BONFIGLIOLI Active ACT 201-05 Referenzhandbuch

www.bonﬁglioli.com

Bonﬁglioli Riduttori S.p.A.

Via Giovanni XXIII, 7/A

40012 Lippo di Calderara di Reno

Bologna, Italy

tel: +39 051 647 3111

fax: +39 051 647 3126

bonﬁglioli@bonﬁglioli.com

www.bonﬁglioli.com

VEC 210 R1

ACTIVE

Brief manual

Frequency Inverter 230 V / 400 V

0.55 kW ... 30.0 kW

Bonﬁglioli has been designing and developing innovative

and reliable power transmission and control solutions

for industry, mobile machinery and renewable energy

applications since 1956.

06/05 1

General Information about the Documentation

The present documentation refers to the frequency inverters ACT 201 and ACT 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

dynamism requirements can be realized easily.

In order to make it as easy as possible for the user to find his/her way through the

documentation, it is structured according to the customer-specific demands made of

the frequency inverter.

Brief Instructions

The Brief Instructions describe the basic steps required for mechanical and electrical

installation of the frequency inverter. The guided commissioning supports you in the

selection of necessary parameters 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 parameters 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 contains additional information facilitating the installation and

commissioning of the frequency inverter, i.e. information on the different issues

relating to the specific application realized by the frequency inverter.

Installation Instructions

Complementing the Brief Instructions and the Operating Instructions, the Installation

Instructions provide information on how to install and use the additional/optional

components.

If you need a copy of the documentation or additional information, contact your

representative of BONFIGLIOLI.

The following pictograms and signal words are used in the documentation:

Danger!

Danger refers to an immediate threat. Non-compliance with the precaution described

will result in death, serious injury or material damage.

Warning!

Warning refers to a possible threat. Non-compliance with the warning may result in

death, serious injury or material damage.

Caution!

Caution refers to an immediate hazard. Non-compliance may result in personal or

material damage.

Attention!

Attention and the related text refer to a possible behavior or an undesired condition

which can occur during operation.

Note

Note and the related text provide useful information which supplements the corre-

sponding part of the documentation.

06/052

2 06/05

TABLE OF CONTENTS

TABLE OF CONTENTS ............................................................................................................ 2

1 General Safety Instructions and Information on Use.................................................... 4

1.1 General Information ................................................................................................ 4

1.2 Purpose of the Frequency Inverters........................................................................ 5

1.3 Transport and Storage............................................................................................. 5

1.4 Handling and Installation ........................................................................................ 5

1.5 Electrical Connection ............................................................................................... 6

1.6 Information on Use.................................................................................................. 6

1.7 Maintenance and Service......................................................................................... 6

2Scope of Supply.............................................................................................................. 7

2.1 Frequency Inverter (0.55 to 4.0 kW)....................................................................... 7

2.2 Frequency Inverter (5.5 to 15 kW).......................................................................... 8

2.3 Frequency Inverter (18.5 to 30 kW)........................................................................ 9

3Technical Data.............................................................................................................. 10

3.1 Frequency Inverter 230 V (0.55 to 3.0 kW) .......................................................... 10

3.2 Frequency Inverter 400 V (0.55 to 4.0 kW) .......................................................... 11

3.3 Frequency Inverter 400 V (5.5 to 15.0 kW) .......................................................... 12

3.4 Frequency Inverter 400 V (18.5 up to 30 kW) ...................................................... 13

3.5 Operation diagrams ............................................................................................... 14

4Mechanical Installation................................................................................................ 15

4.1 Frequency Inverter (0.55 to 4.0 kW)..................................................................... 16

4.2 Frequency Inverter (5.5 to 15 kW)........................................................................ 17

4.3 Frequency Inverter (18.5 to 30 kW)...................................................................... 18

5Electrical Installation ................................................................................................... 19

5.1 EMC Information.................................................................................................... 20

5.2 Block diagram ........................................................................................................ 21

5.3 Mains Connection .................................................................................................. 22

5.3.1 Frequency Inverter (0.55 to 4.0 kW) ....................................................................... 22

5.3.2 Frequency Inverter (5.5 to 15.0 kW) ....................................................................... 23

5.3.3 Frequency Inverter (18.5 to 30 kW) ........................................................................ 24

5.4 Motor Connection .................................................................................................. 24

