage 370 Correct the values SF003 The value entered for parameter Rated Cosine Phi 374 is wrong greater than 1 or smaller than 0 3 Correct the value The calculated slip frequency is negative Check and if necessary correct SF004 the values entered for parameters Rated Speed 372 and Rated Frequency 375 The calculated slip frequency is too high Check and if necessary correct SF005 the values entered for parameters Rated Speed 372 and Rated Frequency 375 The calculated total output of the drive is lower than the rated power SF006 Correct and check if necessary the value entered for parameter Rated Power 376 SF007 The set configuration is not supported by the set up routine SF011 The main inductance measurement has failed because the motor has a high slip Correct the rated motor values in parameters 370 371 372 374 375 and 376 Carry out the guided commissioning once again In case an error message is displayed again enter the value 110 for parame ter Configuration 30 sensorless regulation according to U f characteristic if value 410 was set so far Carry out the guided commissioning once SF012 The leakage inductance measurement has failed because the motor has a high slip Correct the rated motor values in parameters 370 371 372 374 375 and 376 Carry out the guided commissioning once again In case an
244. iglioli 4 5 ACU 201 4 0 to 9 2 kW 230 V ACU 201 8 9 22 3 4 Construction Size Recommended motor shaft power P kW 4 0 5 549 7 5 9 2 Output current a 180 22 0 35 0 Long term overload current 60 s 1 A 263 30 3 51 5 Short time overload current 1 s 1 A 330 33 0 64 0 Output voltage Maximum input voltage three phase Protection o e Short circuit earth fault proof Rotary field frequency 0 1000 depending on switching frequency Switching frequency 2 4 8 12 16 Min brake resistance Recommended brake resistor Uagc 385 V Mains current 3 3ph PE 18 35 6 9 a 4 a Mains voltage Mains frequency 66 4 4 4 250 x 125 x 200 3 7 Dimensions Weight approx Degree of protection Terminals Form of assembly Ears vertical 2 kHz switching frequency 310 420 Coolant temperature 3K3 DIN IEC 721 3 3 Storage temperature H 25 55 Transport temperature T C 25 70 Rel air humidity 95 15 85 not condensing If required by the customer the switching frequency may be increased if the output current is reduced at the same time Comply with the applicable standards and regulations for this operating point Switching frequency eee ee 4 0 kW 5 5 kW 227 A 9 22 0 A 9 9 75 kw 9 9 2 kw 38 3A 1 9 35 0 A 1 9 29 4 A 5 D Three phase connection requires a commutating choke 2
245. imited Now the value of the Mini mum acceleration 726 is set to half the set acceleration ramp so that it is ensured that the acceleration pre control is active The acceleration pre control is not raised by increasing the Mech time constant 727 until the output figure corresponds to the time modification of the drive during the acceleration processes Operating Instructions ACU 06 13 vv Bonfiglioli 17 5 6 Field Controller 06 13 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 The proportional and the integrating part of the field controller are to be set via parameters Amplification 741 and Integral time 742 Description x Fact sett Reference Flux 0 m 2 rT m 100 0096 Amplification 00 100 0 5 0 1000 0 ms 100 0 ms Please note that changes within the Field controller parameters should only be done in the basic speed area When an optimization of the Field controller is necessary set the ntegral Time 742 Act Rotor Time Constant 227 2 meaning to the half of the rotor time constant In most application cases this change is sufficient When further optimizations are necessary follow the step described in the
246. ing 748 depending on the control deviation In particular the small signal behavior in applications with a gearbox can be improved by a value higher than zero percent Parameter Backlash damping 748 is available depending on the type of unit No JBescnpson x Fact sett mW o0 2099 2n Integral time1 Oms 6000ms Amplification 000 20000 0 ms 55 00 Hz 100 D The default setting is relative to the recommended machine data for the amplifica tion and integral time This enables a first function test in a large number of appli cations Switch over between settings 1 and 2 for the current frequency range is done by the software according to the selected limit value 06 13 Operating I nstructions ACU 233 Goo Bonfiglioli 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 First the amplification is increased until the actual value over shoots distinctly during the control process This is indicated by a strong oscillation of the speed and by the running noises In the next step reduce the amplification slightly 1 2 3 4 etc Then reduce the integral time larger component until the actual value overshoots only slightly in the control process If necessary check the speed co
247. ing behavior 3 Stopping behavior 4 Stopping behavior 5 Stopping behavior 6 Stopping behavior 7 Stopping behavior 0 Free stopping 1 Stopping behavior 1 Stop and Switch off Stopping behavior 2 Stop and Hold Stopping behavior 3 Stop and DC brakes Stopping behavior 4 Emergency Stop and Switch off Stopping behavior 5 Emergency Stop 50 and Hold Stopping behavior 6 Emergency Stop and Brake m e 25 35 i i E i 5 3 Z L r 55 o m w o Start clockwise eo 1 Stopping behavior 7 DC brakes 70 w 75 76 AB AB Operation mode 630 of the stopping behavior is to be parameterized according to the matrix The selection of the operation modes can vary according to the control method and the available control inputs Example The machine is to stop according to stopping behavior 2 if the digital logic signals Start clockwise 68 0 and Start anticlockwise 69 0 Additionally the machine is to stop according to stopping behavior 1 if the digital logic signals Start clockwise 68 1 and Start anticlockwise 69 1 To achieve this the parameter Operation mode 630 must be set to 12 By selecting the stopping behavior you also select the control of a mechanical brake if operation mode 41 Brake release is used for one digital output for controlling the brake Operating I nstructions ACU 06 13 Stopping behavior O Free stopping Stopping behavior 1 Stop T
248. ing or disconnecting them Otherwise components may be damaged Operating I nstructions ACU 97 G3 Bonfiglioli 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 Local Remote 412 Via this parameter you can specify which functions will be available to the controller De pending on the operation mode selected only some of the control menu functions are available Refer to chapter 18 3 Bus controller for a detailed description of pa rameter Local Remote 412 7 8 Controlling the Motor via the Control Unit The control unit enables controlling the connected motor in accordance with the se lected operation mode of parameter Local Remote 412 In order to be able to control the drive via the control unit the digital inputs S1IND STOA and S7IND STOB must be connected for enabling the output The unit may only be connected with the power supply switched off Verify that the frequency inverter is discharged A Switch off power supply before connecting or disconnecting the control inputs and outputs Verify that the keyed control inputs and outputs are deenergized before connecting or disconnecting them
249. inputs and 350 Status of digital inputs of multifunctional input 1 in Operation mode 452 digital input 343 Analog input MFI1A Decimally coded status of the two digital outputs 351 Status of digital outputs and of multifunctional output 1 in Operation mode 550 digital The time of the error in hours h minutes m 352 Time since release and seconds s after the release signal hhhhh mm ss 719 100 1000 353 Heat sink temperature Measured heat sink temperature 354 Inside temperature Measured inside temperature 59 ler oded in the conya status o 356 The warning messages coded in warning status 357 Software service parameter 358 Software service parameter 359 Software service parameter 360 Software service parameter 367 The application warnings coded in warning status The Checksum 361 parameter shows whether the storage of the error environment was free of errors OK or incomplete NOK Operating Instructions ACU 269 Goo Bonfiglioli No Description Function 361 Checksum Check protocol of the error environment 270 Operating Instructions ACU 06 13 vv Bonfiglioli 21 Operational and Error Diagnosis 21 1 21 2 06 13 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 Status Display The green and red
250. inputs and outputs as well as the communica tion can be maintained Input voltage range DC 24 V 10 Rated input current Max 1 0 A typical 0 45 A Peak inrush current Typical 20A External fuse Via standard fuse elements for rated current charac teristic slow Safety Safety extra low voltage SELV according to EN 61800 5 1 The digital inputs and the DC 24 V terminal of the electronic control equipment can withstand external voltage up to DC 30 V Higher voltages may destroy the unit Use suitable external power supply units with a maximum output current of DC 30 V or use appropriate fuses to protect the unit Comply with the application manual Safe Torque Off STO especially if you apply this safety related function 6 6 2 Relay Output 72 By default the freely programmable relay output is linked to the monitoring function factory setting The logic link to various functions can be freely configured via the software parameters Connection of the relay output is not absolutely necessary for the function of the frequency inverter X10 Phoenix ZEC 1 5 3ST5 0 L3 02 15mm X10 AWG 24 16 C 02 15mm 1 ssouT AWG 24 16 B 025 1 5 mm AWG 22 16 SC TE 025 15mm AWG 22 16 1 3 Relay output floating change over contact response time approx 40 ms maximum contact load make contact AC 5 A 240 V DC 5 A ohmic 24 V break contact AC 3 A 240 V DC 1A oh
251. instructions of the expansion modules with Profibus interface 1 Refer to the operating instructions of the expansion modules with CAN interface Refer to the application manual Positioning for further details 14 Refer to the operating instructions of the expansion modules with system bus or Profibus interface 15 Refer to the application manual Function Table for further details 06 13 Operating I nstructions ACU 195 I Bonfiglioli 15 4 1 Start command The parameters Start Clockwise 68 and Start Anticlockwise 69 can be linked to the 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 Operation mode 620 for the starting behavior and Op eration mode 630 for the stopping behavior 15 4 2 3 wire control 196 In the case of 3 wire control the drive is controlled using digital pulses The drive is prepared for starting via the logic state of the signal Start 3 wire control 87 and started by a Start clockwise pulse Parameter Start clockwise 68 or a Start anti clockwise pulse Parameter Start anticlockwise 69 By switching off the signal Start 3 wire control 87 the drive is stopped The control signals for Start clockwise and Start anticlockwise are pulses The func tions Start clockwise and Start anticlockwise f
252. into the motor after release The output frequency is kept at zero Hz for the Maximum flux formation time 780 After this time has expired the output frequency follows the ad justed V f characteristic see operation mode 0 Off Operation mode 2 includes operation mode 1 After the Maximum flux formation time 780 has elapsed the out put frequency is increased according to the set accelera tion If the output frequency reaches the value set with the parameter Frequency limit 624 the Starting current 623 is withdrawn There is a smooth transition to 1 4 times the frequency limit to the set V f characteristic As from this operating point the output current depends on the load Operation mode 3 includes operation mode 1 of the start function When the output frequency reaches the value Magnetization set with parameter Frequency limit 624 the increase of IxR compensation the output voltage by the IxR compensation becomes effective The V f characteristic is displaced by the por tion of voltage which depends on the stator resistance Magnetization Magnetization and current impression 134 Operating I nstructions ACU 06 13 vv Bonfiglioli In this operation mode the current set with the parame ter Current during flux formation 781 is impressed into the motor for magnetization after release The output frequency is kept at zero Hz for the Maximum flux formation time 780 After the time has elapsed the out put frequency is i
253. ion 0 01 30 00 17 4 2 612 Integral time ms 1 10000 17 4 2 EX 613 Current Limit A 0 0 0 ley 17 4 2 V Ed 614 Frequency Limit Hz 0 00 999 99 17 4 2 617 Max Temp Windings C 0 200 13 6 618 Derivative Time ms 0 1000 17 3 282 Operating I nstructions ACU 06 13 vv Bonfiglioli 06 13 No Description Unit Setting range Chapter EX 620 Operation mode Selection 12 1 1 621 Amplification 0 01 10 00 12 1 1 622 Integral time ms 1 30000 12 1 1 E 623 Starting Current A 0 0 0 len 12 1 1 1 E 624 Frequency Limit Hz 0 00 100 00 12 1 1 2 625 Brake release time ms 5000 5000 12 1 1 3 626 Create Appl Warning Mask Selection 15 3 9 630 Operation mode Selection 12 2 Ej 631 Braking current A 0 00 N2 I gi 12 3 632 Braking time S 0 0 200 0 12 3 E 633 Demagnetizing time S 0 1 30 0 12 3 634 Amplification 0 00 10 00 12 3 635 Integral time ms 0 1000 12 3 637 Switch off threshold 0 0 100 0 12 2 1 638 Holding time S 0 0 200 0 12 2 2 645 Operation mode Selection 12 5 646 Brak time after search run S 0 0 200 0 12 5 647 Current rated motor
254. ion has been disturbed or interrupted repeat the copy function delete the incomplete file if necessary Invalid identification of a file in the operating unit delete faulty file and format memory if necessary The memory space of the selected target file is occupied delete file or use different target file in the operating unit 3 The source file to be read in the control unit is empty only files containing reasonable data should be selected as a source delete defective file and format memory if necessary The memory in the control unit is not formatted format the memory via the FOr function in the copy menu Error during reading of a parameter from the frequency inverter check connection between the control unit and the frequency inverter and repeat reading operation Error during writing of a parameter in the frequency inverter Check connection between the control unit and the frequency inverter and repeat the writing operation delete faulty file and format memory if necessary repeat the copy function delete the incomplete file if necessary 2 N Operating I nstructions ACU 06 13 wv Bonfiglioli 7 6 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 invert
255. ion on the device type and the fabrication data 8 digit number are indicated Additionally the serial number is printed on the nameplate Serial number 0 603409000 06053980 part no serial no Nameplate Type ACU 401 09 Serial No 06053980 Optional Modules Modular extension of the hardware is possible via the plug in slots The Optional modules 1 detected by the frequency inverter and the corresponding designations are displayed on the control unit and in the optional control software VPlus after ini tialization For the parameters required for the expansion module refer to the corre sponding operating instructions CM 232 EM 1IO 01 I nverter Software Version The firmware stored in the frequency inverter defines the available parameters and functions of the software The software version is indicated in parameter nverter software version 12 n addition to the version the 6 digit software key is printed on the rating plate of the frequency inverter Inverter software version 12 5 4 0 Nameplate Version 5 4 0 Software 15 000 190 Copyright 15 C 2013 BONFIGLI OLI VECTRON Set Password As a protection against unauthorized access the parameter Set password 27 can be set such that anyone who wants to change parameters must enter this password this password before A change of parameter is only possible if the password in entered correctly If the Set password 27 parameter is set to zero no password is required
256. ional performance of the application Change over between variable speed control and torque dependent control is done jerk free during operation Operating I nstructions ACU 119 amp Bonfiglioli 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 contents 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 The reference torque is represented as a percentage and it is transmitted into the corresponding operational performance of the application Change over between variable speed control and torque dependent control is done jerk free during operation Configuration 510 field oriented control of synchronous machine speed controlled Configuration 510 contains the functions for speed controlled field oriented control of a synchron
257. ions will not be evaluated The actual speed and frequency of speed sensor 2 is displayed in Parameters 219 and 220 06 13 Operating I nstructions ACU 115 G Bonfiglioli 8 5 116 Set up via the Communication I nterface 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 These are based on standard applications of the corresponding configura tion and are therefore useful for commissioning Parameter settings may only be changed by qualified staff Before starting the commissioning process read the documentation carefully and comply with the safe ty instructions The parameter SETUP Selection 796 defines the function which is carried out direct ly after the selection if controller enabling signal is present at digital inputs S1IND STOA and S7IND STOB The operation modes include functions which are also carried out automatically one after the other during the guided commissioning procedure 0 Clear Status Uo auto set up routine does not perform a func The warning message is acknowledged and the l Continue ed auto set up routine is continued The auto set up routine is stopped and a RESET of 2 Abort the frequency inverter
258. ior particularly for small speeds Select one of the settings 10 14 for SETUP selec tion 796 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 the voltage constant is unknown set Voltage constant 383 to 0 mV before the com missioning to ensure the automatic calculation and measurement The voltage constant should be optimized after the guided commissioning procedure In no load operation set 50 of the rated speed Change the voltage constant in small steps until parameter Rotor flux 225 displays the value 10196 50 596 In the case of motors with a very high number of pole pairs e g higher than 20 it is possible that the maximum setting range of the parameter is not sufficient In this case divide the voltage constant by 10 and enter the value The division by 10 is con sidered internally 10 2 6 Stator inductance In configuration 5xx for the control of synchronous machines the control behavior can be improved for high dynamic requirements by setting the parameter Stator in ductance 384 The stator inductance 384 is the value between two motor phases and can be taken usually from the data sheet of the motor No Description Min Max Fact sett 384 Stator inductance 0 1 mH 500 0 mH 1 0 mH 10 2 7 Peak current 126 The parameter Peak Current 1192 is
259. is displayed for a short time When the frequency inverter is switched on the next time this actual value will be displayed automatically 3 After saving the parameter you can monitor and display the value again Use the ESC key to switch to the parameter selection of the VAL menu branch Operating I nstructions ACU 89 G Bonfiglioli 7 4 90 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 3 dn s e gi 6 31 m SHU o MH e BEBE e Use the arrow keys to select the required number from the parameters dis played in numerical order The parameter number is displayed with the active data set flashes If the highest parameter number is achieved actuating the A key displays the lowest parameter number If the lowest parameter number is achieved actuating the W key displays the highest parameter number Parameter numbers gt 999 are displayed hexadecimal at the leading digit 999 A00 B5 C66 In the current data set the related parameters are displayed including the corresponding data set number The seven segment display shows data set 0 if the parameter values in the four data
260. is performed The auto set up routine is performed in data set 0 10 Complete Setup DSO and the parameter values are stored in all of the four data sets identically Auto set up complete The parameter values of the auto set up are stored 11 DS1 in data set 1 Auto set up complete The parameter values of the auto set up are stored 12 DS2 in data set 2 13 Auto set up complete The parameter values of the auto set up are stored DS3 in data set 3 Auto set up complete The parameter values of the auto set up are stored 14 DS4 in data set 4 The auto set up routine checks the rated motor 20 c LAE Machine Data DAN parameters in the four data sets 21 Plaus contr motor data The rated motor parameters in data set 1 are DS1 checked for plausibility 22 Plaus contr motor data The rated motor parameters in data set 2 are DS2 checked for plausibility 23 Plaus contr motor data The rated motor parameters in data set 3 are DS3 checked for plausibility 24 Plaus contr motor data The rated motor parameters in data set 4 are DS4 checked for plausibility The auto set up routine determines extended mo tor data via the parameter identification feature calculates dependent parameters and stores the parameter values in all of the four data sets identi cally Calculation and Para 30 ident DSO Additional motor data are measured dependent 31 Calc and para ident DS1 parameters are calculate
261. is se lected The controller enable signal at digital inputs S1IND STOA and S7IND STOB is switched on Start Positioning of Axle 37 is activated The speed sensor monitoring is activated i e operation mode 2 error message for parameter Operation mode 760 of the speed sensor monitoring is selected Operation mode 1004 or 1104 quadruple evaluation with reference impulse is selected for the speed sensor input The actual frequency 241 is smaller than 1 Hz The deviation of the current position from the reference orientation is smaller than the max orientation error 472 148 Operating Instructions ACU 06 13 vv Bonfiglioli The current position after Start Positioning of Axle 37 is recognized by the frequency 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 As soon as the reference signal was recognized twice the drive is positioned to the Reference orientation 469 When using a Resolver the search mode during commissioning is skipped If the motor was already rotating before axle positioning was enabled the posi tioning to the Reference orientation 469 is performed without search mode be cause the position of the reference point was already detected by the frequency inverter If the positioning is carried out after controller enabling and s
262. isture and are exposed to little temperature deviations only The requirements of DIN EN 60721 3 1 for storage DIN EN 60721 3 2 for transport and labeling on the packaging must be met e The duration of storage without connection to the permissible nominal voltage may not exceed one year 2 10 4 Handling and installation e Do not commission any damaged or destroyed components e Prevent any mechanical overloading of the frequency inverter Do not bend any components and never change the isolation distances e 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 Any use of damaged or destroyed components will endanger the ma chine plant safety and shall be considered as a non compliance with the applicable standards e Only install the frequency inverter in a suitable operating environment The frequency inverter is exclusively designed for installation in industrial environments e fseals are removed from the case this can result in the warranty becoming null and void 2 10 5 Electrical connections e The five safety rules must be complied with e Never touch live terminals The DC link may have dangerous voltage levels even up to three minutes after shutdown e When performing any work on with the frequency inverter always comply with the applicable national and international regulations