5.4.1 Frequency Inverter (0.55 to 4.0 kW) ....................................................................... 25

5.4.2 Frequency Inverter (5.5 to 15 kW) .......................................................................... 26

5.4.3 Frequency Inverter (18.5 to 30 kW) ........................................................................ 27

5.5 Connection of a Brake Resistor ............................................................................. 28

5.5.1 Frequency Inverter (0.55 to 4.0 kW) ....................................................................... 28

5.5.2 Frequency Inverter (5.5 to 15 kW) .......................................................................... 28

5.5.3 Frequency Inverter (18.5 to 30 kW) ........................................................................ 29

06/05 3

TABLE OF CONTENTS

5.6 Control Terminals .................................................................................................. 29

5.6.1 Relay Output ......................................................................................................... 30

5.6.2 Control Terminals – Terminal Diagram..................................................................... 31

5.6.2.1 Configuration 110 – Sensorless Control ............................................................. 31

5.6.2.2 Configuration 410 – Sensorless Field-Oriented Control........................................ 32

5.7 Optional Components ............................................................................................ 33

6Control Unit KP500 ...................................................................................................... 34

6.1 Actual Value Menu (VAL) ....................................................................................... 35

6.2 Parameter Menu (PARA)........................................................................................ 36

6.3 Controlling the Motor via the Control Unit ............................................................ 37

7 Commissioning of the Frequency Inverter................................................................... 39

7.1 Switching on Mains Voltage .................................................................................. 39

7.2 Setup Using the Control Unit ................................................................................. 39

7.2.1 Configuration ........................................................................................................ 40

7.2.2 Data Set ............................................................................................................... 40

7.2.3 Motor Type ........................................................................................................... 40

7.2.4 Machine Data ........................................................................................................ 41

7.2.5 Plausibility check ................................................................................................... 41

7.2.6 Parameter identification ......................................................................................... 43

7.2.7 Application data..................................................................................................... 45

7.2.7.1 Acceleration and deceleration........................................................................... 45

7.2.7.2 Set points at multi-functional input ................................................................... 45

7.2.8 Selection of an actual value for display .................................................................... 46

7.3 Check direction of rotation .................................................................................... 46

8Basic parameters.......................................................................................................... 47

8.1 Menu branch PARA ................................................................................................ 47

8.2 Menu branch VAL................................................................................................... 50

9 Operational and error diagnosis .................................................................................. 51

9.1 Status message...................................................................................................... 51

9.2 Warning message .................................................................................................. 51

9.3 Fault message........................................................................................................ 52

06/054

4 06/05

1General Safety Instructions and Information on Use

Warning! The specifications and instructions contained in the documentation must

be complied with strictly during installation and commissioning. Only

qualified staff who has read the documentation and, in particular, the

safety instructions carefully is allowed to carry out installation or

commissioning work or to operate the frequency inverters. The term

„Qualified Staff“ refers to anybody who is familiar with the installation,

assembly, commissioning and operation of the frequency inverter and

has the proper qualification for the job.

The present documentation was prepared with great care and it was subjected to

extensive and repeated reviews. For reasons of clarity, it was not possible to include

all details of all the different types of the product 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 local

BONFIGLIOLI agent.

We would also like to point out that the contents of this documentation 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. The manufacturer's obligations are exclusively 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.

1.1 General Information

Warning! The DC-link circuit of the frequency inverter is charged during operation,

i.e. there is always the risk of contact with high voltage. Frequency

inverters are used for driving moving parts and they may become hot at

the surface during operation.

Any unauthorized removal of the necessary covers, improper use, wrong

installation or operation may result in serious injuries or material

damage.

In order to avoid such injuries or damage, only qualified staff may carry

out the transport, installation, setup or maintenance work required. The

standards EN 50178, IEC 60364 (Cenelec HD 384 or DIN VDE 0100),

IEC 60664-1 (Cenelec HD 625 or VDE 0110-1), BGV A2 (VBG 4) as well

as the applicable national regulations must be complied with. The term

„Qualified Staff“ refers to anybody who is familiar with the installation,

assembly, commissioning and operation of the frequency inverter as well

as the possible hazards and has the proper qualification for the job.