263. it The parameter Operation level 28 in the PARA menu branch defines the selection of the actual value parameters to be selected 210 Stator Frequency 211 R m s current 212 Output voltage 213 Active power 214 Active current 215 Isd 216 Isq 221 Slip frequency 226 Winding temperature Operating I nstructions ACU 06 13 vv Bonfiglioli 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 The parameters of the actual value memory can be read out via a communication interface and displayed via the operating unit In addition the operating unit provides monitoring of the peak and mean values in the VAL menu branch No Description Function Utilization of the device dependent overload of 231 Peak Value Long Term Ixt 60 seconds 232 Peak Value Short Term Ixt E of the device dependent overload of 1 287 Peak value Vdc The maximum DC link voltage measured The mean DC link voltage calculated in the pe riod of observation 289 Peak value heat sink temp A A e Neal Smk Eemperatune or Average value heat sink The mean heat sink temperature calculated in 290 i l temp the period of observation 291 Peak value inside temp The maximum measured inside temperat
264. its reference frequency at the set acceleration or according to the parameter Acceleration on mains resumption 674 If the value of parameter Acceleration on mains resumption 674 is set to the default value of 0 00 Hz s the drive is accelerated at the values set for the ramp parameters Acceleration clockwise 420 or Acceleration anticlockwise 422 Operating I nstructions ACU 213 G6 Bonfiglioli 214 No Description Min Max Fact sett Mains failure threshold 200 0 V 50 0 V 100 0 V 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 A control via externally sup plied control signals is only possible in the case of a no break supply As an alterna tive supply for the control signals through the frequency inverter is to be used Operation mode power failure regulation p gt 7 7 Mains voltage P673 V f or P683 FOC SERVO Power failure Off t The DC link voltage which is available in the case of a power failure is supplied by the motor The output frequency is continuously reduced and the motor with its rotating masses is switched over to generator operation The maximum reduction of the out put frequency is done at the current set by the parameter Gen ref current limit 683 or the ramp Mains support decel
265. k wall of the frequency inverter to the assembly panel The dimensions of the device and the installation dimensions are those of the stand ard device without optional components and are given in millimeters a b c at bi fb2 3 ci 2 3 510 412 351 480 392 382 342 338 305 110 401 75 132 kW Operating I nstructions ACU 47 G5 Bonfiglioli 6 Electrical I nstallation 48 A 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 Do not touch the terminals because the capacitors may still be charged Only connect suitable voltage sources The nominal voltage of the frequency inverter must correspond to the supply voltage The frequency inverter must be connected to ground potential If voltage supply is switched on no covers of the frequency inverter may be re moved The connecting cables must be protected externally considering the maximum volt age and current values of the fuses The mains fuses and cable cross sections are to be selected according to EN 60204 1 and DIN VDE 0298 Part 4 for the nominal oper ating point of the frequency inverter According to UL CSA the fre
266. kHz 16 kHz D This switching frequency can be set for parameter Min switching frequency 401 Operating Instructions ACU 06 13 vv Bonfiglioli 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 e Current lt Current below P 777 is in effect 776 gt Amplification low Current 777 e Current above P 700 is in effect 775 gt Current gt Current below P 700 is in effect 757 gt Amplification 700 e Current gt Current above P 759 is in effect 758 gt Amplification high Cur rent 759 By default the parameters are pre assigned so that the parameters are not active and only the basic parameters are active No Desenphon x Fact sett 757 ueneno 10s ek ooo orm o Inn 758 Current above P 759 is in effet 0 00 o lm 0 Inn 759 Amplification high Current 0 00 800 0 00 775 Current above P 700 is in effect 0 00 o l 0 00 776 Current below P 777 is in effect 0 00 o lm 0 00 777 Amplification low Current 000 800 0 00 Icy Nominal Output current of Frequency inverter 0 Overload capability of Frequency inverter The motor autotuning changes the parameters 17 5 3 Torque Controller The torque controlled configurations 230 430 530 and 630 can be used for sensor less torque control alternative to
267. l com 362 No of errors missioning of the frequency inverter The error and warning behavior of the frequency inverter can be set in various ways The automatic error acknowledgment enables acknowledgment of the faults Overcur rent F0500 Overcurrent F0507 and Overvoltage F0700 without intervention by an overriding control system or the user The No of self acknowledged errors 363 shows the total number of automatic error acknowledgments No Description Function 363 No of self acknowledged Total number of automatic error acknowledg errors ment with synchronization 20 1 1 Error Messages 264 The error code stored following a fault comprises the error group FXX and the fol lowing code number XX Code A Meamingg F00 00 No fault has occurred Frequency inverter overloaded F01 Frequency inverter overloaded 60 s check load behavior E Short term overload 1 s check motor and application parameters Table Fault Messages continued on next page Operating Instructions ACU 06 13 vv Bonfiglioli Code Meaning 00 Heat sink temperature too high check cooling and fan 01 Temperature sensor defective or ambient temperature too low 00 Inside temperature too high check cooling and fan 01 Inside temperature too low check electrical cabinet heating Motor temperature too high or sensor defective check connection S6IND F03
268. l inputs 06 13 Operating Instructions ACU vv Bonfiglioli Logic signals ttt tare 191 Technical data 31 52 Digital outputs Logic signals 180 Technical data a 31 52 Direction of rotation Changez d deerant ug 127 CHECK qu 113 Start clockwise Start anticlockwise 196 E Electrical connections ssssss 20 ge EUN 50 aseo Pm 114 CORDecblOn sione oso senno aai 58 Division marks sseeeeeee 130 Evaluation rr 128 132 Gear factor c tt rei ei rud 131 Monitoring eee eeeees 253 Error acknowledgment V jieTopr ju eser D tad aiecatees 153 via logic signal 197 Error environment eere 269 iagojsi eee EO 264 Error messages sssessseeeseeene 264 of auto setup sssseenee 110 Expansion module s 53 External GrfQEF uieie e oerte eerta taa 200 External fan 186 External power supply ssssssss 72 F dE 241 external aieiai 2 tertie iaia 186 Field controller seeren 237 Filter time constant 175 Filter time constant speed sensor 1 131 Fixed frequencies an 161 Fixed frequency change over 199 Fixed percentage change over 199 Fixed percentages ne 162 Flow Gornttol eoe errore rire nnn 220 Flux forming finished ssssssse 186 Frequency ramps s sse 163 Function table onere tn tnus 205 G General information about the documentation
269. l riw 17 5 2 vV E 758 Current above P 759 is in effect 0 00 O l iw 17 5 2 vV E 759 Amplification high Current 0 00 8 00 17 5 2 760 Operation mode Selection 18 7 3 761 Timeout Signal fault ms 0 65000 18 7 3 762 Timeout Track fault ms 0 65000 18 7 3 763 Timeout Direction of rotation fault ms 0 65000 18 7 3 766 Source of actual speed value Selection 17 5 4 767 Frequency upper limit Hz 999 99 999 99 17 5 2 768 Frequency lower limit Hz 999 99 999 99 17 5 2 769 Frequency upper limit source Selection 17 5 2 770 Frequency lower limit source Selection 17 5 2 vV EJ 775 Current above P 700 is in effect A 0 00 O l gin 17 5 2 vV E 776 Current below P 777 is in effect A 0 00 Oley 17 5 2 vV EH 777 Amplification low Current 0 00 8 00 17 5 2 718 Reduction Factor Flux 96 20 00 100 00 17 5 6 779 Min Flux Formation Time ms 1 10000 12 1 2 vV E 780 Max flux formation time ms 1 10000 12 1 2 v E 781 Current during flux formation A 0 1 l riw Ole 12 1 2 790 Operation mode Timer 1 Selection 15 5 1 791 Time 1 Timer 1 s m h 0 650 00 15 5 1 1 792 Time 2 Timer 1 s m h 0 650 00 15 5 1 1 793 Operation mode Timer 2 Selection 15 5 1 794 Time 1 Timer 2 s m h 0 650 00 15 5 1 795 Time 2 Timer 2 s m h 0 650 00 15 5 1 796 SET UP Select Selection 8 5 EJ 1190 Stator Resistance Ohm 0 001 100 000 10 2 1 0 01 len T 1192 Peak current A 100 000 0 lg
270. l without feedback The stator frequency and speed are corrected depending on the load The slip compensation is activated during the guided commissioning The Stator Re sistance 377 is required to ensure a correct function and is measured during the guided commissioning If no guided commissioning is executed the slip compensation can be activated manually In these cases enter the value for the Stator Resistance 377 manually according to the motor data sheet 0 Off The slip compensation is deactivated The load dependent slip speed is compensated The control behavior of the slip compensation can only be optimized via the parame ters in the case of specific applications The parameter Amplification 661 determines the correction of the speed and the effect of the slip compensation proportionally to the change of load The Max Slip ramp 662 defines the max frequency change per second in order to avoid an overload in the case of a load change The parameter Minimum frequency 663 determines the frequency as from which the slip compensation becomes active Description Fact sett aM 36 S 2 100 0 Max Slip Ramp 0 01 Hz s 650 00Hz s 5 00 Hzjs Minimum Frequency 0 01 Hz 999 99 Hz 0 01 Hz 17 4 2 Current limit value controller 226 Via a load dependent speed control the current limit value controller ensures that the drive system is not overloaded This is extended by the intelligent current limits described in the previou
271. le At least one file must be stored in the control unit The communication module was fitted to slot B without disconnection of the mains voltage switch mains voltage off After 6 warm starts in less than 3 minutes this fault is triggered due to the expectation that a faulty programming of the PLC or the function table is at hand Additionally the PLC Function table is stopped P 1399 2 0 only in RAM In error occurrence the signal 162 Error Signal is set The signal can be linked with inverter functions Output signals in error occurrence Errors are indicated by digital signals 1 162 Error Signal 5 Monitoring function signals an error which is displayed in parameter Current Error 259 1 For linking with inverter functions For digital output 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 Please store the parameter file on your PC before contacting BONFIGLIOLI 268 Operating Instructions ACU 06 13 vv Bonfiglioli 20 2 Error Environment 06 13 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 th
272. ler 1 1 1eee ee eeei eere eene eene nana nna nura 216 Functions of Sensorless Control 1 e eere rere enne nnne nan 226 Slip compensation Aisian Q 226 Current limit value controller eee mener 226 Functions of Field Orientated Control eres 227 Current COFRtrollem icosscenesteacin e diritti tr hdd dedo t Cad e ra ati ae liar 227 Extended Current Controller cci nasa tnnt arai ark n a au ca ag et Fa n cd 229 Torque Controler iersinii a n A Ra 229 Torque Refererice oci nente aaia aa A AAE dea a A a RA eM dus 230 Upper and lower limit of the frequency in Torque Control sssssssss 230 Limit Value Sources eene nennen rennen rennen nn 231 Switching over between speed control and torque control sssssss 231 Speed COMMONERS c 232 Limitation of Speed Controller ssssee eem 234 Limit Value SOUFCes iieri coti a a Fra ar va ew a Pea ed dd 235 Integral time speed synchronization sssssssseee e 236 Acceleration Pre Controlliidisieidindedoactedndsdasadeiacdiaanvaesandanes veveedevetsoniadieateaeatanads 236 PICA Controller ossada oriri Dore rrr ex d rr n uda vidt aa Na d Bx vb X eR er aw das 237 Limitation of field controller seee eene 238 Modulation Controller eeeeeee eene 239 Limitation of Modulation Con
273. light emitting diodes give information about the operating point of the frequency inverter If the control unit is connected the status messages are addi tionally displayed by the display elements RUN WARN and FAULT ALLT RUN o0 WARN green LED red LED Display Description off off Nosupply voltage on lon Initialization and self test flashes RUN flashes Ready for operation no output signal on Operating message on flashes Operational message current warning 269 flashes Ready for operation current warning 269 off flashes Last error 310 of frequency inverter off on FAULT Last error 310 acknowledge fault Status of Digital Signals The status display of the digital input and output signals enables checking of the vari ous control signals and their assignment to the corresponding software functions in particular during commissioning Assignment Control sig Control sig Control sig Control sig Control sig Control sig Control sig Control sig FPNWARU ON Operating I nstructions ACU 271 G Bonfiglioli 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 OOI OOOOI Thus the following contact inputs or out puts are active Control signal at digital input or output 1 Control signal at digital
274. load detection for lifting gear S ramps for jerk limitation during acceleration and deceleration Technology PI controller Parameterizable Master Slave operation via system bus Error memory Simplified and extended control via PC commissioning parameterization data set backup diagnosis with Scope Freely programmable digital inputs and outputs Various logic modules for linking and processing of signals Four separate data sets incl motor parameter Operating I nstructions ACU 06 13 vv Bonfiglioli 4 2 Technical Data Control Electronic Equipment X210A 1 DC 20 V output 1 472180 mA X210B 1 Digital input or DC 24 V 10 input for external power supply X210A 2 GND 20 V GND 24 V ext X210B 2 Digital input STOB sec safety ond shutdown path relevant X210A 3 Digital input STOA safety X210B 3 Digital output first shutdown path relevant X210A 4 Digital inputs X210B 4 Multifunction output voltage sig nal proportional act frequency factory settings X210A 5 X210B 5 Supply voltage DC 10 V for refer ence value potentiometer lmax 4 mA X210A 6 X210B 6 Multifunction input reference speed 0 10 V factory settings X210A 7 X210B 7 Ground 10 V S3OUT 1 Inverted Error Signal 1 Control terminals are freely configurable e Control Safe Torque Off Contacts o
275. lows the user to prevent an imminent I t fault trip through appro priate measures Warning limit motor Pt 615 is used to set the warning signal between 6 and 10096 of thermal capacity No Description Min Max Fact sett 608 Thermal time constant Motor 609 Thermal time constant Stator Warning Limit Motor t 100 Output signals Digital signals indicate the triggering of the function Motor Protection Switch 180 E TRE Warning Motor Triggering of the function Motor Protection Switch 14 Protection 2 according to Operation Mode 571 is signalized For linking with inverter functions For digital output 18 6 V belt Monitoring Continuous monitoring of the load behavior and thus of the connection between the 3 phase machine and the load is the task of the V belt monitoring system Parameter Operation Mode 581 defines the functional behavior if the Active Current 214 or the torque forming current component sq 216 field orientated control method drops below the set Trigger Limit lactive 582 for a time longer than the set Delay Time 583 0 Off The function is deactivated 1 Warnin If the active current drops below the threshold value g the warning A8000 is displayed 2 Error The unloaded drive is switched off and fault message F0402 is displayed The error and warning messages can be read out by means of the digital outputs signal 22 Warning V Belt or rep
276. lue memory 1 1seeeeeeieei esee iin an ena na aaa n aaa ana a aaa a n aua 261 19 4 Actual Values of the System eeecseseeeeeieieee ee eeie nena n nnn 262 19 4 1 Actual System Value iiie toten aa ee uH PU RR c DEOR ERE ERE 262 19 4 2 Volume Flow and Pressure sssssssssee mme eem 263 20 1 Error List a E E E 264 20 1 1 Error ucerp rr 264 20 2 Error Environment eee ec eee rennen nennen nnne nnn nun annua annu nane nanus anna 269 21 1 Status Display P 271 21 2 Status of Digital Signals ee eeeeee eee eeeiee rennen anna anum nna nan 271 21 3 Controller Status e eeeeieee e ciei eene seis aenean ananas u ananas uada nnus au una nan 272 21 4 Warning Status and Warning Status Application 273 22 1 Actual Value Menu VAL csccsccsscsscnsscneensensensensensenssensensensensensensensensenses 275 22 2 Parameter Menu PARA csscssccsccsscnscnsenscnsensecnsensensensensensensensennsensensenses 278 06 13 Operating I nstructions ACU 9 GO Bonfiglioli 1 General information about the documentation r For the series of devices ACU ACTIVE Cube is for the safety related commissioning and 1 operation to be complied with the following documentation e This Operating instructions e Application manual Safe Torque Off ACU The pre
277. may result in claims for damages All rights relating to patent utility model or design registration reserved 1 6 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 In case the frequency inverter is sold to other users this user manual must also be handed over 06 13 Operating I nstructions ACU 13 Goo Bonfiglioli 2 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 2 1 Terminology According to the documentation different activities must be performed by certain persons with certain qualifications The groups of persons with the required qualification are defined as follows Operator This is the entrepreneur company who which operates the frequency inverter and uses it as per the specifications or has it operated by qualified and instructed staff Operating staff The term Operating Staff covers persons instructed by the Operator of the frequency inverter and assigned the task of operating the frequency inverter Qualified staff The term Qualified Staff cov
278. me Flow and Pressure The output frequency is limited by the Minimum frequency 418 and Maximum fre quency 419 Frequency 419 Frequency 418 Frequency 418 Max 1 Component Max Frequency 419 Integral Time 445 Differential Time 618 Amplification 444 Volume flow Ind Vol Flow Contr Fact 446 7 Q FEE 2 1 0 TAR Baie 59g He Coo Bla v EP g 222 Ba 5 ous coco ES 7 Operating Instructions ACU 06 13 06 13 vv Bonfiglioli Structural image I ndirect volume flow control Reference percentage source 476 EK gt Ind volume flow control factor 446 in t Technology controller Actual values Volumetric flow 285 Pressure 286 Actual percentage source 478 Operating I nstructions ACU 225 G Bonfiglioli 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 This dependency can be compensated by the current measurement in the output phases of the frequency inverter The activation of Operation mode 660 for the slip compensation enables as speed contro
279. mic 24 V Operating Instructions ACU 06 13 vv Bonfiglioli Vectron 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 and 15 4 5 Thermo contact 6 6 4 Control terminals Connection diagrams of configurations B 06 13 The control hardware and the software of the frequency inverter are freely configu rable to a great extent Certain functions can be assigned to the control terminals and the internal logic of the software modules can be freely selected Thanks to the modular design the frequency inverter can be adapted to a great range of different driving tasks The demands made of the control hardware and software are well known in the case of standard driving tasks This control terminal logic and internal function assign ments of the software modules are available in standard configurations These as signments can be selected via parameter Configuration 30 The configurations are described in the following section The ACU units of the ACTIVE Cube series feature the function STO Safe Torque Off If this function is not required the Controller release signal must be connected to inputs S1IND STOA and S7IND STOB Inputs S1IND
280. mponent is too dynamic the system will be unstable and oscillates If the integral component is too passive the steady state control deviation will not be cor rected adequately Therefore the integral component must be adjusted installation dependent 1 Dynamic behavior fast correction of deviations 2 Passive behavior slow correction of deviations In the factory setting Derivative time 618 0 ms the differential component is disa bled If the control behavior of the PI controller or P controller is too slow the setting of the differential component Derivative time 618 allows a faster control If the dif 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 Integral time 445 and Derivative time 618 higher than the sample time which is 2 ms at the ACU device Parameter Max P Component 442 limits the frequency change at the controller output This prevents oscillations of the system at steep acceleration ramps Via Parameter Hysteresis 443 changes of the integral component outside a specified range hysteresis band can be suppressed This causes more passive behavior of the technology controller This can be helpful when the stator frequency cannot follow the reference frequency of the Technology controller Hysteresis 443 is related to Rated frequency 375 in most cases therefore 50 Hz The hys
281. ms The factory setting of parameter Min Flux Formation Time 779 depends on the setting of parameter Configuration 30 2 configurations 2xx 4xx 3 configurations 6xx Min Flux Formation Time 779 0 Flux forming ends when reference flux value is reached or after flux formation time Min Flux Formation Time 779 0 The current for flux forming is impressed at least for this time even if the reference flux value is reached Min Flux Formation Time 779 Flux forming ends after flux formation time Max Flux Formation Time 780 even if the reference flux value is not reached Min Flux Formation Time 779 gt Flux forming ends after maximum flux Max Flux Formation Time 780 formation time 06 13 Operating I nstructions ACU 137 G Bonfiglioli 12 2 Stopping Behavior 138 The stopping behavior of the three phase machine can be defined via parameter Operation mode 630 Via the logic signals or digital inputs for the parameters Start clockwise 68 and Start anticlockwise 69 stopping is activated Assign digital inputs or logic signals to these parameters Dependent on the setting of Configuration 30 the parameters are preset to digital inputs By combining the digital input signals or logic signals the stopping behavior can be selected from the following table Start clockwise 0 and Start anticlockwise 0 Operation mode 630 Stopping behavior O Stopping behavior 1 Stopping behavior 2 Stopp
282. n X210A 3 and X210B 2 open e Release of frequency inverter Contacts on X210A 3 and X210B 2 closed By default the different configurations occupy the control terminals with certain set tings These settings can be adjusted to the specific application and various functions can be assigned freely to the control terminals An overview of the settings is displayed at the last but one page of these operating instructions Digital inputs X210A 3 X210B 2 Low Signal DC 0 3 V High Signal DC 12 30 V Input resistance 2 3 kQ response time 2 ms STOA and STOB 10 ms PLC compatible X210A 6 and X210A 7 additionally Frequency signal DC 0 V 30 V 10 mA at DC 24 V fmax 150 kHz Digital output X210B 3 Low Signal DC 0 3 V High Signal DC 12 30 V maximum output current 50 mA PLC compatible Relay output X10 Change over contact response time approx 40 ms make contact AC 5 A 240 V DC 5A ohmic 24 V break contact AC 3 A 240 V DC 1 A ohmic 24 V Multifunction output X210B 4 analog signal DC 19 28 V maximum output current 50 mA pulse width modulated fpwm 116 Hz Digital signal Low Signal DC 0 3 V High Signal DC 12 30 V output current 50 mA PLC compatible Frequency signal Output voltage DC 0 24 V maximum output current 40 mA maximum output frequency 150 kHz Multifunction input X210B 6 analog signal Input voltage DC 0 10 V R 270 KQ input current DC 0 20 mA Ri 500 Q
283. n motor and encoder this can be changed by two actions 1 Change the track A and track B at the encoder inputs at the terminals of ACU 2 Change the evaluation of the sense of rotation of the connected encoder with parameter 490 respectively 493 10 3 Internal values The following parameters are used for internal calculation of motor data and do not require any set up No Description No Description 399 Internal value 01 706 Internal value 08 402 Internal value 02 707 Internal value 09 508 Internal value 03 708 Internal value 10 702 Internal value 04 709 Internal value 11 703 Internal value 05 745 Internal value 12 704 Internal value 06 798 Internal value 13 705 Internal value 07 06 13 Operating I nstructions ACU 127 I Bonfiglioli 10 4 Speed Sensor 1 The frequency inverters are to be adapted to the application depending on the re quirements A part of the available Configuration 30 demand continuous measure 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 With expansion modules EM and sensor input modules it is also possible to connect and evaluate sensors as speed sensor 2 Please refer to the corresponding operating instructions Speed sensor 1 and speed sensor 2 are c
284. nature without delay Obvious defects such as exterior damage of the packing and or the unit must be notified to the sender within seven days for insurance reasons 26 Operating I nstructions ACU 06 13 3 3 vv Bonfiglioli ACU 401 18 5 to 30 0 kW 06 13 Frequency inverter Plug in terminals for the relay output Terminal strip X10 Phoenix ZEC 1 5 3ST5 0 for vertical assembl Brief Instructions and Operating Instructions on CD ROM Standard fittings with fitting screws M4x20 M4x70 Ed Control terminals X210A X210B Wieland DST85 RM3 5 P S Plug in terminal for connection of the control signals lease check incoming goods for quality quantity and nature without delay Obvious defects such as exterior damage of the packing and or the unit must be notified to the ender within seven days for insurance reasons Operating I nstructions ACU 27 Goo Bonfiglioli 3 4 ACU 401 37 0 to 65 0 kW pum e Ray Frequency inverter 3 Terminal strip X10 Phoenix ZEC 1 5 3ST5 0 Plug in terminals for the relay output 9 Standard fittings with fitting screws M5x20 for vertical assembl Brief Instructions and Operating Instructions on CD ROM Control terminals X210A X210B Wieland DST85 RM3 5 Plug in terminal for connection of the control si
285. ncreased according to the set accelera Magnetization tion If the output frequency reaches the value set with 4 current impr the parameter Frequency limit 624 the Starting current IxR K 623 is withdrawn There is a smooth transition to the V f characteristic and a load dependent output current is obtained At the same time the increase of the output voltage by the xR compensation becomes effective as from this output frequency The V f characteristic is dis placed by the portion of voltage which depends on the stator resistance Operation mode 12 contains an additional function to guarantee a starting behavior under difficult conditions The magnetization and starting current impression are Magn done according to operation mode 2 The ramp stop current impr takes the current consumption of the motor at the corre w ramp stop sponding operating point into account and controls the frequency and voltage change by stopping the ramp The Controller status 275 signals the intervention of the controller by displaying the message RSTP In this operation mode the functions of operation mode 12 are extended by the compensation of the voltage drop Magn across the stator resistance When the output frequency current impr reaches the value set with parameter Frequency limit w R 624 the increase of the output voltage by the IxR com IxR K pensation becomes effective The V f characteristic is displaced by the portion of voltage which
286. nction Data set change over 1 Data set change over 2 X210A 2 X210A 3 X210A 4 X210A 5 X210A 6 X210A 7 X210B 1 Motor thermal contact X210B 2 Digital input STOB 2 shutdown ath of safety function STO X210B 3 Run Signal X210B 4 Analog signal of actual frequenc X210B 5 Supply voltage 10 V for reference value potentiometer Reference speed 0 10 V or refer ence torque as percentage value X210B 7 Ground 10 V X210B 6 82 Operating Instructions ACU 06 13 vv Bonfiglioli 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 X210A 1 Voltage output 20 V or input for external power supply DC 24 V 10 GND 20 V GND 24 V ext Digital input STOA 1st shutdown ath of safety function STO Start of clockwise operation Start of anticlockwise operation Data set change over 1 Data set change over 2 X210A 2 X210A 3 X210A 4 X210A 5 X210A 6 X210A 7 X210B 1 Motor thermal contact X210B 2 Digital input STOB 2 shutdown ath of saf
287. ng I nstructions ACU 37 Goo Bonfiglioli 4 9 ACU 401 18 5 to 30 0 kW 400 V ACU 401 E o a op a p o Construction Size Recommended motor shaft power Output current Long term overload current 60 s Short time overload current 1 s Output voltage Protection Rotary field frequenc Jaf 400 595 o faf s 08 He E Shorcrcut earthfaulproof 2 4 8 Min brake resistance Recommended brake resistor Uagc 770 V Mains current 3ph PE Pp ot faf 420 500 580 Mains voltage 320 528 Mains frequenc 45 66 Fuses 1 fal 5 J 63 UL type 600 VAC RK5 LL AJ 50 60 Dimensions Degree of protection Terminals up to 25 Form of assembly vertical Hi ese T C 0 40 3K3 DIN IEC 721 3 3 15 85notcondenig If required by the customer the switching frequency may be increased if the output current is reduced at the same time Comply with the applicable standards and regulations for this operating point Energy 2 kHz switching frequency Coolant temperature Storage temperature Transport temperature Rel air humidit dissipation Frequency inverter nominal power 22 kW 45 0 A 45 0 A 45 0 A 30 kW 60 0 A 2 60 0 A 9 60 0 A 9 D Three phase connection requires a commutating choke 2 Mains current with relative
288. ng current enables high drive dynamics with a high load moment The necessary speed sensor feedback results in a precise speed and torque performance Operating Instructions ACU 06 13 d 7 7 F U Eg a RUN RUN 06 13 vv Bonfiglioli 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 The reference torque is represented as a percentage and it is transmitted into the corresponding operational performance of the application The switch over between variable speed control and torque dependent control is done without jerk in operation Configuration 510 field oriented control of synchronous machine speed controlled Configuration 510 contains the functions for speed controlled field oriented control of a synchronous machine with speed sensor feedback The separate control of torque and flux forming current enables high drive dynamics with a high load mo ment The necess
289. ning Motor Temperature Operation Mode 570 signalizes a critical g 2 10 point of operation For linking with inverter functions 2 For digital output If the temperature value max Temp Windings 617 is exceeded a warning or an error switch off is initiated according to Motor Temp Operation Mode 570 No Description Min Max Fact sett max Temp Windings 50 C 200 C 150 C The parameter is only available if an expansion module with KTY temperature sensor input is installed e g EM 1O 04 Via parameter Therm Contact 204 a digital input signal can be linked to the Motor Temp Operation Mode 570 152 Operating Instructions ACU 06 13 vv Bonfiglioli 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 576 allows to adjust the behavior in case of a failure In the case of a phase failure the fault switch off takes place after 5 minutes fault F0703 is displayed During this time the warning message A0100 is displayed The phase monitor switches the frequency inverter off immediately with error message F0403 in the case of a motor phase failure i Mains Error Switch Off i Mains amp Motor Error Switch Off after 5 minutes with error message F0703 in the case of a mains phase failure
290. nnnnnnnnnnnnnnnnnnnnnnnnn RR RR S ad dna 119 CONFIQUIrATION P n 119 Language cseccnseeenneeeeeneeeoueeeenseuenuenenueseeogeueuagseeousueeuseeeauseenasueoeeeeogeneoasens 122 Programming 122 10 Machine Data 10 1 10 2 10 2 1 10 2 2 10 2 3 10 2 4 10 2 5 10 2 6 10 2 7 10 2 8 10 3 10 4 10 4 1 10 4 2 10 4 3 10 4 4 10 5 Rated Motor ParameterS c sseeccsseseeeeesesseeeeneeseeseennaeeueeenaseuseeneneesesnanees 123 Further motor parameters 1 eeeeceeiee eee sei ase nan nana nana 124 Staton Resistance eiecit ere ee ER EE a Ee PRATER E ER a 124 Leakage Coefficient eene ennemi enne 124 Magnetizing Current 2 eite set eni a ke Rh st Lu eR RPM Li ER Lee Re pa dd 125 Rated slip correction factor esee etie Fut karte ceased etui a dA 125 Mieres a E a E a E A a 126 Stator IMAUCtANCE cn 126 Peak CULTGDIE eni annann E E E A A E E ERE 126 Change sense of rotation cie cese ste e Re RISE a aiaa ee 127 Internal values ninnan reisen anna anaa aana 127 Speed Sensor 128 Operation Mode Speed Sensor 1 cece eem 128 Division marks speed sensor Loo meme 130 Gear factor speed sensor 1 ssssssssssssseeeemeemeennne enn 131 Filter time constant speed sensor 1 cece tte eter erent eee 131 Sensor evaluation 11 Leeeee e ceei esee esie een ana aan n a aana a 132 Actual S
291. nputs and the set starting and stopping behavior for control ling the digital output According to the configured starting behavior the output is switched on when the magnetizing of the motor is finished When the Brake release time 625 has elapsed the drive is accelerated The stopping behavior of the drive depends on the configuration of the parameters Operation Mode 630 This is described in chapter Stopping Behavior If stopping behavior 2 or 5 with stop function is selected the drive is controlled to zero speed and the digital output is not switched off In the other operation modes of the stop behavior the control of the brake is possible At the start of a free coasting of the drive the digital output is switched off This is similar to the behavior in the case of the stopping behavior with shutdown The drive is decelerated and supplied with current for the set holding time Within the set holding time the control output is switched off and thus the brake activated Operation mode 41 Open brake switches off the digital SEN output assigned to the function immediately The me chanical brake is activated Operation mode 41 Open brake switches off the digital output assigned to the function when Switch Off Thresh old 637 is reached The mechanical brake is activated Operation mode 41 Open brake leaves the digital out put assigned to the function switched on The mechanical brake remains o Stopping Behavior 1 3 4 6 7
292. ns 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 gram ming 34 or the logic signal can be acknowledged with parameter Error ac knowledgment 103 15 4 4 Timer The time functions can be selected via the parameters Operation mode Timer 1 790 and Operation mode Timer 2 793 The sources of the logic signals are selected with the parameters Timer 1 83 and Timer 2 84 and processed according to the config ured timer functions 15 4 5 Thermo contact The monitoring of the motor temperature is a part of the error and warning behavior which can be configured as required The parameter Thermocontact 204 links the digital input signal to the defined Operation mode Motor PTC 570 which is de scribed in chapter Motor Temperature The temperature monitoring via a digital input checks the input signal for the threshold value Accordingly a thermocontact or an additional circuit must be used if a temperature dependent resistor is used 15 4 6 n M Control Change Over 06 13 The field orientated control procedures in configurations 230 430 530 and 630 con tain the functions for speed or torque dependent control of the drive The change over can be done in ongoing operation as an additional functionality monitors the transition be
293. nt limit val controller Lage ex oe de qe oae SE E Current Controller 1751 x x x ixixi ix x xi x x X Limit Value Sources us2 xIx IxixIxIxixixixIxIx Acceleration Pre Control 1755 x x x ixixi x x xi x x X Field Controller 175 6 j xix x x x x j Modulation Controller ABT a Starting behavior 121 1 Ixtixixixixixixixixixixix X X E eek COO pression Flux Formation 1212 x Ixix xlxl1x Stopping behavior See ERES ONE x Direct current brake 123 xx l f Auto Start x Search Run x Reference point positioning 1261 x x x x x Axle Positioning 1262 x txt Frequency reference ch 144 x x Ixix x x xix X Reference percentage ch 145 x x x x x x x x Fixed Frequencies 1461 x x x x x x x x x x x x Fixed Percentages 1463 x x x xix x xx Block Frequencies 19 x xixix x x x x x x x x UE RSBeEHOR frequency pags x x x x xx x x x x x x x inpu Brake chopper 184 x x x x x x x x x x x x x Motor protection switch EC NESESESE3E3ESESEXE3ESESXES X V belt Monitoring 1852 x x x x x x x x x x x x x Motor Chopper a ee ee ea cp ps3 Temperature Adjustment 1872 x x x ixixi ix Speed Sensor Monitoring 18 7 3 x x x 06 13 Operating I nstructions ACU 121 Goo Bonfiglioli 9 8 Language The parameters are stored in the frequency inverter in various languages Th
294. ntelligent current limits in particular in applications with dynamic load alternations The criteri on to be selected via the parameter Operation Mode 573 defines the threshold to the activation of the intelligent current limit The parameterized rated motor current or the reference current of the frequency inverter is synchronized as the limit value of the intelligent current limits 31 Ud temp Operation mode 10 20 and Tc Tmotor IXt The threshold value selected via the parameter Operation Mode 573 is monitored by the intelligent current limits In the operation modes with motor and heat sink tem perature monitoring the reduction of power selected with the parameter Power lim it 574 is done when the threshold value has been reached This is achieved by a reduction of the output current and the speed in motor operation The load behavior of the connected machine must be a function of the speed to ensure a sensible use of the intelligent current limits The total time of the power reduction as a result of an increased motor or heat sink temperature contains not only the cooling time but also the additionally defined Limitation time 575 The definition of the power limit should be selected as small as possible in order to give the drive sufficient time to cool down The reference value is the rated output of the frequency inverter or the set rated power of the motor No Description Min Max Fact sett 40 00 95 00 80 0096
295. nticlockwise 422 or anticlockwise Emergency Stop anticlockwise 425 Fax Y Operating Instructions ACU 163 G Bonfiglioli 164 The parameter Maximum leading 426 limits the difference between the output of 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 In this case the drive cannot follow the defined acceleration or deceleration ramps With Maximum leading 426 you can limit the max leading of the ramp No Description Min Max Fact sett Maximum leading 0 01 Hz 999 99 Hz 5 00 Hz Example Fixed value at ramp output 20 Hz current actual value of drive 15 Hz selected Maximum leading 426 5 Hz The frequency at the ramp output is increased to 15 Hz only it is not increased fur ther The difference leading between the frequency value at the ramp output and the current actual frequency of the drive is limited to 5 Hz in this way The load occurring in a linear acceleration of the drive is reduced by the adjustable modification speeds S curve The non linear course of the frequency is defined as a ramp and states the time range in which the frequency is to be guided to the set ramp The values set with parameters 4
296. ntrol settings in the case of dynamic operations ac celeration deceleration The frequency at which a switch over of the controller pa rameters is affected can be set via parameter Speed control switch over limit 738 17 5 4 1 Limitation of Speed Controller 234 The output signal of the speed controller is the torque forming current component Isq The output and the component of the speed controller can be limited via pa rameters Current limit 728 Current limit generator operation 729 Torque limit 730 Torque limit generator operation 731 or Power limit 739 Power limit genera tor operation 740 The limits of the proportional component are set via parameter P component torque upper limit 732 and parameter P component torque lower limit 733 The output value of the controller is limited by an upper and a lower current lim it parameter Current limit 728 and parameter Current limit generator opera tion 729 The limit figures are entered in Amperes The current limits of the con troller can be linked to the fixed limits and analog input parameters The assign ment is done via the parameters Isq limit source motor operation 734 and Isq limit source generator operation 735 The output value of the controller is limited by an upper and a lower torque limit parameter Torque limit 730 and parameter Torque limit generator opera tion 731 The limit values are input as a percentage of the rated motor torque The assignment of fixed
297. ol deviation actual value reference value or if the control devia tion is negative actual value gt reference value the output frequency is guided to Minimum frequency 418 This is done using the set Controller settings Additionally Deceleration clockwise 421 limits the ramp If Minimum frequency 418 0 Hz the power stage is switched off in this case The drive accelerates as soon as an actual value is present again or the control de viation exceeds the positive Hysteresis 443 The drive stops if Actual value 2 Refer ence value the control output reached 0 Hz and Minimum frequency 418 0 Hz is set Limitation Frequency 419 Frequency 418 I Component Frequency 418 Max Integral Time 445 Differential Time 618 Amplification 444 e i a a D o ES A g u O O x oO ro y g 9 RS ie o o v2 8 5 fei a VI 2 AR re 2 po 990 Bald S c 95r7 sa 5 9 gEB y ae og Os cB 5 9 Buc EEZ E 5538 O X o Operating Instructions ACU 06 13 06 13 Bonfiglioli Vectron 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 Maximum frequency 419 o wi t gt o o 3 c o x iL Frequency 419 Max
298. old 507 is set larger than the maximum admissible DC link voltage the motor chopper cannot become active the motor chopper is switched off If the set Trigger threshold 507 is smaller than the maximum DC link voltage the mains can generate error message F0706 chapter Error Messages is displayed when the frequency inverter is switched on The motor chopper function only works if activated via voltage Controller Operation Mode 670 See chapter 17 2 Voltage controller For synchronous motors Configuration 30 5xx the motor chopper function is de activated to prevent damages to the motor The other functions of the voltage control ler are not affected by this Please note that by default the Motor chopper Trigger Threshold 507 and the Trigger Threshold 506 are set up with different values Check that the two thresholds are set up fittingly for your application Soe 06 13 Operating I nstructions ACU 251 I Bonfiglioli 18 7 2 Temperature Adjustment 252 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 stant 227 is calculated from the inductivity of the rotor circuit and the rotor re sistance The dependence of the rotor time constant on the motor temperature can be taken into account in the case of particula
299. oller Current Limit Tc sink temperature Tc reached Controller Current Limit Intelligent Current Limits active Maximum mo 19 Motor Temp tor temperature reached 17 2 Voltage controller 06 13 The voltage controller contains the functions necessary for monitoring the DC link voltage The DC link voltage which rises in generator operation or in the braking process of the 3 phase machine is controlled to the set limit value by the voltage control ler The power failure regulation uses the rotation energy of the drive to bridge short term power failures The voltage controller is set with the parameter Operation Mode 670 in accordance with the application The function is switched off Brake and Motor chopper are active and switch with the parameterized thresh olds of P506 and P507 DC link limitation active Overvoltage controller switched on the Brake and Motor chopper are active and switch with the parameterized thresholds of P506 and P507 Factory setting Power failure regulation switched on Brake and Motor chopper are active and switch with the parameterized thresholds of P506 and P507 Suitable for quick shut down Supp active switched on with motor chopper Power failure regulation switched on During the Mains Support motor and brake chopper are deac tivated In all other cases motor and brake chopper are active and switch with the parameterized thresh olds of P506 and P507 Ove
300. on Selection 17 5 4 2 735 Isq limit source gen operation Selection 17 5 4 2 736 Torque limit source motor operation Selection 17 5 4 2 737 Torque limit source gen operation Selection 17 5 4 2 V amp 738 Speed control switch over limit Hz 0 00 999 99 17 5 4 739 Power Limit kW 0 00 2 0 Pry 17 5 4 1 740 Power limit generator operation kW 0 00 2 0 Pein 17 5 4 1 741 Amplification 0 0 100 0 17 5 6 V EF 742 Integral time ms 0 0 1000 0 17 5 6 Vi amp 743 Ref Isd upper limit A 0 Olf 17 5 6 1 vV E 744 Ref Isd lower limit A leiy ees T ri 17 5 6 1 I 748 Backlash damping 96 0 300 17 5 4 750 Reference modulator 96 3 00 105 00 17 5 7 752 Integral time ms 0 0 1000 00 17 5 7 Operating Instructions ACU 06 13 vv Bonfiglioli No Description Unit Setting range Chapter 753 Operation mode Selection 17 5 7 754 Filter time constant ms 0 128 17 5 4 C 755 Reference Imr lower limit A 0 01 lgiw Olen 17 5 7 1 756 Control deviation limitation 96 0 00 100 00 17 5 7 1 vV E 757 Current below P 700 is in effect 0 00 O
301. onal and integrating part of the current controller can be set via the parameters Amplifica tion 648 and Integral Time 649 The control functions can be deactivated by setting the parameters to 0 No Description Min Max Fact sett 648 Amplification 0 00 1000 649 Integralime Oms 1000ms If the Operation mode Synchronization 645 parameter was set to operation mode 1 to 5 search run the search run is not started before the Demagnetization time 633 has elapsed If synchronization to the drive mechanism is not possible the Braking current 631 is impressed into the motor in operation modes 1 to 5 for the duration of the Braking time after search run 646 The impress of the direct current set in the parameters of the direct current brake DCB leads to a heating of the motor and should only be done for a short period in internally ventilated motors No Description Min Max Fact sett 646 Brak time after search run 0 05 200 0 s 10 0s NOTE The Flying Start or Search function is designed for the operation of motors without brake Brake motors may not be operated optimum in individual cases depending of parameterization and brake control with the Flying start function Operating I nstructions ACU 143 69 Bonfiglioli 12 6 Positioning Positioning is done in operation mode Reference positioning via the definition of the positioning distance or in operation mode Axle p
302. onfigured independently from one another 10 4 1 Operation Mode Speed Sensor 1 Operation mode 490 for speed sensor 1 can be selected according to the connected incremental speed sensor Connect an unipolar speed sensor to the standard control terminals 0 Off Speed measurement is not active the digital inputs are available for other functions Two channel speed sensor with recognition of direction 1 Single evaluation of rotation via track signals A and B one signal edge is evaluated per division mark Two channel speed sensor with recognition of direction of rotation via track signals A and B four signal edges are evaluated per division mark One channel speed sensor via track signal A the actual Single evaluation speed value is positive One signal edge is evaluated per without sign division mark The digital input SAI ND is available for further functions One channel speed sensor via track signal A the actual Double evaluation speed value is positive Two signal edges are evaluated without sign per division mark The digital input S4IND is available for further functions One channel speed sensor via track signal A The actual speed value is positive for signal Low and negative for signal High at digital input S4IND One signal edge is evaluated per division mark One channel speed sensor via track signal A The actual speed value is positive for signal Low and negative for signal High at digital input S4IND Two sign
303. ons ACU 06 13 vv Bonfiglioli 7 5 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 The memory space available in the control unit for the files is dynamically scaled to match the scope of the data The Copy Menu CPY is accessible in control level 3 The control level can be adjusted if necessary via parameter Control Level 28 7 5 1 Reading the Stored I nformation When you open the CPY menu branch the data stored in the 2 control unit are read out This process takes a few seconds TE During this time init and a progress indicator are displayed After the initialization in the copy menu the function can be M 1 selected If the information stored in the control unit is not valid the ali initialization is stopped and an error message is displayed ud In this case the memory in the control unit must be formatted Err as follows e Use the ENT key to confirm the error message e Use the arrow keys to select the function FOr m e Use the ENT key to confirm the selection During the formatting process FCOPY and a progress in dicator are displayed TES aes The pro
304. ontactor An emergency stop according to EN 60204 must be functioning in all operation modes of the frequency inverter Resetting of an emergency stop must not result in uncon trolled starting of the drive The drive is started again when the function STO is no longer triggered In order to comply with EN 60204 it must be ensured by taking external measures that the drive does not start without prior confirmation Without a mechanical brake the drive might not stop immediately but coast to a standstill If this may result in personal or material damage additional safety measures must be taken If persons may be endangered after disconnection of the motor control by STO ac cess to the hazard areas must be prevented until the drive has stopped 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 The STO function is one fault fail safe No single fault or component failure can cause a disabled drive to produce motor shaft torque Only in extremely unlike combinations of component faults the motor shaft could move jerky with sudden acceleration max imum 180 number of pole pairs for example jerky movement of 90 for 4 pole mo tor 180 2 and produce torque It must be checked if this behavior can cause a dangerous machine movement If the STO function is used the special safety installation and instr
305. ontroller is not reported No message The controllers influencing the operating behavior are displayed in the Controller status 275 parameter 0 1 Warning Status The limitation by a controller is displayed as a warning by the control unit 11 Warning status and The limitation by a controller is displayed as a warning LED by the control unit and the LED s Refer to chapter 15 3 8 Warning Mask and 21 3 Controller Status for a list of control lers and further possibilities to evaluate the controller states I DC Compensation Limit At the output of the frequency inverter a DC component can occur in the output cur rent due to unbalances This DC voltage component can be compensated by the fre quency inverter The maximum output voltage of the compensation is set with pa rameter IDC compensation limit 415 f a higher voltage than the set limit is needed for the compensation of a DC voltage component error F1301 IDC COMPENSA TION is triggered If this fault occurs it should be checked whether the load is defective The voltage limit may have to be increased If the parameter DC compensation limit 415 is reduced to zero the DC compensa tion is deactivated No Description Min Max Fact sett pia ca PE The factory setting of parameter Limit IDC compensation 415 depends on the setting of parameter Configuration 30 1 Configurations 1xx 2x Configurations 2xx 4xx 5xx 6xx Operating I nstructions ACU 151
306. ool machine because part of the machine data depends on the operating temperature After completion of the parameter identification warning messages may be dis played Depending on the warning message code the following instructions should be fol lowed and the measures indicated should be taken Operating I nstructions ACU 107 Goo Bonfiglioli 8 2 7 Status messages during commissioning SS The following status messages are possible during commissioning setup SS000 OK 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 5S003 STO The parameter identification demands enable on digital input STOA and STOB SS004 Parameter identifica The rated motor values are checked by the parameter identifica tion tion feature SS010 Setup already active The setup routine via the operator panel is being carried out SS030 No Release No enable signal The parameter identification demands enable on digital input STOA and STOB SS031 Error see 259 Error during the auto set up routine Check the value of Actual error 259 SS032 Warning Phase The parameter identification feature diagnosed an unbalance dur Asymmetry ing the measurements in the three motor phases SS099 Setup not carried out The setup is not carried out until now 8 2 8 Warnings during commi
307. or 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 Using Brake resistors without temperature switches can result in critical states Connection of a brake resistor is done via terminal X2 Rb1 Rb2 L112 L3 Rb1 4 Rb2 Y K1 X1 Limit the length of the brake resistor cables to the necessary minimum Operating I nstructions ACU 59 G3 Bonfiglioli 6 5 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 Degree of protection IP20 EN60529 is only guaranteed with the terminals plugged 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 When the frequency inverter is disconnected from power supply the mains DC link voltage and motor terminals may still be live
308. or for motor control The other speed sensor is used external Comply with the application manuals Electronic gear and Positioning Operating I nstructions ACU 06 13 vv Bonfiglioli 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 Mode 490 of speed sensor 1 For a detailed description of possible settings refer to section 10 4 Description Fact No Operation Mode speed sensor 1 Selection Division Marks speed sensor 1 8192 Dependent on the Operation Mode 490 of speed sensor 1 the digital inputs S4IND S5IND and S6IND are disabled for other functions The functions will not be evaluated The actual speed and frequency of speed sensor 1 is displayed in Parameters 217 and 218 1024 8 4 2 Speed sensor 2 Speed sensor 2 must be connected to an expansion module For connection func tions and detailed parameter description refer to the applicable operation instructions manual of the expansion module No Description Min Max Fact Operation Mode speed sensor 2 Division Marks speed sensor 2 8192 1024 The parameters 493 494 and 495 are selectable dependent on the installed expan sion module Dependent on the Operation Mode 493 of speed sensor 2 some digital inputs of the expansion module are disabled for other functions The funct
309. or short shut downs of the application In settings 101 102 111 and 112 of Operation Mode 571 the same values should be set in all data sets Motor protection in particular self ventilation motors is improved via the Frequency limit 572 which can be set as a percentage of the rated frequency The measured output current in operating points below the frequency limit is assessed by a factor of 2 higher in the calculation of the trigger characteristic Description Mn Max raat sett Frequency Limit 300 Output signals Digital signals indicate the triggering of the function Motor Protection Switch n 1 199 Warning Motor Triggering of the function Motor Protection Switch according to Operation Mode 571 is signalized 14 Protection Switch 2 For linking with inverter functions For digital output Operating I nstructions ACU 247 69 Bonfiglioli 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 The table shows in extracts factors for motor rated frequency 50Hz 4 Frequency limit 572 30096 20096 150 100
310. or the drive are latching type functions when signal Start 3 wire control 87 is switched on Latching is cancelled when the latching signal is switched off Machine y R f R Nt y Start clockwise Xx i N Start anticlockwise X i li L j Start 1 1 1 t gt R Clockwise 1 Signals are ignored L Anticlockwise 2 Time t lt 32 ms The drive is started according to the configured starting behavior if the signal Start 3 wire control 87 is switched on and a positive signal edge for Start clockwise or Start anticlockwise is detected Once the drive has started new edges 1 on the start signals will be ignored If the start signal is shorter than 32 ms 2 or if both start signals were switched on within 32 ms 2 the drive will be switched off according to the configured stopping behavior 3 wire control is activated with parameter Local Remote 412 Control 3 wire sense of rot via contacts 3 wire control of direction of rotation and signal 3 wire control 87 via contacts Control via 3 wire KP 3 wire and control unit control of direction of rotation dir of rot via con and signal 3 wire control 87 via contacts or control unit tacts KP For further operation modes of parameter Local Remote 412 refer to chapter Bus Controller Operating I nstructions ACU 06 13 vv Bonfiglioli 15 4 3 Error Acknowledgment The frequency inverters feature various monitoring functio
311. orted to an overriding control system The Trig ger limit Iactive 582 is to be parameterized as a percentage of the Rated current 371 for the application and the possible operating points No Description Min Max Fact sett Trigger limit lactive 100 0 10 0 600 0 s 250 Operating Instructions ACU 06 13 vv Bonfiglioli 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 This en ables the realization of dynamic speed changes at minimum system costs The torque and speed behavior of the drive system is not influenced by the parameterized brak ing behavior The parameter Trigger threshold 507 of the DC link voltage defines the switch on threshold of the motor chopper function Description ACU Min Max Fact sett No 400 Trigger threshold 1000 0 V The parameter Trigger threshold 507 is to be set in such a way that it is between the maximum DC link voltage which the mains can generate and the maximum ad missible DC link voltage of the frequency inverter U Netz 1 1 42 lt U amc lt Ud max If the parameter Trigger thresh
312. ositioning 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 Axle positioning uses a digital reference signal from a speed sensor The function Reference positioning is available in configurations 110 210 410 510 and 610 and is activated by selecting operation mode 1 for parameter Operation mode 458 The function Axle positioning is available in configurations 210 and 510 Parameter Configuration 30 and is activated by selecting operation mode 2 for parameter Op eration mode 458 0 Off Positioning switched off Positioning from reference point via definition of positioning distance rotations The reference 1 Reference positioning point is acquired via a Signal Source 459 Available in Configuration 110 210 410 510 610 Reference positioning via definition of the posi tioning angle reference signal from speed sen sor Available in Configuration 210 510 2 Axle positioning 12 6 1 Reference Positioning 144 The feedback of the current position is referred to the revolutions of the motors rela tive to the time of the reference signal The accuracy of the positioning for the appli cation to be realized is dependent on the current Actual frequency 241 the deceler ation clockwise 421 the No of pole pairs 373 the selected Positioning dis tance 460 and th
313. ounters No Description Min Max Fact sett Allowed no of auto acknowl 0 20 5 Restart delay 0 ms 1000 ms 06 13 Operating I nstructions ACU 153 G Bonfiglioli 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 Minimum frequency 418 and Maximum frequency 419 The corresponding control methods use the two limit values for scaling and calculat ing the frequency No Description x Fact sett 3 50 Hz Minimum Frequency 0 00 Hz 999 99 Hz 0 00 Hz 2 Maximum Frequency 0 00 Hz 999 99 Hz 50 00 Hz The factory setting is dependent on the adjustment of parameter Configuration 30 D 3 5 Hz in configurations 1xx 4xx 6xx 2 0 00 Hz in configurations 2xx 5xx 14 2 Slip Frequency The torque forming current component and thus the slip frequency of the 3 phase machine depend on the required torque in the case of the field oriented control methods The field oriented control method also includes the parameter Slip frequen cy 719 to limit the torque in the calculation of the machine model The rated slip calculated from the rated motor parameters is limited in accordance with the Slip frequency 719 which is parameterized as a percentage
314. ous machine with speed sensor feedback The separate control of torque and flux forming current enables high drive dynamics with a high load mo ment The necessary speed sensor feedback results in a precise speed and torque performance Configuration 530 field oriented control of synchronous machine with speed torque control 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 Change over between variable speed control and torque dependent control is done jerk free during operation Configuration 610 Sensorless Field Oriented Control of Synchronous Ma chine 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 Configuration 611 Sensorless Field Orientated Control 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
315. ove sea level Mounting altitude in m above sea level Power reduction Derating 2 5 K upper 40 C T 55 C Output current in 10 20 30 40 50 55 Coolant temperature in C Reduction of output current at constant output power Derating 0 22 V upper 400 V U 480 V 100 83 um Sus e ete ee ee ee ee 63 40 Output current in 20 400 420 440 460 480 Mains voltage equal output voltage in V 06 13 Operating I nstructions ACU 41 SZ Bonfiglioli 5 Mechanical Installation A A 42 The frequency inverters of degree of protection IP20 are designed as a standard for installation in electrical cabinets e During installation both the installation and the safety instructions as well as the device specifications must be complied with To avoid serious physical injuries or major material damage only qualified persons are allowed to work on the devices During assembly make sure that no foreign particles e g chips dust wires screws tools can get inside the frequency inverter Otherwise there is the risk of short cir cuits and fire The frequency inverters comply with protection class IP20 only if the covers and ter minals are mounted properly Overhead Installation or installation in horizontal position is not permissible NOTE Mount the devices with sufficient clearance to other components so that the cooling air can circulate freely Avoid soiling by grease and air pollu
316. ows the inverse reference value specification with additional reversal of the direction of rotation This is often used in pressure control systems Y 50 Hz ee value Point 1 par Pernt nee X1 2 00 10 V 0 20 V Y1 100 0096 50 00 Hz 50 00 Hz Point 2 X2 98 00 10 V 9 80 V Y2 80 0096 50 00 Hz 40 00 Hz The reversal of the direction of rotation is affected in this example at an analog input signal of 5 5V X2 98 Y2 80 The definition of the analog input characteristic can be calculated via the two point form of the line equation The speed Y of the drive is controlled according to the analog control signal X sy x2 X1 Y x X1 Y1 06 13 Operating I nstructions ACU 173 G Bonfiglioli 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 The percentage values of the characteristic points are relative to the limits selected Description x Fact sett 3 50 Hz Minimum Frequency 0 00 Hz 999 99 Hz 0 00 Hz 7 Maximum Frequency 0 00 Hz 999 99 Hz 50 00 Hz The factory settings depend on the setup of parameter Configuration 30 1 3 50 Hz in configurations 1
317. parameter value 0 000U default defines a direct stop of the drive with the deceleration behavior selected in parameter Op eration mode 630 and the selected Deceleration clockwise 421 If a Position ing distance 460 is set the positioning is affected at the set deceleration The Signal correction 461 of the signal run time from the measurement point to the frequency inverter is not used if it is set to Oms The Load correction 462 can compensate a faulty positioning by the load be havior By default this function is deactivated i e set to 0 The Activity after positioning 463 is defined by operation mode 0 End of posi tioning The Waiting time 464 is not considered because operation mode 0 is selected for the parameter Action after positioning 463 The actual value Revolutions 470 enables a direct comparison to the required Positioning distance 460 n the case of deviations a Signal correction 461 or Load correction 462 can be carried out 12 6 2 Axle Positioning 06 13 For axle positioning a feedback system is mandatory In most cases an expansion module for the feedback evaluation is needed as well The operation modes for pa rameter Operation mode Speed sensor 2 493 are to be set to 1004 or 1104 For in formation on how to set the parameter refer to the instructions on the optional ex pansion module The positioning is started if a start signal is received and the fre quency drops below an adjustable
318. pe 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 The source of the actual speed value is selected via parameter Actual Speed Source 766 By default speed sensor 1 is used as the actual speed source If speed sensor 2 of an expansion module delivers the actual value signal for the speed control ler speed sensor 2 must be selected as the source The actual speed source is speed sensor 1 of the 1 Speed Sensor 1 basic device factory setting 2 Speed Sensor 2 The actual speed source is speed sensor 2 of an expansion module 1 Only available if an expansion module is installed Dependent on the application and applied speed sensors the settings of parameters must be adapted according to the following table 490 Operation Mode gt 0 0 Off gt 0 speed sensor 1 491 Division Marks 1 8192 X 1 8192 speed sensor 1 493 Operation Mode 0 Off gt 0 gt 0 speed sensor 2 494 Division Marks X 1 8192 1 8192 speed sensor 2 495 Level X Selection Selection 766 Actual Speed Source 1 2 lor2 X can be set to any value it is not evaluated The above mentioned parameters are selectable dependent on configuration setting and installed expansion module Some applications require two speed sensors Parameter Actual Speed Source 766 must be set to the motor speed sens
319. per condition corrosion Shorten Motor Line using Switching frequency 16 kHz parameters Rated speed 372 and Rated frequency 375 parameters Rated speed 372 and Rated frequency 375 06 13 108 Operating I nstructions ACU vv Bonfiglioli 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 For delta operation change the motor cable connec tion For star operation check the entered rated motor values Repeat the parameter identification SA053 A phase asymmetry was measured Check the cables at the terminals of the motor and the frequency inverter for proper connection and check the contacts for corrosion SA053 The Resolver angle was not estimated correctly 06 13 Operating I nstructions ACU 109 Goo Bonfiglioli 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 Code Measures Remedy SF000 No error message exists SF001 The value entered for parameter Rated Current 371 is too low Correct the value SF002 T
320. ph 400V AC FC 15 25mm AWG 16 4 L1L2L3 PE 64 Operating I nstructions ACU 06 13 vv Bonfiglioli Vectron 2 5 Nm 22 1 Ib in 18 5 kW 30 kW 25 6 15 00 od 05 35mm AWG 20 2 j 6 05 25mnf AWG 20 4 Ul VLW Ul viw Ct 1 00 25 mnt AWG 18 4 F CIA 15 25 mn eee AWG 16 4 Star connection Delta connection X2 A Rb1 4 Rb2 18 5 kW 30 kW T1 oo T2 25 6 15 00 t 05 35 mnm zie AWG 20 2 j E 05 25mm AWG 20 4 1 00 25 mni AWG 18 4 FC 15 25 mm AWG 16 4 06 13 Operating I nstructions ACU 65 GO Bonfiglioli 6 5 4 ACU 401 37 0 to 65 0 kW 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 When the frequency inverter is disconnected from power supply the mains DC link voltage and motor terminals may still be live for some time Switch off power supply before connecting or disconnecting the mains cable to from terminal X1 the motor cables and the brake resistor to from terminal X2 TUN S 37 0 kW 65 0 kW threaded bolt M8x25 2 wire cross section up to 70 mm 8 Nm 70 8 Ib in L1 L2 L3 P
321. ply is restored Operating Instructions ACU 06 13 vv Bonfiglioli 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 If the drive is to start automatically after restoration of the mains supply if the inverter is released permanently Operation mode 651 of Auto Start must be switched on Description Fact sett Shutdown Threshold 0 s Hz 999 99 Hz 0 00 Hz 387 5 365 Reference Shutdown Value 715 730 Reference Shutdown Value 676 becomes effective below the frequency value Shut down Threshold 675 The voltage controller uses the limit values of the DC link voltage The frequency change necessary for this is parameterized by the generator reference current value or the ramp The Gen ref current limit 683 or the ramp Mains support deceleration 673 defines the maximum deceleration of the drive necessary in order to reach the voltage value Reference mains support value 672 The Acceleration on mains re sumption 674 replaces the set values of the ramp parameters Acceleration clock wise 420 or Acceleration anticlockwise 422 if the figure set in the factory is changed The voltage control in a mains failure changes from the frequency limit Shutdown threshold 675 from Reference mains su
322. ports a fault warning is only rele D E Sg vant with the EM SYS option A 40 00 UDC er link voltage has reached the type dependent minimum A 80 00 WARN2 in Warning status application 367 a warning is present Operating I nstructions ACU 273 I Bonfiglioli 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 1 2 The output of a warning message in Warnings 269 is signaled 169 General Warning 11 Warning General 1 For linking with inverter functions 2 For digital output Meaning of code displayed by parameter Application Warning Status 367 A 00 00 NO WARNING No warning message present A 00 01 BELT Warning V belt by Operation mode 581 The positive SW limit switch was reached parameter A 00 0A SW LIMCW Positive SW limit switch 1145 The negative SW limit switch was reached parameter bai Negative SW limit switch 1146 A 00 08 HW LIM CW The positive HW limit switch was reached A 00 10 HW LIM CCW The negative HW limit switch was reached The contouring error monitoring range adjusted with AD 20 CONE parameter Warning Threshold 1105 was left A 00 40 Enc E encoder with data tr
323. pplications The motor speed is set according to the V f characteristic in accordance with the voltage frequency ratio Configuration 111 sensorless control with technology controller Configuration 111 extends the functionality of the sensorless control by software functions for easier adaptation to the customer s requirements in different applica tions Depending on the application the technology controller may be used which enables the control of flow rate pressure contents level or speed 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 In this configuration par allel connection of several 3 phase motors is possible to a limited extent only Configuration 411 sensorless field oriented control with technology controller Configuration 411 extends the functionality of Configuration 410 by a Technology Controller which enables a control based on parameters such as flow rate pressure contents level or speed Configuration 430 sensorless field oriented control with speed torque control Configuration 430 extends the functionality of Configuration 410 by functions for torque dependent field oriented control The reference torque is represented as a percentage and it is transmitted into the corresponding operat
324. pport value 672 to the Reference shutdown value 676 DesenpHon x Fact sett m Mains support deceleration 0 01 Hz s 50006 Hz s 50 00 Hz s 0 00 Hz s 9999 99 Hz s 0 00 Hz s Mains Support Deceleration 673 is active in configuration 1xx V f Gen Ref Current Limit 683 is active in configurations 2xx 4xx and 5xx FOC and SERVO The proportional and integrating part of the current controller can be set via parame ters Amplification 677 and Integral time 678 The control functions are deactivated by setting the parameters to 0 The controllers are P and controllers in the corre sponding settings Description i nee Tom ane LESER REIR om iui imi 23ms ms The factory settings depend on the selected configuration and control procedure According to the setup of parameter Configuration 30 there is the following assign ment U Configurations 1xx Configurations 4xx 2xx 5xx 6xx 06 13 Operating I nstructions ACU 215 Gg Bonfiglioli 17 3 Technology Controller 216 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 In this way applications such as pressure volume flow or speed control can be implemented
325. ption x Fact sett PR HERES Limit 0 00 Hz TUE Hz 0 00 Hz The control behavior of the current limit value controller can be set via the propor tional component the parameter Amplification 611 and the integrating component the parameter Integral time 612 f an optimization of the controller parameters is necessary in exceptional cases a setting should be done by a jump alteration of the parameter Current limit 613 Description x Fact sett L Amica A 00 1 00 10000 ms 24ms The dynamics of the current limit value controller and the voltage controller is influ enced by the setting of the parameter Dyn voltage pre control 605 17 5 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 In the course of the guided commissioning a map of the connected machine is produced by the parameter identification and transferred to various parameters Some of these parameters are visible and can be optimized for various operating points 17 5 1 Current Controller 06 13 The inner control loop of the field orientated control comprises two current control lers The field orientated control thus impresses the motor current into the machine via two components to be controlled This is done by controlling the flux forming current value lsa controlling the torque forming current value lt q By separate regulation of the
326. que refer to the calculated Torque from Rated Mech Power 376 Mo tor power and Rated Speed 372 Motor nominal speed Parameter Torque 224 shows the actual torque Select an applicable operation mode for parameter Operation Mode Flying Start 645 Refer to chapter 12 5 Search Run 17 5 3 2 Upper and lower limit of the frequency in Torque Control 230 In many cases limitation of the speed is required in the operating points with reduced or without load torque because the speed regulates itself to the torque reference and the load behavior To avoid an unintentional speed mostly too high speeds in some cases also too small speeds and avoidance of current impression the frequen cy is limited by Frequency upper limit 767 and Frequency lower limit 768 by the speed controller As from the limit value the drive is controlled to maximum speed Frequency Upper Limit 767 and Frequency Lower Limit 768 which corresponds to the behavior of the speed controller Additionally the controller limits the speed to Maximum Fre quency 419 This limitation is set by the speed controller changes in the speed controller affect the speed behavior in the limit area of the 3 mentioned parameters In the current impression the speed is limited additional to Minimum Frequency 418 in Direct Torque Control this limit is not active No Description Min Max Fact sett 767 Frequency upper limit 999 99 Hz 999 99 Hz 999 99 Hz 768 Frequency lower
327. quency inverter is suitable for operation at a supply network of a maximum of 480 VAC which delivers a maximum symmetrical current of 5000 A effective value if protected by fuses of class RK5 Only use copper cables with a temperature range of 60 75 C The frequency inverters are to be grounded properly i e large connection area and with good conductivity The leakage current of the frequency inverters may be 3 5 mA According to EN 50178 a permanent connection must be provided The protective conductor cross section required for grounding the fixing plate must be selected ac cording to the size of the unit In these applications the cross section must corre spond to the recommended cross section of the wire Degree of protection IP20 is only achieved with terminals plugged and properly mounted covers Connection conditions e The frequency inverter is suited for connection to the public or industrial supply mains according to the technical data If the transformer output of the supply mains is 500 kVA a mains commutation choke is only necessary for the fre quency inverters identified in the technical data The other frequency inverters are suitable for connection without a mains commutating choke with a relative mains impedance gt 196 e t must be checked based on the specifications of EN 61000 3 2 if the devices can be connected to the public supply means without taking additional measures The frequency inverters lt
328. r the function of the motor protection switch is similar to that of motors connected alternately to the mains with their own protection switches In operation modes 101 and 111 additionally the integrated current over the time is stored when the device is switched odd and set to the stored value when switched on again Parameter Operation Mode 571 2 22 102 or 122 In single motor operation only one motor protection switch which monitors the out put current of the frequency inverter is active In the case of a data set change over only the switch off limits derived from the rated machine parameters are changed over Accumulated thermal values are used after the change over as well In the case of the data set change over please ensure that the machine data are stated identi cally for all data sets In combination with the data set change over the function of the motor protection switch is similar to that of motors connected alternately to the mains with one common protection switch In operation modes 102 and 122 additionally the integrated current over the time is stored when the device is switched odd and set to the stored value when switched on again Parameter Operation Mode 571 101 102 111 or 122 The internal state of the motor protection switch is latched reset stable These set tings are to be used when regularly short mains interruptions occur This way the motor protection is considered correctly for short mains failures
329. r function and the parame ters Frequency Motorpoti Up 62 Frequency Motorpoti Down 63 or Percent Motor poti Up 72 Percent Motorpoti Down 73 the connection with the available logic sig nals Motorpoti Up M nun Function Output signal does not change 1 Output value drops at set ramp Output value is reset to initial value 0 contact open 1 contact closed 1 0 jOutputvalue rises at set ramp 06 13 Operating I nstructions ACU 199 G9 Bonfiglioli 15 4 10 15 4 11 15 4 12 200 Handshake Traverse Function Via parameter Handshake Traverse Function 49 the signal source is selected for specification of the direction of rotation of the slave drive of the shot effect function The shot effect function is switched on via parameter Operation mode 435 User warning For setting up external warnings parameters User Warning 1 1363 and User Warn ing 2 1364 can be used Parameterization of a user warning enables triggering a warning in the device via a digital signal if a critical state in the plant occurs The warning is displayed in Warnings Application 273 and can be transmitted to a high er level control like a PLC Please check parameter Create warning mask application 626 and chapter 15 3 9 Application warning mask for further explanations External error Parameterization of an external error enables switching off or shutting down several frequency inverters at a time if a fault occurs in the plant or the drive I
330. r is discharged A Wait for some minutes until the DC link capacitors have discharged before starting to work at the unit When the frequency inverter is disconnected from power supply the mains DC link voltage and motor terminals may still be live for some time The mains fuses and cable cross sections are to be selected according to EN 60204 1 and DIN VDE 0298 Part 4 for the nominal operating point of the frequency inverter According to UL CSA approved Class 1 copper lines with a temperature range of 60 75 C and matching mains fuses are to be used for the power cables The electrical installation is to be done according to the device specifications and the applicable standards and directives The cables connected to the frequency inverters may not be subjected to high voltage The control mains and motor lines must be kept physically separate from one another insulation tests unless appropriate circuitry measures are taken before 6 4 3 Motor Connection Disconnect the frequency inverter from mains voltage and protect it against being energized unintentionally Verify that the frequency inverter is discharged A Wait for some minutes until the DC link capacitors have discharged before starting to work at the unit 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 cabl
331. re quency 400 and when the drive is in no load operation The flux forming actual cur rent value sd 215 to be read out should roughly match the set Rated magnetizing current 716 The field orientated control with speed sensor feedback uses the parameterized Rat ed magnetizing current 716 for the flux in the motor The dependence of the magnetizing on the frequency and voltage at the correspond ing operating point in question is taken into account by a magnetizing characteristic The characteristic is calculated via three points in particular in the field weakening area above the rated frequency The parameter identification has determined the magnetizing characteristic and set the parameters Magnetizing current 50 713 Magnetizing current 80 714 and Magnetizing current 110 715 No Description Min Max Fact sett 713 Magnetizing current 5096 31 00 714 65 00 715 145 00 716 0 34 rm 10 2 4 Rated slip correction factor The rotor time constant results from the inductivity of the rotor circuit and the rotor resistance Due to the temperature dependence of the rotor resistance and the satu ration effects of the iron the rotor time constant is also dependent on temperature and current The load behavior and thus the rated slip depend on the rotor time con stant The guided commissioning determines the machine data during the parameter identification and sets the parameter Rated slip correction factor 718 accordingly For the
332. rence channel and Reference percentage channel Availability of functions Motorpoti MP and Motorpoti KP differs in the individual reference value channels Reference frequency Reference percentage source 475 source 476 Motorpoti MP X X Motorpoti KP X 0 X function available 0 function not available Depending on the active reference value channel the function is assigned to a digital signal via parameters Frequency motorpoti up 62 Frequency motorpoti down 63 or Percent motorpoti up 72 Percent motorpoti down 73 For a summary of available digital signals refer to chapter Digital inputs 06 13 Operating I nstructions ACU 167 Goo Bonfiglioli 14 10 1 14 10 2 168 The Operation mode 474 of the motor potentiometer function defines the behavior of the function at various operating points of the frequency inverter 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 In the operation mode storing latching the motor goes to the reference value selected before the switch off at the start The reference value is also stored when the device is switched off The operation mode Motorpoti taking over is to be used for the data set change over of the reference value channel The current reference value is used when the motorpoti function is activated This operation mode combines the
333. rent limit is reached the hysteresis is passed through with a delay The behavior of the reference value can be determined from its direction of movement according to the following dia gram Fact sett Max 999 99 Hz 449 100 00 Hz reference value output EN Pd ihysteresis hysteresis 1 4 1 No Description Min y M internal f hysteresis fuathysteresis reference value Operating Instructions ACU 06 13 vv Bonfiglioli 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 Motorpoti MP Motorpoti KP Function Up Down Up Down 0 0 Output signal does not change 1 0 A Output value rises at set ramp 0 1 v Output value drops at set ramp 1 1 At Y Output value is reset to initial value 0 contact open 1 contact closed A V Arrow keys on control unit KP 500 The motor potentiometer function and its link to other reference value sources can be selected in the corresponding reference value channels with parameters Reference frequency source 475 or Reference percentage source 476 For a description of the possible links of the reference value sources refer to chap ters Reference Values Frequency refe
334. rly high precision requirements via a suitable measurement Via Operation mode 465 for the temperature adjustment you can select different methods and actual value sources for temperature measurement The function is deactivated Temperature synchronization Temp meas on MFI1A 0 200 C gt 0 10 V 0 20 mA actual temperature value at multifunctional input 1 Determination of temperature by frequency invert Temp Meas at Start er via measurement of the winding resistance without external temperature measurement Temperature synchronization act temperature value across analog multi function input 26 0 C 207 8 C gt 0 10V 0 20 mA Vectron temp meas on MFI1A Operation mode 1 requires an external temperature measurement system which evaluates the temperature sensor and maps the temperature range from 0 200 C to an analog voltage or current signal The Operation mode 452 of multifunction input MFI1 must be selected accordingly Operation mode 4 is available in configurations 210 211 and 230 When the signals Controller release and Start clockwise or Start anticlockwise are present the motor temperature and the rotor time constant are synchronized by means of the measured winding resistance For operation mode 11 an optional temperature measurement board by BONFIGLIO LI VECTRON is required This board can be connected to the 20 V power supply on the frequency inverter This board converts th
335. rmined 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 MFI1A X210A 1 Voltage output 20 V or input for external power supply DC 24 V 10 X210A 2 GND 20 V GND 24 V ext X210A 3 Digital input STOA 1st shutdown ath of safety function STO X210A 4 Start of clockwise operation X210A 5 Start of anticlockwise operation X210A 6 Data set change over 1 X210A 7 Data set change over 2 X210B 1 Motor thermal contact X210B 2 Digital input STOB 2 shutdown ath of safety function STO X210B 3 Run Signal X210B 4 Analog signal of actual frequenc X210B 5 Supply voltage 10V for reference value potentiometer X210B 6 Reference speed 0 10 V X210B 7 Ground 10 V 76 Operating Instructions ACU 06 13 vv Bonfiglioli 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 X210A 1 Voltage output 20 V or input for m external power supply DC 24 V 10 Digital input STOA 1st shutdown path of safety function STO X210A 4 Fixed percentage value change over 1 X2
336. rning lt 1V 2mA If the input signal is lower than 1 Vor 2 mA a warning message is issued If the input signal is lower than 1 V or 2 mA a 2 Shut Down 1V 2mA warning message is issued the drive is deceler ated according to stopping behavior 2 If the input signal is lower than 1 V or 2 mA a 3 ims warning and fault message is issued and the drive coasts to a standstill stopping behavior 0 Monitoring of the analog input signal is active regardless of the release of the fre quency inverter according to the operation mode selected Operation mode 2 defines the shut down and stopping of the drive regardless of the setting of parameter Operation mode 630 for the stopping behavior The drive is stopped according to stopping behavior 2 If the set holding time has expired an error message is issued The drive can be started again by switching the start signal on and off Operation mode 3 defines the free coasting of the drive like described for stopping behavior 0 regardless of the setting of parameter Operation mode 630 for the stopping behavior The monitoring of the analog input signal via the parameter Error Warning behavior 453 demands the examination of the parameter Characteristic point X1 454 Example Error Warning behavior 453 2 Stop lt 1V 2mA or 3 fault switch off lt 1V 2mA In the factory settings of the parameter Point X1 454 shutting down or fault switch off are affected at an output frequ
337. rning signs at frequency inverter e Comply with all safety instructions and danger information provided on the frequency inverter e Safety information and warnings on the frequency inverter must not be removed 16 Operating I nstructions ACU 06 13 Bonfiglioli Vectron 2 6 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 Identification of immediate threat holding a high risk of death or serious injury if not A avoided Identification of immediate threat holding a medium risk of death or serious injury if not avoided Identification of immediate threat holding a low risk of minor or moderate physical inju ry if not avoided NOTE Identification of a threat holding a risk of material damage if not avoided 2 6 2 Hazard symbols Symbol Meaning Symbol Meaning General hazard N Suspended load Electrical voltage Hot surfaces 2 6 3 Prohibition signs Symbol Meaning No switching it is forbidden to switch the machine plant assembly on 06 13 Operating I nstructions ACU 17 Goo Bonfiglioli 2 6 4 Personal safety equipment Symbol Meaning Q Wear body protection 2 6 5 Recycling Symbol Meaning C AY Recycling to avoid waste collect all GO materials for reuse 2 6 6 Grounding symbol
338. rresponding RxPDO signal sources of the system bus or OUT PZD signal sources of Profibus to parameter DeMux input 1253 The transmitted signals are available at the receiver as signal sources 910 to 925 06 13 Operating I nstructions ACU 207 G Bonfiglioli 16 V f Characteristic 208 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 The torque to be applied by the motor at the cor responding operating point demands the control of the output voltage proportional to the frequency At a constant output voltage output frequency ratio of the frequency inverter the magnetization is constant in the nominal operating range of the 3 phase motor The rating point of the motor or end point of the V f characteristic is set via the guided commissioning with the parameter Cut off voltage 603 and the para meter Cut off frequency 604 The lower frequency range where an increased voltage is necessary for the start of the drive is critical The voltage at output frequency zero is set with the parameter Starting voltage 600 An increase in voltage deviating from the linear course of the V f characteristic can be defined by the parameters Voltage rise 601 and Rise fre quency 602 The percentage p
339. rvoltage controller and power failure regulation Udc Limit amp Mains switched on During the Mains Support motor and 13 Supp active Chopper brake chopper are deactivated In all other cases not active motor and brake chopper are active and switch with the parameterized thresholds of P506 and P507 1 Udc Limitation active 2 Mains Support active Mains Support active Chopper not active The function motor chopper is available in the field oriented control methods in con figurations 210 230 410 411 and 430 Operating I nstructions ACU 211 Goo Bonfiglioli When an operation mode with motor chopper is selected set the Trigger Threshold 507 Reference DC Link Limitation 680 10 V See chapter 18 7 1 Motor Chop n per For synchronous motors Configuration 30 5xx the motor chopper function is de activated to prevent damages to the motor The other functions of the voltage control ler are not affected by this For asynchronous motors in V f control Configuration 30 1xx the motor chopper function is not operative The other functions of the voltage controller are not affected by this The brake chopper is active dependent of the setting of Reference DC Link Limitation 680 See chapter 18 4 Brake Chopper and Brake Resistance for parameterizing the switching threshold Operation mode Overvoltage control Voltage controller Parameter Operation mode 670 1 Ud f Overvoltage controller activ
340. s Connect control unit KP 500 to the frequency inverter After initialization the data sources available for transmission are displayed Use the arrow keys to select the data source Src Fy for the transmission to the frequency inverter The files stored in the control unit are available as data sources The files stored in the control unit contain all information and parameters stored ac cording to the selected copy function ALL or Act see Chapter Copy Menu in the control unit Confirm your selection by pressing the ENT key The copy process is started While the copy operation is in process COPY and as a progress indicator the number of the currently processed parameter will be displayed As soon as the copy operation is complete the control unit will be re initialized 96 Operating Instructions ACU 06 13 vv Bonfiglioli 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 Press RUN and STOP keys on control unit simultaneously for approx 1 second When the process is complete is displayed briefly Then the top menu level of the control unit is available In the parameter menu PARA use the arrow keys to select parameter Pro gram ming 34 and confirm your selection by pressing th
341. s chapter The current limit value controller reduces the load on the drive e g during acceleration by stopping the acceleration ramp The switch off of the frequency inverter which happens when the acceleration ramps have been set at an excessive gradient is prevented in this way The current limit value controller is switched on and off via parameter Operation mode 610 The current limit value controller functions and the intelli 0 Off S gent current limits have been deactivated The current limit value controller is active Operating Instructions ACU 06 13 vv Bonfiglioli Behavior in motor operation If the current set via parameter Current limit 613 is exceeded the activated current 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 set by the parameter Frequency limit 614 f the Current limit 613 is fallen short of the output frequency is raised back to the reference value Behavior in generator operation If the current set via parameter Current limit 613 is exceeded the activated current limit value controller will increase the output frequency until the current limit is no longer exceeded The output frequency is increased as a maximum to the set Max imum frequency 419 f the current is below the Current limit 613 the output fre quency is reduced to the required reference value again Descri
342. se two parameters a decoupling of the system equiva lent to an externally excited direct current machine is achieved Operating I nstructions ACU 227 Goo Bonfiglioli 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 Amplification 700 and Integral time 701 are available The proportional and integra tion and component of the current controllers can be switched off by setting the pa rameters to zero No Description Min Max Fact sett Amplification 000 800 013 10 00 ms 10 00ms The guided commissioning has selected the parameters of the current controller in such a way that they can be used without having to be changed in most applications If in exceptional cases an optimization of the behavior of the current controller is to be done the reference value jump during the flux formation phase can be used for this The reference value of the flux forming current components leaps to the figure Current during flux formation 781 with suitable parameterization and then changes controlled to the magnetizing current after the expiry of the Maximum flux formation time 780 The operating point necessary for the adjustment demands the setting of parameter Minimum Frequency 418 to the value 0 00 Hz as the drive is accelerated after magnetizing The measurement of the step response which is defined
343. sent documentation refers to the frequency inverters ACTIVE Cube 201 and ACTIVE Cube 401 series With their factory settings both series of devices are suited for a wide range of applications The modular hardware and software structure enables customer specific adaptation of the frequency inverters Applications with high functionality and dynamics requirements can be realized easily The ACTIVE Cube series can be recognized by its label on the case and the identification below the top cover Position of ID de pends on device size 1 1 Instruction manuals For better clarity the documentation is structured according to the customer specific requirements made on the frequency inverter Quick start guide The Quick Start Guide describes the basic steps required for mechanical and electrical installation of the frequency inverter The guided commissioning supports you in the selection of necessary parame ters and the configuration of the frequency inverter by the software Operating instructions The Operating Instructions describe and document all functions of the frequency inverter The param eters required for adapting the frequency inverter to specific applications as well as the wide range of additional functions are described in detail Application manual The application manual supplements the documentation for purposeful installation and commissioning of the frequency inverter Information on various subjects connected wi
344. sets are identical Change to the last parameter edited Display of last parameter highest number Display of first parameter lowest number 9 Use the ENT key to select the parameter The parameter is displayed including its value unit and the active data set If settings are edited in data set 0 the arameter values are changed in the four data sets Use the arrow keys to adjust the parameter value or to select an operation mode The adjustment possibilities you have depend on the parameter Keep the arrow keys pressed for a while to change the displayed values quickly If you release the keys again the speed at which the values change is reduced again If the parameter value starts to flash the speed at which the values change is reset to the initial value again FUN ENT Change of the data set in the case of data set related parame ters Use the ENT key to save the parameter For a short time the message SEt including the parameter number and the data set is displayed To leave the parameter unchanged press the ESC key Errl EEPrO Err2 StOP 3 After saving the parameter you can edit the value again or return to the pa rameter selection menu by pressing the ESC key Parameter has not been saved Parameter can only be read i e not edited when the unit is in operation Other error Operating Instructi
345. sett Warning Limit Heat Sink Temp Warning Limit Inside Temp Minimum temperatures are defined as 10 C interior and 30 C heat sink tempera ture Output signals Digital signals indicate the attainment of warning limits 166 Warning Heat Sink The value 80 C minus Warning Limit Heat Sink 8 Temperature Temp 407 is attained 167 Warning Inside The value 65 C minus Warning Limit Inside Temp 9 Temperature 7 408 is attained 170 1 The value Warning Over E Warning Limit Heat Sink Temp 2 4 HEHIDETSBUG 65 C minus Warning Limit Inside Temp 408 is attained 1 For linking with inverter functions For digital output Operating Instructions ACU 06 13 vv Bonfiglioli 13 3 Controller status 13 4 06 13 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 Controller status 275 The limit values and events which result in the interven tion by the corresponding controller are described in the corresponding chapters The behavior during the intervention of a controller is configured with the parameter Con troller status message 409 The intervention of a c
346. should be avoided exceeding 10096 capacity of the stator winding permanently PT1 Element PT1 Element 7120756 stator Therm time const motor Therm time const stator Warning Operating Instructions ACU 06 13 vv Bonfiglioli 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 10096 This corresponds to the complete thermal capacity of the motor If 10296 is reached the drive switches off with an error message Both outputs are connected to the adjustable alarm limit I t Single Motor Error Switch Off I t Multi Motor Opera tion Warning I t Single Motor Warning I t Multi Motor Opera tion Warning and Error Switch Off The I t capacity of the motor is monitored with rated values from the active dataset If the fixed threshold values exceed 100 motor 120 stator the drive switches off with fault F0401 in the active dataset The I t capacity of the motors regarding their related ratings is monitored in each of the four data sets If the Warning Limit Motor Pt 615 is reached the warning message A0200 is signaled from the active data set The I t capacity of the motor is monitored with rated values from the active dataset If the Warning Limit Motor It 615 is reached the warning message A0200 is signaled from the active data set The I t capacity of
347. splay and edit parameters M Menu branch CPY in N e Copy parameters ooocc eec Menu branch CTRL WV Select control and test functions Use the arrow keys to select the required menu branch The selected menu branch is displayed flashing Select the menu branch by pressing the ENT key The first parameter or the first function in the selected menu branch will be displayed If you press the ESC key you will return to the main menu of the control unit A VY Navigate through the menu structure and select a menu branch Open the selected menu branch Cancel the current menu branch and return to the main menu 88 Operating I nstructions ACU 06 13 7 3 06 13 vv Bonfiglioli 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 amp gui T Jii 9 r5 SEE eji 3 NS e U 9o ibl z HH S N prim IN Use the arrow keys to select the required number from the actual values dis played in numerical order If the highest parameter number is achieved actuating the A key displays the lowest parameter number If the lowest parameter number is a
348. ssioning SA Measures Remedy SA000 SA001 range cated No warning message present This message can be read out via an option al communication board The value of the parameter Rated voltage 370 is out of the rated voltage of the frequency inverter The maximum reference voltage is indi on the nameplate of the frequency inverter For a three phase motor the calculated efficiency is in the limit range SA002 Check the values entered for the parameters Rated voltage 370 Rated current 371 and Rated power 376 SA003 The value entered for parameter Rated cos phi 374 is outside of the nor mal range 0 6 to 0 95 Check the value For three phase motor the calculated slip is in the limit range SA004 Check the values entered for parameters Rated speed 372 and Rated fre quency 375 SA011 Current Controller non typical value refer to 17 5 1 SA012 Current Controller non typical value with 2 kHz refer to chapter 17 5 1 SA014 Current Controller non typical value with 4 kHz refer to chapter 17 5 1 SA021 The stator resistance is very high The following causes are possible The motor cable cross section is not sufficient The motor cable is too long The motor cable is not connected correctly The contacts are not in a proper condition corrosion The motor cable cross section is not sufficient The motor cable is too long The motor cable is not connected correctly The contacts are not in a pro
349. st switching on Set up fitting values during commissioning Op Mode Digital Output 1 530 or Op Mode Digital Output 2 531 or Op Mode Digital Output 3 532 With expansion module 4 Setting Frequency Op Mode EM SIOUTD 533 or Op Mode EM SIOUTD 534 Setting Frequency 510 Set value Hz For linking with functions 164 Setting Frequency 184 Operating I nstructions ACU 06 13 wy Bonfiglioli ectron 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 Signal source 163 Reference Frequency reached or 178 Reference Percentage reached can be linked with inverter functions The hysteresis can be defined as a percentage of the adjustable range Max Min via parameter Max Control Deviation 549 Description Min Max Fact sett 5 00 Op Mode Digital Output 1 530 or Op Mode Digital Output 2 531 or 5 Reference Frequency reached Op Mode Digital Output 3 532 or With expansion module 6 Reference Percentage reached Op Mode EM SIOUTD 533 or Configuration 30 x11 x30 Op Mode EM SI OUTD 534
350. supply DC 24 V 10 GND 20 V GND 24 V ext Digital input STOA 1st shutdown ath of safety function STO Start of clockwise operation n M change over control function Speed sensor track B Speed sensor track A X210A 2 X210A 3 X210A 4 X210A 5 X210A 6 X210A 7 X210B 1 X210B 2 Motor thermal contact Digital input STOB 2 shutdown ath of safety function STO Run Signal Analog signal of actual frequenc Supply voltage 10 V for reference value potentiometer Reference speed 0 10 V or refer ence torque as percentage value X210B 7 Ground 10 V X210B 3 X210B 4 X210B 5 X210B 6 80 Operating I nstructions ACU 06 13 vv Bonfiglioli 6 7 9 Configuration 510 FOC of Synchronous Machine Speed Controlled 06 13 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 Comply with the operating instructions for the expansion module for the connection of the resolver or absolute encoder Configuration 510 contains the functions for speed controlled field oriented control of a synchronous machine with resolver feedback The separate control of torque and flux forming current enables high drive dynamics with a high load moment The nec essary resolver feedback results in a precise
351. t is to synchronize to the drive in positive direction clockwise field of rotation If this attempt fails it is tried to synchronize to the drive in negative direction anticlockwise field of rotation The first attempt is to synchronize to the drive in nega 3 th tive direction anticlockwise field of rotation If this at then clockw Se wae te gs pe DCB tempt fails it is tried to synchronize to the drive in posi tive direction clockwise field of rotation Synchronization to the drive is only done in positive di DCB rection clockwise field of rotation Synchronization to the drive is only done in negative DCB direction anticlockwise field of rotation An attempt is made to synchronize to the drive in positive direction clockwise field of rotation and in negative direction anticlockwise field of rotation The search direction is defined by the sign in front of the reference value If a positive reference value clockwise Quick Synch acc to field of rotation is entered the search is in a positive di Preset Value rection clockwise field of rotation with a negative refer ence value the search is in a negative direction anti clockwise field of rotation Quick synch Synchronization to the drive is only done in positive di 14 p f clockw onl rection clockwise field of rotation 15 Quick synch Synchronization to the drive is only done in negative anticlockw onl direction anticlockwise field
352. t or re mote operation via communication interface The defined warning mask of parameter Create 157 Warning Mask Warning Mask 536 signals a critical operating point i Output signal of the time function according to rue qum the input connection Timer 1 83 Output signal of the time function according to ime mers the input connection Timer 2 84 Frequency inverter is initialized and ready for Signal enable STO S1IND STOA and 74 S5IND 75 S6IND 161 Run Signal S7IND STOB and a start command are present output frequency available 162 Error Signal Monitoring function signals an operational fault Reference Frequency Signal when the Actual frequency 241 has 163 reached reached the reference frequency Signal when the actual value Stator Frequency 164 Setting Frequency 210 exceeds the value of Setting Frequen cy 510 The monitoring functions report an overload of the frequency inverter Warning Heat Sink Tem Max heat sink temperature Tx of 80 C less the 165 Warning Ixt bid perature Warning Limit Heat Sink Temp 407 reached 167 Warning Inside Tempera Max inside temperature T of 65 C less the ture Warning Limit Inside Temp 408 reached Warning Motor Tempera Warning behavior according to parameterized 168 Motor Temp Operation mode 570 at max motor ture temperature Toprc Signal when Warnings 269 are displayed with a critical operating point The value 80 C minus Warning Limit He
353. t the voltage drop is as small as possible If the voltage drop is too great the motor will not reach its full torque Also comply with any additional national and application specific regula tions and the separate UL instructions For typical mains fuses refer to chapter Technical Data According to EN61800 5 1 the cross sections of the PE conductor shall be dimen sioned as follows Mains cable up to 10 mm Install two protective conductors of the same size as the mains cable or one protective conductor of a size of 10 mm Mains cable 10 16 mm Install one protective conductor of the same size as the mains cable Mains cable 16 35 mm Install one protective conductor of a size of 16 mm Mains cable gt 35 mm Install one protective conductor of half the size of the mains cable 6 4 1 1 Typical cross sections 54 The following tables provide an overview of typical cable cross sections copper cable with PVC insulation 30 C ambient temperature and continuous mains current max 100 rated input current Actual mains cable cross section requirements may devi ate from these values due to actual operating conditions 230 V One phase L N and two phase L1 L2 connection 01 0 25 kW 03 0 37 kW 05 0 55 kW 1 5 mm aKa m Or 1 5 mm 07 0 75 kW 1x10 mim 09 L1KW 11 L5KW 13 22kW 2 5 mm SO IM M 1 5 mm 15 3 kW 1x10 mm i 2x4 mm or 2 2
354. tal inputs described in chap ter Digital inputs The positioning starts on condition that the Actual frequency 241 of the output sig nal is smaller than the value entered in parameter Positioning frequency 471 Due to a stopping behavior the actual frequency drops below the positioning frequency No _Descri ption Min Max Fact sett 1 00 Hz 50 00 Hz 50 00 Hz Via the parameter Max positional error 472 the maximum permissible deviation from the Reference orientation 469 can be set Descri ption Min Max Fact sett Via parameter Time constant positioning controller 479 the time constant for con trolling the positional error can be set The value of the time constant should be in creased if oscillations of the drive around the reference orientation occur during the positioning No Description Min Max Fact sett time constant positioning contr 9999 99 ms 20 00 ms To make sure that the set position is maintained if a load torque is applied a stop ping behavior should be selected for parameter Operation mode 630 which impress es a starting current either permanently when the drive is at a standstill or for the stopping time The status message 60 Target Position Reached which is displayed when the ref erence orientation is reached can be assigned to a digital output The message is output on the following conditions Operation mode 2 axle positioning for parameter Operation mode 458
355. tart command when the motor is at a standstill The motor is positioned clockwise to the reference orientation if the value for the reference orientation is higher than the value adjusted before The motor is positioned anticlockwise to the reference orientation if the value for the reference orientation is smaller than the value adjusted before The sense of rotation during the positioning is independent of whether Start Clock wise or Start Anticlockwise was activated The time required until the reference orientation is reached depends on Actual frequency Frequency ramp for deceleration Rotational angle to reference orientation Max positional error Time constant positioning contr 13 Error and warning behavior 06 13 Operation of the frequency inverter and the connected load are monitored continu ously The monitoring functions are to be parameterized with the corresponding limit values specific to the application If the limits were set below the switch off limit of the frequency inverter a fault switch off can be prevented by suitable measures if a warning message is issued The warning message is displayed by the LED s and can be read out on the operating unit via parameter Warnings 269 or output via one of the digital control outputs Operating I nstructions ACU 149 Goo Bonfiglioli 13 1 Overload I xt The admissible load behavior depends on various technical data of the frequency invert
356. tarted During the time of initialization init and a progress indicator are displayed After initialization the control unit KP 500 is ready for transfer of data to the frequency inverter Adjustment of parameter Program ming 34 to the value Parameter transmission can be undone via the control unit provided that the control unit has not been initial ized yet e n parameter Program ming 34 use the arrow keys to set the value 110 Nor mal operation again and confirm by pressing the ENT key Operating I nstructions ACU 95 Go Bonfiglioli 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 Establish connection to frequency inverter Start communication and select parameter Program ming 34 via the communi cation interface Via the communication interface enter value 111 in parameter Program ming 34 and confirm this value Via the communication interface enter value 123 in parameter Program ming 34 and confirm this value The frequency inverter is re initialized The display of the control unit reads rE SEt After that the unit is initialized 7 6 2 Data transfer In order to transmit a file from the control unit to the frequency inverter proceed as follow
357. ted Operation Mode Timer 1 790 gen Timer 1 erates an output signal of the function 2 2 2 2 5 3 24 Timer 2 The selected Operation Mode Timer 2 793 gen erates an output signal of the function Message of the configurable parameter Create 2 599 NA URBIS Warning Mask 536 Warning application is signaled Display of the 26 Warning Application actual value is affected via parameter Warnings Application 273 e Message of the configurable parameter Create l Warning Mask AppUEason Warning Mask Application 626 28 Application Warning or warning application is signaled Warn Mask gen Warn Message of configurable parameters Create a Appl um Warning Mask 536 and Create Warning Mask HOMES Application 626 30 Flux Forming finished Magnetic field has been impressed Activation of a brake unit depending on the Op eration Mode 620 for the starting behavior Op eration Mode 630 for the stopping behavior or the configured brake control system 43 External Fan The Switch On Temperature 39 has been reached ns The phase error of the index control exceeded i 1 50 Synchronization Fault the Warning limit 597 51 Signal Fault Index signal period too short during index con trol Message of phasing function For positioning in combination with the function of the electronic gear the value Phasing Offset 1125 was reached Synchronization of the electronic gear is reached 57 In Gear The slave drive is engaged an
358. ted control methods only require the definition of the limit values Maximum flux formation time 780 and Current during flux formation 781 for the adjustment of the acceleration behavior The acceleration behavior of the sensorless control method in configurations 110 and 111 can be selected as described in the following chapter 12 1 1 Starting Behavior of Sensorless Control System The parameter Operation mode 620 for the starting behavior is available in configu rations 110 and 111 Depending on the operation mode selected the machine is magnetized first or a starting current is impressed The voltage drop across the stator resistance which reduces the torque in the lower frequency range can be compen sated by the IxR compensation To ensure the correct function of the IxR compensation the stator resistance is de termined during the guided commissioning The IxR compensation is only activated when the stator resistance was determined correctly At the start the voltage with the value of parameter Starting Voltage 600 is set at an output frequency of 0 Hz After this the output voltage and the output fre quency are changed according to the control method The break away torque and the current at the start are determined by the adjusted starting voltage It may be necessary to optimize the starting behavior via the pa rameter Starting voltage 600 In this operation mode the Current during flux formation 781 for magnetization is impressed
359. ter ramp Keypad Motorpoti 473 No Description Minm Max Fact sett Ramp Keypad Motorpoti 0 00 Hz s 999 99 Hz s 2 00 Hz s 06 13 Operating I nstructions ACU 169 I Bonfiglioli 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 digital inputs is evaluated according to the selected Operation mode 496 PWM frequencies in the range between 50 Hz and 150 kHz can be evaluated PWM signal capture on terminal X210A 4 2 PWM S2IND 0 100 0 10096 of Maximum reference percentage 519 or 0 10096 of Maximum frequency 419 PWM signal capture on terminal X210A 5 PWM S3IND 0 10096 0 10096 of Maximum reference percentage 519 or 0 10096 of Maximum frequency 419 PWM signal capture on terminal X210B 1 6 PWM S6IND 0 100 0 10096 of Maximum reference percentage 519 or 0 10096 of Maximum frequency 419 PWM signal capture on terminal X210A 4 1 PWM S2IND 100 100 100 100 of Maximum reference percentage 519 or 100 100 of Maximum frequency 419 PWM signal capture on terminal X210A 5 PWM S3IND 100 100 100 100 of Maximum reference percentage 519 or 100 10096 of Maximum frequency 419 6 X E 1 1 PWM signal capture on terminal X210B 1 PWM S6IND 100 100 100 100 of Maximum reference percentage 51
360. teresis acts as a limiter at the input of the integral part Excessive differences between the stator current and the output of the controller technology are so limited and so prevent excessive integration of the integral value The deviation A between Reference frequency of the Technology Controller ften and Stator 2 Hysteresis 443 frequency fstator is too big The Integrator is halted fon H J oie Rated frequency 315 The Stator frequency fstator can follow the reference frequency of the technology control lt Hysteresis 443 er sufficiently The deviation A is mall enough tech JD ados Rated frequenz 375 Operating Instructions ACU 06 13 06 13 vv Bonfiglioli No Description x Fact sett 441 0 00 Hz 442 50 00 Hz 443 ieee 10 00 444 1 00 445 200 ms 446 1 00 618 0 ms In modes 1 2 3 and 5 the output frequency is shifted along the ordinate axis to the Minimum Frequency 418 The percentage of the technology controller output value corresponds to 0 Minimum Frequency 418 D Maximum Frequency 419 X2 100 Y2 P 419 P 419 P 418 S x1 0 Y1 P 418 X 100 96 The parameterization of the technology controller in the individual data sets enables an adaptation to various operating points of the application with the data set change over via control contacts The technology controller operates in motor clockwise operation The
361. terference 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 Install the frequency inverters and commutating chokes on a metal mounting panel Ideally the mounting panel should be galvanized not painted Provide proper equipotential bonding within the system or the plant Plant com ponents such as control cabinets control panels machine frames etc must be connected by means of PE cables The shield of the control cables is to be connected to ground potential properly i e with good conductivity on both sides shield clamp Mount shield clamps for cable shields close to the unit Connect the frequency inverter the commutating choke external filters and oth er components to an earthing point via short cables Keep the cables as short as possible make sure that cables are installed properly using appropriate cable clamps etc Contactors relays and solenoids in the electrical cabinet are to be provided with suitable interference suppression components L1 1 fuse L2 2 circuit breaker L3 3 line choke optional N 4 input filter optional 1 5 cable shield 6 brake resistor optional 7 output filter optional Operating I nstructions ACU 06 13 06 13 vv Bonfiglioli Y Mains Connection The length of the mains supply cable is not lim ited However it must
362. th 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 10 Operating I nstructions ACU 06 13 tv Bonfiglioli The following instructions are available for the ACT VE CUBE series Operating Instructions ACT VE CUBE Functions of the frequency inverter Quick Start Guide ACT VE CUBE Installation and commissioning Delivered with the device Manuals CM CAN Manual CANopen Communication Interfaces CM PDP V1 Manual Profibus DP V1 CM 232 CM 485 Manual VABus Serial protocol CM 232 CM 485 Modbus Manual Modbus ASCII and RTU CM VABus TCP Ethernet Module CM VABus TCP i P CM ModbusTCP Ethernet Module CM Modbus TCP i P CM EtherCAT Ethernet Module CM EtherCAT CM ProfiNet Ethernet Module CM ProfiNet i P CM EtherNet I P Ethernet Module CM EtherNet I P i P Manuals EM ABS 01 Absolute Encoder Module Expansion Modules EM ENC 01 Encoder Module EM ENC 02 Encoder Module EM ENC 03 Encoder Module EM ENC 04 Encoder Module EM ENC 05 Encoder Module EM 10O 01 Expansion Module for Digital inputs outputs EM 10O 02 Expansion Module for Digital inputs outputs EM 10O 03 Expansion Module for Digital inputs outputs EM 1O 04 Expansion Module for Digital inputs outputs EM RES 01 Resolver Module EM RES 02 Resolver Module EM RES 03 Resolver Module EM SYS Systembus Module
363. the motors regarding their related ratings is monitored in each of the four data sets If the Warning Limit Motor It 615 is reached the warning message A0200 is signaled from the active data set If the fixed threshold values exceed 100 motor 120 stator the drive switches off with fault F0401 in the active dataset Both incidences are triggered from the active dataset The I t capacity of the motor is monitored with rated values from the active dataset If the Warning Limit Motor t 615 is reached the warning message A0200 is signaled from the active data set If the fixed threshold values exceed 100 motor 120 stator the drive switches off with fault F0401 in the active dataset Both incidences are triggered from the active dataset I t Single Motor Warning and Error Switch Off The thermal time constant of the motor is in the range from few minutes to a couple of hours This motor specific parameter is set via Thermal time constant motor 608 Substantially smaller is the thermal stator time constant To protect the stator wind ing additional monitoring is required which is determined by Thermal time constant stator 609 These values can be taken from the corresponding motor data sheets When estimat ed time constants are used because the required data are not available then an opti mal thermal motor protection cannot be guaranteed 06 13 Operating I nstructions ACU 249 G Bonfiglioli A warning limit al
364. the operation modes 1 10 40 32 34 F2 EM S1INA and 2 V Combination of the operation modes 1 10 40 30 32 F3 F2 EM S1I NA 34 and 2 Combination of the operation modes 1 10 20 32 and EM S1INA 2 7 91 Abs value MFI1A FF MP F1 Combination of the operation modes 1 10 20 30 32 F3 EM S1INA and 2 92 Abs value MFI1A FF MP F3 Combination of the operation modes 1 10 20 32 34 F2 2 EM S1INA and 2 99 Abs value MFI1A FF MP F1 Combination of the operation modes 1 10 20 30 32 F3 F2 2 EM S1INA 34 and 2 101 to 199 Operation modes with signs The reference value source is only available if an expansion module with analog input is connected For infor mation refer to the expansion module operating instructions The reference value source is only available if an expansion module with speed sensor input is connected For information refer to the expansion module operating instructions 32 06 13 Operating I nstructions ACU 155 Goo Bonfiglioli 14 4 1 Block diagram The following table describes the software switches shown in the circuit diagram as a function of the selected Frequency reference value source 475 Operation mode 1 1 10 11 1 12 14 1 20 21 1 22 24 1 30 31 1 32 33 1 34 35 1 40 41 1 42 44 80 81 82 89 90 91 92 99 101 199 ejejejejejejejeje 156
365. the reference percentage source The analog signal on the multifunction input 1 in La Anao pU MFA analog Operation mode 452 32 Repetition frequency The frequency signal on the digital input corre input F3 sponding to the selected Operation mode 496 No Description Min Max Fact sett Technology Controller Release Selection 6 On Operating Instructions ACU 06 13 06 13 vv Bonfiglioli Via parameter Technology Controller Release 58 the technology controller can be halted The P and D part remain at the value before switching off The output value and the part resets with each switching off of the Technology Controller Release 58 The default assignment of parameter Start clockwise 68 to the logic signal of the technology controller must be observed Start Clockwise 68 13 Technology Controller Start This assignment may not be changed The technology controller becomes active with the controller release at digital input S1IND STOA Structural image I nputs for reference percentage source Technology Controller Actual Percentage Source 478 Repetition Frequency I Operation mode 496 Devider 497 Multifunctional Input analog Actual values o 3 gt Actual Percentage Value 230 digital l Operation mode 452 The function selected via the parameter Operation mode 440 defines the behavior of the technology controller
366. the timeouts is set to zero this monitoring function is deactivated No Description Max Fact sett Min 761 Timeout Signal fault 65000 ms 1000 ms Timeout Track fault 65000 ms 1000 ms Timeout Direction of rotation fault 65000 ms 1000 ms Timeout Signal fault The actual speed measured is compared with the output value of the speed control ler If the actual speed value is exactly zero for the time selected with the parameter Timeout Signal fault 761 although a reference value is available the fault is dis played with the message F1430 Timeout Track fault The actual speed measurement monitors the sequence in time of the signals in the quadruple evaluation of the speed sensor operation mode If the speed sensor signal is faulty for the time selected with the parameter Timeout Channel fault 762 the fault is displayed with the message F1431 Timeout Direction of rotation fault The actual speed measured is compared with the reference speed If the sign be tween reference value and actual value differs for the time selected with the parame ter Timeout Direction fault 763 the fault is displayed with the message F1432 The monitoring function is reset when the drive mechanism has moved in the refer ence value direction by a quarter of a revolution 06 13 Operating I nstructions ACU 253 Goo Bonfiglioli 18 8 Traverse function With the traverse function a triangle shaped frequency signal with the accelera
367. ting current 623 is impressed in configurations 1xx 4xx and 6xx for control in the selected configuration until the Frequency limit 624 is reached Permanent operating points below the frequency limit are only admissible if forced ventilated motors are used The transition to the control method of the selected configuration 30 takes place above the frequency limit The Frequency limit 624 is set up automatically during the guided motor commis sioning in field oriented control configurations 4xx and 6xx In V f control configura tions 1xx the parameter Frequency limit 624 is not changed by the guided motor commissioning No Description Min Max Fact sett 0 00Hz 100 00 Hz _ 2 60 Hz 12 1 1 3 Brake release time In order to protect the motor holding brake against damage the motor may only start after the brake has been released Startup to reference speed is affected only after the Brake release time 625 has elapsed The time should be set such that it is at least as long as the time required for releasing the holding brake By using nega tive values for the parameter release of the brake is delayed This can be done in order to prevent loads from falling down for example No Description Min Max Fact sett 5000 ms 5000 ms 0 ms 136 Operating Instructions ACU 06 13 vv Bonfiglioli 12 1 2 Flux Formation Field oriented control in the configurations 2xx and 4xx are based on separate regu lation of t
368. tion 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 The function can be used for example for drives which wind up thread on coils in textile machines To avoid winding errors at the turning point of the thread guide a proportional jump is performed which causes a quick speed change Proportional Step 439 fA Master drive Traverse Amplitude 438 Reference Frequency 48 fA t Slave drive Reference Frequency 48 0 gt Deceleration t Acceleration Time 437 lt Time 436 gt Handshake gt b In the case of the master drive the superimposed traverse frequency proceeds line arly to the limit Traverse Amplitude 438 and then reverses its direction When the direction is reversed a proportional step is affected Via a handshake signal the master drive informs the slave drive that the traverse output has changed its direc tion The traverse function of the slave drive has the same gradient as the traverse function of the master drive but with opposite sign When the slave drive reaches the limit Traverse Amplitude 438 before switch over of the handshake signal the frequency is maintained until switch over is affected If the handshake signal is re ceived before the frequency limit is reached the direction is reversed immediately No
369. tion and quick and easy assembly 3 1 ACU 201 up to 3 0 kW and 401 up to 4 0 kW Q Frequency inverter Terminal strip X1 Phoenix ZEC 1 5 ST7 5 Plug in terminals for mains connection and DC linking O Terminal strip X10 Phoenix ZEC 1 5 3ST5 0 Plug in terminals for the relay output Standard fixtures for vertical assembly Key Brief Instructions and Operating Instructions on CD ROM bd Terminal strip X2 Phoenix ZEC 1 5 ST7 5 Plug in terminal for brake resistor and motor connection 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 Obvious defects such as exterior damage of the packing and or the unit must be notified to the sender within seven days for insurance reasons 06 13 Operating I nstructions ACU 25 GW Bonfiglioli 3 2 ACU 201 4 0 to 9 2 kW and 401 5 5 to 15 0 kW XM rw pem Vaid CERTE Ey 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 assembl 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
370. tion by dust aggressive gases etc Operating I nstructions ACU 06 13 vv Bonfiglioli 5 1 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 x gt 100 mm Assembly is affected by inserting the long side of the fixing plate in the heat sink and screwing it to the mounting plate The dimensions of the device and the installation dimensions are those of the standard device without optional components and are given in millimeters ACU a byj c al j a hl d 201 9 25 KW 1 1KW 190 60 178 210 230 260 30 133 L5kW 3 0KW 250 60 178 270 290 315 30 133 Aoi 0 25 KW 1 5 kW 190 60 178 210 230 260 30 133 1 85 kW 4 0 kW 250 178 270 290 315 133 06 13 Operating I nstructions ACU 43 G Bonfiglioli 5 2 44 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 gt x gt 100 mm fixing bracket top fixing with screws M4x20 fixing bracket bottom fixing with screws M4x60 S Assembly is done by screwing the two fixing brack
371. tion can be detected additionally The two tracks are commonly referred to as A and B Depending on when the edges occur it can be determined if the motor rotates in clockwise or in anticlockwise direction With double or quadruple evaluation internal calculation for motor control is im proved The number of division marks does not change In addition to tracks A and B sensors often feature a reference track also referred to as Z track zero track C track The reference track delivers one pulse per revolu tion This track is used for plausibility checking or for additional functions If an operation mode with reference track is selected for the speed sensor the fre quency inverter will make sure that the Z track occurs according to the parameterized Division marks speed sensor 1 491 If the evaluation is not consistent a reaction as per parameter Operation mode 760 is triggered Example quadruple evaluation that the cycle is restarted The type of edges OD B Potion indicates the direction of rotation Clockwise direction of rotation A rising edge of A 1 is followed by a rising edge of B 2 Tib Anticlockwise direction of rotation A rising Oe Ls BA edge of A 1 is followed by a falling edge LELELLLLLELL oo A daria t Z Track Z One pulse per revolution HTL sensors can be connected to the basic device The connection of TTL sensors requires an expansion module type E
372. tionally 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 When the frequency inverter is disconnected from power supply the mains DC link voltage and motor terminals may still be live for some time Switch off power supply before connecting or disconnecting the mains cable to from terminal X1 the motor cables and the brake resistor to from terminal X2 X1 L1 L2 L3 PE 3ph 230V AC 3ph 400V AC ACTIVE Cube 201 18 4 0 kW cE L1 N PE 1ph 230V AC 4 0 kW 9 2 kW 11 kW 15 kW 6qmm RM7 5 16qmm RM10 15 f L 0 2 6 mn f L 02 16mm AWG 24 10 AWG 24 6 f a 02 6mm f a 02 16mnt AWG 24 10 AWG 24 6 0 25 4 mm T 025 10 mnf AWG 22 12 AWG 22 8 0 25 4 mm f p 0 25 10 mnf AWG 22 16 AWG 22 8 ACU 201 18 4 0 kW one and three phase connection possible ACU 201 19 5 5 kW and higher three phase connection possible 62 Operating Instructions ACU 06 13 Delta connection UL VIW amp s 4 0 kW 9 2 kW 6qmm RM7 5 a 95 6mm AWG 24 10 02 6mnf AWG 24 10 0 25 4 mm AWG 22 12 SCT 025 4mnf AWG 22 16 Xp 4 0 kW 9 2 kW 6qmm RM7 5 C3 02 6mnf AWG 24 10 amp m 02 6mnf AWG 24 10 0 25 4 mnt AWG 22 12 C 4 0 25 4 mn AWG 22 16
373. tor In the case of three phase machines the speed can be increased at a constant torque if the motor winding can be switched over from star to delta connection The change over leads to a modification of the dependent rated figures by a square root of three NOTE The rated data of the motor are to be entered according to the specifications on the rating plate for the motor connection type used star or delta connection If the data entered deviate from the rating plate the parameters will not be identified correctly 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 Operating I nstructions ACU 123 69 Bonfiglioli 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 10 2 1 Stator Resistance The resistance of the stator winding is measured during the guided commissioning The measured value is saved as a phase value in parameter Stator resistance 377 and is 3 times smaller than the winding resistance in delta connection By default the equivalent stator resistance of a standard motor is entered to mat
374. tor e g PTC resistor in order to avoid damage 6 4 3 5 Speed sensor connection 58 Install sensor cables physically separate from motor cables Comply with the sensor manufacturer s specifications Connect the shield close to the frequency inverter and limit the length to the neces sary minimum Operating Instructions ACU 06 13 Bonfiglioli Vectron 6 4 4 Connection of a Brake Resistor Install a brake resistor if feedback of generator energy is expected Overvoltage shutdowns can be avoided by this A A 06 13 Disconnect the frequency inverter from mains voltage and protect it against being ener gized 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 When the frequency inverter is disconnected from power supply the mains DC link voltage and motor terminals may still be live for some time During operation the surface of the brake resistor can reach high temperatures The surface can keep high temperatures after operation for a certain time Do not touch the brake resistor during operation or operational readiness of the frequency inverter Non compliance may result in skin burn Install a safeguard for protection against contact or fix warning labels Do not install the brake resistor in the proximity to flammable or heat sensitive materi als Do not cover the brake resist
375. tor Type 454 em The properties of the control functions and methods to be set vary depending on the motor which is connected The parameter Motor type 369 offers a range of motor variants with the corresponding values The verification of the entered rated values 104 and the guided commissioning are carried out on the basis of the parameterized motor type The selection of motor types varies according to the applications of the different control methods In operating instructions the functionality and operating performance are described for 3 phase motors 0 Unknown 1 Asynchronous 2 Synchronous 3 Reluctance 10 Transformer Transformer with three primary windings D For setting of parameter Motor type 369 to operation mode 10 Transformer no param eter identification is performed NOTE Polling and setting of parameter values depends on the operation mode selected for parameter Motor type 369 If the motor type is not entered correctly the drive may be damaged When the motor type is specified the machine data must be entered This is de scribed in the following chapter The data are polled in accordance with the table below Operating Instructions ACU 06 13 vv Bonfiglioli 8 2 4 Machine Data din 7 7 Li ULT 06 13 The machine data to be entered during the guided commissioning procedure are indi cated on the type plate or the data sheet of the motor The
376. trol the guided commissioning must be stopped after the message SEtUP by pressing the ESC key in order to set parameter Offset 382 first To do this proceed according to the operating instructions for the expansion module EM RES installed Otherwise personal or machine damage may occur When the unit is in as delivered condition the guided commis Ene sioning procedure is started automatically After successful commis sioning the guided commissioning can be carried out again later via Phe the sub menu CTRL and the function can be called again Ng e Use the ENT key to switch to the CTRL sub menu e Inthe CTRL sub menu select the menu item SEtUP and con firm by pressing the ENT key LEL p e Use the ENT key to select parameter Configuration 30 a e The available configurations are displayed automatically depending on the selected Control level 28 e Use the arrow keys to enter the number of the required config lL uration for a description of the configurations refer to the fol a lowing chapter If the setup was changed the hardware and software functionality will be configured The message SEtUP is displayed again Confirm this message by pressing the ENT key in order to continue the commissioning procedure Operating I nstructions ACU 101 Goo Bonfiglioli e Switch to the next parameter e After initialization confirm the selected configuration by pressing the ENT ke
377. trolled 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 Change over between variable speed control and torque dependent control is done jerk free during operation Operating I nstructions ACU 103 Goo Bonfiglioli 8 2 2 Data Set d i 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 In the factory settings the frequency inverter uses data set 1 as the active data set For information on data set change over via logic signals refer to the chapter Data Set Change Over For example if data set 2 is selected for guided commissioning SETUP all values which were determined or entered are saved in this data set In this case the other data sets still contain the factory settings For the operation of the frequency invert er data set 2 must be selected as the active data set in this case y Funtion sd All data sets DSO Data set 1 DS1 Data set 2 DS2 Data set 3 DS3 Data set 4 DS4 8 2 3 Mo
378. troller seseeenmR Hee 239 18 1 18 2 Operating Instructions ACU 06 13 tv Bonfiglioli Vectron 18 3 Bus corntroller i conus annoa osa corna ena Una aan nona EEonaoraaER E saa aaaea ainakaa 241 18 4 Brake Chopper and Brake Resistance eeeeeeeeeeeernnnnee 243 18 4 1 Dimensioning of Brake Resistor esssssssee mmn 244 18 5 Motor Protection 22 o 1cos eis aasronanisaRas aRanRORRRDUFRRERER SNRRRERROSRERRRRUERNRREDRRRE 245 18 5 1 Motor Protection SWIRCH ics iiis oc oret ente ree a ha Rea dre eara d TR Era EMT 245 18 5 2 Motor Protection by I2t Monitoring esse mH 248 18 6 V belt Monitoring nee e urere rennen nennen nnn nnn n nnn n annua anaana 250 18 7 Functions of Field Orientated Control 1 eren nnn 251 18 7 1 Weisen 251 18 7 2 Temperature Adjustment reer ene 252 18 7 3 Speed Sensor Monitoring ssssssee memes 253 18 8 Traverse FUNCTION oie ooei ees esee or GnR Us EuRUs ra UE ORE UERDERREONRREUREUNPRRRRDNERNRO EDEN 254 18 9 Converter Profibus from to I nternal Notation nennen 256 19 Actual Values 19 1 Actual Values of the Frequency I nverter eene 257 19 1 1 STO Status a itadeiias Lm 259 19 2 Actual Values of the Machine scsscssesseeeeeeeseeeeeseseaseeeegseeseneeeeeneseenennee 260 19 3 Actual va
379. tt 1250 Mux input index write 1251 Mux input index read D Non volatile fixed parameterization Volatile 0 All indices in EEPROM 17 All indices in RAM 1 16 One Index of 1 16 in EEPROM 18 33 One Index of 1 16 in RAM NOTE The setting 0 for Mux input index write 1250 changes all data in EEPROM and RAM In the case of non volatile storage 0 16 the changed values are still available when power supply is switched on again In the case of volatile storage 17 33 the data is only stored in RAM If the unit is switched off this data is lost and the data required are loaded from EEPROM after restart Demultiplexer The demultiplexer features an input DeMux Input 1253 whose signal can be for the process data RxPDO of the system bus or OUT PZDx of Profibus On the output of the demultiplexer the logic signals 910 Output DeMux Bit 0 to 925 Output DeMux Bit15 are available e g for control of FT instructions 9 Zero 704 727 RXPDO Word 740 741 Remote control word remote state word 754 757 OUT PZD word 900 Controller status 927 Output MUX 910 925 Output DeMux Bit 0 output DeMux Bit 15 Operating Instructions ACU 06 13 tv Bonfiglioli 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
380. tween the two control systems The speed controller or the torque con troller is active depending on the n M control change over 164 Operating I nstructions ACU 197 G Bonfiglioli 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 assigned with the parameters Data set change over 1 70 and Data set change over 2 71 The actual value parameter active data set 249 shows the selected data set Data set change Data set change A over 1 70 Function active data set 0 Dataset DS 0 contact open 1 contact closed If Configuration 30 110 111 410 411 430 510 530 610 611 or 630 is select ed in the factory setting a timer function is interconnected between the digital input S4IND and the data set change over 1 Timer 1 83 73 S4IND wD 158 Timer 1 Pese Data set change over 1 70 The data set change over 1 is linked with timer 1 Data set change over I 70 158 Timer 1 Timer 1 is linked with the digital input S4IND terminal X210A 6 Timer I 73 SAIND In the factory setting the data set change over 1 is not affected by the Timer 1 Signal delay Time 1 Timer 1 791 0 00 s m h Signal duration Time 2 Timer 1 792 0
381. ual frequenc Supply voltage 10V for reference value potentiometer X210B 6 Reference speed 0 10 V X210B 7 Ground 10 V X210B 3 X210B 4 X210B 5 6 7 2 Configuration 111 Sensorless Control with Technology Controller Configuration 111 extends the functionality of the sensorless control by software functions for easier adaptation to the customer s requirements in different applica tions The Technology Controller enables flow rate pressure level or speed control X210A 1 Voltage output 20 V or input for external power supply DC 24 V X210A E ML 420 V 180 mA X210A 2 GND 20 V GND 24 V ext GND 20 V X210A 3 Digital input STOA 1st shutdown S1IND ath of safety function STO 4 S2IND X210A 4 Fixed percentage value change S3IND over 1 L6 SAIND X210A 5 Fixed percentage value change S5IND over 2 X210A 6 Data set change over 1 X210B X210A 7_ Data set change over 2 X210B 1 X210B 2 Motor thermal contact Digital input STOB 2 shutdown ath of safety function STO Run Signal Analog signal of actual frequenc Ais X210B 3 X210B 4 X210B 5 X210B 6 ercentage value 0 10 V X210B 7 Ground 10 V 06 13 Operating I nstructions ACU 75 Goo Bonfiglioli 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 dete
382. uctions on use instructions shall be complied with Comply with the Application manual Safe Torque Off STO especially when the de scribed safety relevant function is used Operating I nstructions ACU 23 GSD Bonfiglioli 24 A 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 Even if power supply to the motor is disconnected and the motor is coasting to a standstill or has already stopped high voltages may still be present on the motor terminals Before working e g maintenance on live parts the plant must always be discon nected from mains supply main switch This must be documented on the plant When the function Safe Torque Off is triggered the motor is not isolated from the DC link of the frequency inverter High voltage levels may be present at the motor Do not touch live terminals Operating I nstructions ACU 06 13 vv Bonfiglioli 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 The plug in type connection terminals enable a safe func
383. ue to be displayed as from now e Use the ENT key to display the value of the parameter e Press the ENT key again SEt is displayed for confirmation As from now the selected actual value is displayed after each restart If the parameter settings were made via the optional control software or in the PARA menu branch of the operating unit the display of the selected actual value must be activated manually Use the ESC key to switch to the selection of the actual value for display again 112 Operating Instructions ACU 06 13 Bonfiglioli Vectron 8 3 Check direction of rotation A 06 13 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 Do not touch the terminals because the capacitors may still be charged Only connect suitable voltage sources The nominal voltage of the frequency invert er must correspond to the supply voltage The frequency inverter must be connected to ground potential If voltage supply is switched on no covers of the frequency inverter may be re moved To check if the reference value and the actual direction of rotation of the drive cor respond to one another proceed as follo
384. uencies 06 13 The four fixed frequencies define reference values which are selected via the Fixed frequency change over 1 66 and Fixed frequency change over 2 67 The Reference frequency source 475 defines the addition of the various sources in the reference frequency channel No pescription Fact sett 480 0 00 hz 481 10 00 Hz 482 25 00 Hz 483 Fixed frequency 4 50 00 Hz By combining the logic states of the fixed frequency change over modes 1 and 2 fixed frequencies 1 through 4 can be selected Fixed frequency Fixed frequency change over 1 66 change over 2 67 RUN Han PADNE TAA value o fo rived frequency 1 480 of rived frequency 2 481 Fixed frequency 3 482 OO Five frequency 4 483 0 contact open 1 contact closed If an optional expansion module with digital inputs is installed additional fixed fre quencies can be selected In this case refer to the instruction manual of the expansion module Operating I nstructions ACU 161 G Bonfiglioli 14 6 2 J OG 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 pressed The drive starts and the machine turns at the set JOG frequency 489 f the J OG frequency has been changed using the arrow keys this value is stored No Description Min Max
385. uired by the customer the switching frequency may be increased if the output current is reduced at the same time Comply with the applicable standards and regulations for this operating point FRE oe 75 kW 150A 150A 150A 0 kW 180A 180 A 180A 110 kW 210A 210 A 210 A 132 kW 250A 250A 250 A 1 Three phase connection requires a commutating choke 2 Mains current with relative mains impedance gt 1 see chapter Electrical installation 3 Reduction of switching frequency in thermal limit range Maximum current in continuous operation 5 Optional the frequency inverter of this size is purchasable without brake transistor For the UL conform fuse protection the mentioned fuses of the company Cooper Bussmann must be used Other fuses must not be used for the UL conform fuse protection 40 Operating Instructions ACU 06 13 vv Bonfiglioli 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 Power reduction Derating max coolant temperature 5 1000 m above sea level 3 3 C 1000 m above sea level h 7 4000 m 100 755 ss m 85 Been I Se ee ee pe 5 60 2 E E o 40 2 Qa c 5 S O 20 S O 1000 2000 3000 4000 1000 2000 3000 4000 Mounting altitude in m ab
386. ure in the frequency inverter The mean inside temperature calculated in the 292 Average value inside temp d R period of observation 293 Peak value labs The highest abs current calculated from the measured motor phases 294 Average value labs The mean abs current calculated in the period of observation The largest calculated active power in motor op eration Maximum generator active power calculated from the voltage the current and the control variables f The mean active power calculated in the period 297 Average value active power of observation 301 Energy positive The calculated energy to the motor in motor op eration The calculated energy from the motor in gen 292 PNOY negaave erator operation The actual values can be read out and monitored in the VAL menu branch of the oper ating unit The parameter Operation level 28 in the PARA menu branch defines the selection of the actual value parameters to be selected 288 Average value Vdc 295 Peak value active power pos 296 Peak value active power neg 06 13 Operating I nstructions ACU 261 G Bonfiglioli The Reset memory 237 parameter to be selected in the PARA menu branch of the 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 11 Peak Value Pactive pos 12 Peak Value
387. uring operation X210A 1 Voltage output 20 V or input for external power supply DC 24 V 10 GND 20 V GND 24 V ext Digital input STOA 1st shutdown ath of safety function STO Start of clockwise operation n M change over control function Data set change over 1 Data set change over 2 X210A 2 X210A 3 X210A 4 X210A 5 X210A 6 X210A 7 X210B l Motor thermal contact X210B 2 Digital input STOB 2 shutdown ath of safety function STO X210B 3 Run Signal X210B 4 Analog signal of actual frequenc X210B 5 Supply voltage 10 V for reference value potentiometer X210B 6 Reference speed 0 10 V or ref erence torque as percentage value X210B 7 Ground 10 V 06 13 Operating I nstructions ACU 85 G Bonfiglioli 6 8 I nstallation 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 and 18 5 Motor Protection For an installation according to UL508c only allowed fuses can be used for mains protection The al lowed fuses are described in chapter 4 Technical Data For an install
388. uth Africa 55 Galaxy Avenue Linbro Business Park Sandton Tel 27 11 608 2030 OR Fax 27 11 608 2631 www bonfiglioli co za bonfigsales bonfiglioli co za Bonfiglioli T rkiye Ataturk Organize Sanayi B lgesi 10015 Sk No 17 Cigli Izmir Tel 90 0 232 328 22 77 pbx Fax 90 0 232 328 04 14 www bonfiglioli com tr info bonfiglioli com tr Bonfiglioli United Kingdom Industrial Solutions Unit 7 Colemeadow Road North Moons Moat Redditch Worcestershire B98 9PB Tel 44 1527 65022 Fax 44 1527 61995 www bonfiglioli com uksales bonfiglioli com Mobile Solutions 3 7 Grosvenor Grange Woolston Warrington Cheshire WA1 4SF Tel 44 1925 852667 Fax 44 1925 852668 www bonfiglioli co uk mobilesales bonfiglioli co uk Bonfiglioli USA 3541 Hargrave Drive Hebron Kentucky 41048 Tel 1 859 334 3333 Fax 1 859 334 8888 www bonfiglioliusa com Bonfiglioli Vietnam Lot C 9D CN My Phuoc Industrial Park 3 Ben Cat Binh Duong Province Tel 84 650 3577411 Fax 84 650 3577422 www bonfiglioli vn salesvn bonfiglioli com 5 Bonfiglioli power control and green solutions 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 Via Giovanni XXIII 7 A fax 39 051 647 3126 40012 Lippo
389. valuation inv sense of rot via contact with ref track 1132 Operating I nstructions ACU 129 GW Bonfiglioli In configurations 210 211 and 230 digital input S4IND is by default set for the evalu ation of a speed sensor signal track B If an operation mode without sign is selected Operation Mode 11 or Operation Mode 12 this input is not set for the evaluation of a speed sensor signal and can be used for other functions 10 4 2 Division marks speed sensor 1 130 The number of increments of the connected speed sensor can be adjusted via pa rameter Division marks speed sensor 1 491 Select the division marks of the speed sensor according to the speed range of the application The maximum number of division marks Smax is defined by the frequency limit of fmax 150 kHz of the digital inputs S5IND track A and S4IND track B 60 Smax fmax o nmax 150000 Hz max speed of the motor in RPM fm ax Nmax for example S 150000 Hz LN 6000 max 1500 To guarantee true running of the drive an encoder signal must be evaluated at least every 2 ms signal frequency f 500 Hz The minimum number of division marks Smin Of the incremental encoder for a required minimum speed Nmin can be calculated from this requirement Ser tf BOR min min A min Nmin min speed of the motor in RPM A evaluation 1 2 4 for example 60s _ Description X Fact sett Division marks speed sensor 1 um sius 1024
390. values or analog limit values is done via the parameters Torque limit source motor op 736 and Torque limit source generator op 737 The output value of the P component is limited with parameter P comp torque upper limit 732 and P comp torque lower limit 733 The limit values are input as torque limits as a percentage of the rated motor torque The power output by the motor is proportional to the product of speed and torque This output power can be limited at the controller output with Power lim it 739 and Power limit generator operation 740 The power limits are entered in kW Operating Instructions ACU 06 13 vv Bonfiglioli No Description Min Max Fact sett 728 lewn 729 leun 730 Torque limit 650 00 96 731 650 00 732 P comp torque upper limit 650 00 100 00 733 P comp torque lower limit 650 00 96 100 00 96 739 2 Prun 740 Power limit generator operation 2 U Prun Anticlockwise Clockwise operation operation Torque Limit Generator Operation 731 ir Torque Limit 730 generator motor motor generator p Torque Limit Generator Operation 731 Torque Limit 730 EE ROTEN TEET E za L i Speed is limited by Maximum Frequency 419 17 5 4 2 Limit Value Sources As an alternative to limiting the output values by a fixed value linking to an analog input value is also possible The analog value is limited via parameters Minimum reference percentage
391. via digital signals Fixed direction of rotation clockwise rotation only Control via keypad The start and stop commands are controlled via key clockwise onl pad Fixed direction of rotation clockwise rotation only The Start and Stop commands are controlled from the control unit or via digital signals Fixed direction of rota tion clockwise rotation only Control via state ma Es chine 4 Control via cont clockwise only Control via cont KP clockwise rot only Control via KP The start and stop commands are controlled via digital dir of rot via con signals The statement of the direction of rotation tacts comes from the operating unit or via digital signals Control via cont KP The Start and Stop commands as well as the sense of sense of rot via cont rotation can be controlled from either the control unit KP or via digital signals Control via 3 wire 3 wire and control unit control of direction of rotation KP i 46 and signal 3 wire control 87 via contacts or control dir of rot via con unit tacts KP If the operation mode is changed while the drive is running the drive will not be stopped if no stop command is present in the new operation mode 242 Operating Instructions ACU 06 13 vv Bonfiglioli 18 4 Brake Chopper and Brake Resistance 06 13 The frequency inverters feature a brake chopper transistor The external brake resis tor is connected to terminals Rb1
392. wer failure Resumption of power t 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 rameter Mains Failure Threshold 671 f a mains failure is detected the controller tries to regulate the DC link voltage to the value set with parameter Reference Mains Support Value 672 To that end the output frequency is continuously reduced and the motor with its rotating masses is switched over to generator operation Using field oriented Control FOC SERVO the reduction of the output frequency is done according to the configuration with a maximum of the current set by the parameter Gen Ref Current Limit 683 nm Gen Ref Current Limit 683 is active in configurations 410 and 610 FOC and SERVO 06 13 The threshold values of the voltage controller are calculated starting with the current DC link voltage with the parameters Mains failure threshold 671 and Reference mains support value 672 Output signals Digital signals indicate mains failure and power failure regulation 1 179 Mains failure Mains failure and power failure regulation selected via 13 Mainsfailure Operation Mode 670 of the voltage controller 1 For linking with inverter functions For digital output If the mains voltage is restored before a switch off is affected by the mains un dervoltage detection system the drive is accelerated to
393. ws e Operate the drive at low speed i e specify a reference value of approx 10 e Switch on release of frequency inverter briefly Connect digital inputs S1IND STOA and S7IND STOB as well as S2IND Start clockwise or connect S1IND STOA and S7IND STOB as well as S3IND Start an ticlockwise e Check if the motor shaft turns in the required direction In case the sense of rotation is wrong exchange two motor phases e g U and V at the terminals of the frequency inverter The mains side connection of the frequency inverter does not affect the sense of rotation of the drive In addition to checking the drive the corresponding actual values and operating messages can be read out by means of the operating unit The commissioning of the frequency inverter is complete and can be complemented by further settings in the PARA menu The set parameters have been selected in such a way that they are sufficient for commissioning in most applications The other set tings which are relevant to the application can be checked according to the operating instructions If the controller release of the frequency inverter at S1IND STOA and S7IND STOB is switched off the power output stage will be disabled The motor will coast down or if installed a break will be activated Operating I nstructions ACU 113 Goo Bonfiglioli 8 4 Speed sensor 114 For some configurations an incremental speed sensor must be connected Dependent on the speed sensor ty
394. xer 206 P Parameter identification 107 Parameter list sseseseesenes 275 Percentage value ramps 166 Plausibility check s 106 Positioning Axle positioning scce 147 starting from reference point 144 Power failure regulation 213 Pressure control 133 220 263 Pulse width modulation 240 PWIMMM PUL ice metre enit eaae 170 R Reference frequency channel 154 Reference percentage channel 158 Reference positioning ssssssse 144 Reference value Fixed frequency sea 161 Fixed reference value 161 JOG frequency 162 Motor potentiometer 167 reached ienaa a 185 Reference values 154 Fixed percentages 162 Relay OUtpUt caret ttti 72 Technical data teeeeeeeeee eae 31 Repetition frequency input 170 hii PETER 97 S SA Warning messages auto set up 108 Safe torque off 23 Safety General orae aA tud 14 Safety function Status of the Inputs 259 Ius 22 Setting frequency eeen 184 bj 116 SF Error messages auto setup 110 Slip compensation sseeeese 226 Speed controller sssssss 232 Switch over speed torque control 197 Speed sensor sssseseenne 114 Division
395. ximum frequency 419 The acceleration corresponds to the factory setting 2 Hz s for the parameter Ramp Keypad Motorpoti 473 The parameters Acceleration clockwise 420 and Deceleration clockwise 421 are taken into account with lower acceleration figures Internal reference value int OnE Em The drive is in operation i e output signals are present at the a frequency inverter and the current actual value is displayed HHH T 9 Press an arrow key to switch to the motor potentiometer func tion Pot The current frequency value is taken over in the mo tor potentiometer function Pot Function Motorpoti KP inP in eS RUN Using the arrow keys you can adjust the output frequency of a the frequency inverter from Minimum frequency 418 to Max HH i bis 9 imum frequency 419 The frequency value adjusted via the control unit can be linked to other reference values via the Reference frequency source 475 Chapter Reference frequen cy source and Motorpoti KP JOG frequency JOG MEF eme RUN This function is useful for manual setup and positioning of a a machine The frequency of the output signal is set to the en HHE T 9 tered value if the FUN key is pressed e Press FUN key to switch from the internal reference value int or the motor potentiometer function Pot to parameter JOG frequency 489 e While keeping the FUN key pressed press the arrow keys to adjust the required frequency e The frequency value last a
396. xx 4xx 0 00 Hz in configurations 2xx 5xx The control system uses the maximum value of the output frequency which is calcu lated from the Maximum Frequency 419 and the compensated slip of the drive The frequency limits define the speed range of the drive and the percentage values sup plement the scaling of the analog input characteristic in accordance with the func tions configured Description X Fact sett Minimum Reference Percentage 0 s 2 s m 0 00 Maximum Reference Percentage 0 00 300 00 100 00 15 1 1 3 Tolerance Band and Hysteresis 174 The analog input characteristic with change of sign of the reference value can be adapted by the parameter Tolerance band 450 of the application The adjustable tolerance band extends the zero passage of the speed relative to the analog control signal The parameter value percent is relative to the maximum current or voltage signal Description Min Max Fact sett YET 0 00 96 25 00 96 2 00 96 X2 Y2 pos maximum value 0v 0 mA zero point 20 mA tolerance band X1 Y1 o Y1 X1 Y1 s Y1 neg maximum value neg maximum value Without tolerance band With tolerance band Operating Instructions ACU 06 13 vv Bonfiglioli The default Minimum Frequency 418 or Minimum Percentage 518 extends the pa rameterized tolerance band to the hysteresis X2 Y2 pos maximum value 4 8 1 pos minimum value 4
397. y e Continue the guided commissioning procedure according to the following chap ters 8 2 1 Configuration 102 Parameter Configuration 30 determines the assignment and basic function of the control inputs and outputs as well as the software functions The software of the frequency inverter offers several configuration options These differ with respect to the way in which the drive is controlled Analog and digital inputs can be combined and complemented by optional communication protocols as further reference value sources The operating instructions describe the configurations and the relevant parameters in the third Control level 28 adjustment of parameter Control level 28 to value 3 Please also comply with the following manuals Application Manual Electronic Gear x15 x16 Application Manual Positioning x40 Application Manual Hoisting Gear Drives x60 Configuration 110 sensorless control Configuration 110 contains the functions for variable speed control of a 3 phase machine in a wide range of standard applications The motor speed is set according to the V f characteristic in accordance with the voltage frequency ratio Configuration 111 sensorless control with technology controller Configuration 111 extends the functionality of the sensorless control by software functions for easier adapt
398. you read the user manual carefully 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 please contact the manufacturer In case any problems occur which are not covered by the documentation sufficiently 1 3 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 These contractual warranty provisions are neither extended nor limited by the specifications contained in this documentation The manufacturer reserves the right to correct or amend the specifications product information and omissions in these operating instructions without notice The manufacturer shall not be liable for any damage injuries or costs which may be caused by the aforementioned reasons In addition to that BONFIGLIOLI VECTRON GmbH excludes any warranty liability claims for any per sonal and or material damage if such damage is due to one or more of the following causes e inappropriate use of the
399. ystem Value 11 ueeeeeeeiee ee iiei esee nena nana ananas aaa anna ana a 133 Volume Flow and Pressure 2 neon enun nnuununuuuuuuuuuuuuuRu Ra au RR RR RR RR RR 133 Starting Behavior eeeieeeee ee eeie eene en aaa n nna nana nn nana nnus u aaa n uaa uua 134 Starting Behavior of Sensorless Control System 134 Starting enc 136 Frequency A BI EET 136 Brake release tiIrie iuii cessere beri art Ra ve antra erai Vna Ursa a FerRa YR AP ere at 136 Flux desta LN 137 Stopping Behavior 1 e eene eere eren nennen nnn n nena nnn nnn nanasan 138 Switch Off Threshold sseeee Henne mener ne 140 Holding TIME sorrera beendet be amita Rte vna omen inst ax hr Re ARS 140 Direct current brake 4 esee annua unuuuuuuuuuuu uuu RR RR RRRRSRRRRSRRRSRRRRRRRRRSA 140 Auto Start dnneiessreuRsEnRuEEREREREUREINRREZRERURERREERRREERDNEEUREE NR RERRRBENEN 141 Search Run iiuieiccse cuosu ap aa co zen u nu sspNE aiaa REUERRRREEUEMDREERUREN REUS RENE ERES 142 POSITIONING ea e E 144 Reference Positlonilig tesa santa rade tr hada he de a e DR d RR 144 Operating Instructions ACU 06 13 tv Bonfiglioli vectron 13 1 13 2 13 3 13 4 13 5 13 6 13 7 13 8 Overload p 150 Temperature ccssecenseecneeeeseueueeuenaeeeuueeeeogeueuagseengeuenasseeogeuenassnengeneogeens 150 Controller status cssscecccsesse

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