06/05 5

1.2 Purpose of the Frequency Inverters

Warning! 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 machine meets

the requirements of the EC Machinery Directive 98/37/EEC and

EN 60204. In accordance with the CE marking requirements, the

frequency inverters comply with the Low Voltage Directive 72/23/EEC as

well as EN 50178 / DIN VDE 0160 and EN 61800-2. The user shall be

responsible for making sure that the requirements of the EMC Directive

89/336/EEC are met. Frequency inverters are only available at specialized

dealers and are exclusively intended for professional use as per EN

61000-3-2.

The frequency inverters are also marked with the UL label according to

UL508c, which proves that they also meet the requirements of the CSA

Standard C22.2-No. 14-95.

The technical data, connection specifications and information on ambient

conditions are indicated on the name plate and in the documentation and

must be complied with in any case. Anyone involved in any kind of work

at the device must have read the instructions carefully and understood

them before starting the work.

1.3 Transport and Storage

The frequency inverters must be transported and stored in an appropriate way.

During transport and storage the devices must remain in their original packaging.

The units may only be stored in dry rooms which are protected against dust and

moisture and are exposed to small temperature deviations only. Observe the climatic

conditions according to EN 50178 and the marking on the packaging. The units must

not be stored for more than one year without connecting them to the rated mains

voltage.

1.4 Handling and Installation

Warning! Damaged or destroyed components must not be put into operation

because they may be a health hazard.

The frequency inverters are to be used in accordance with the documentation as well

as the applicable directives and standards. They must be handled carefully and

protected against mechanical stress. Do not bend any components or change the

isolating distances. Do not touch electronic components or contacts. The devices are

equipped with components which are sensitive to electrostatic energy and can easily

be damaged if handled improperly. Any use of damaged or destroyed components

shall be considered as a non-compliance with the applicable standards. Do not

remove any warning signs from the device.

06/056

6 06/05

1.5 Electrical Connection

Warning! 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.

Comply with the information given in the operating instructions and on

the frequency inverter label.

When working at the frequency inverters, comply with the applicable standards BGV

A2 (VBG 4), VDE 0100 and other national directives. Comply with the electrical

installation instructions given in the documentation as well as the relevant directives.

Responsibility for compliance with and examination of the limit values of the EMC

product norm EN 61800-3 for variable-speed electrical drive mechanisms is with the

manufacturer of the industrial plant or machine.

The documentation contains information on EMC-conforming installation. The cables

connected to the frequency inverters may not be subjected to high-voltage insulation

tests unless appropriate circuitry measures are taken before. Otherwise the

frequency inverter may be damaged.

1.6 Information on Use

Warning! The frequency inverter may be connected to power supply every 60 s

only. Otherwise the unit may be damaged. For this reason, a jog

operation of a mains contactor is not permissible. For commissioning or

after an emergency 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.

Before commissioning and the start of the operation fix all covers and

check the terminals. Check the additional monitoring and protective

devices according to EN 60204 and applicable the safety directives (e.g.

Working Machines Act, Accident Prevention Directives etc.).

No connection work may be performed, while the system is in operation.

1.7 Maintenance and Service

Warning! Unauthorized opening and improper interventions can lead to personal

injury or material damage. Repairs on the frequency inverters may only

be carried out by the manufacturer or persons authorized by the

manufacturer. Check protective equipment regularly.

06/05 7

2Scope of Supply

Thanks to the modular hardware components, the frequency inverters can be

integrated in the automation concept easily. The scope of delivery described can be

supplemented by optional components and adapted to the customer-specific

requirements. The plug-in type connection terminals enable a safe function and an

economical assembly.

2.1 Frequency Inverter (0.55 to 4.0 kW)

ACT 201 (230 V) and ACT 401 (400 V)

Power range 0.55 kW to 4.0 kW

Scope of Supply

Frequency inverter

Terminal strip X1 (Phoenix ZEC 1,5/ST7,5)

Plug-in terminals for mains connection and DC linking

Terminal strip X10 (Phoenix ZEC 1.5/3ST5.0)

Plug-in terminals for the relay output

Standard fixtures for vertical assembly

Brief Instructions and manuals on CD

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

Note: 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.

06/058

8 06/05

2.2 Frequency Inverter (5.5 to 15.0 kW)

ACT 401 (400 V)

Power range 5.5 kW to 15 kW

Scope of Supply

Frequency inverter

Terminal strip X10 (Phoenix ZEC 1.5/3ST5.0)

Plug-in terminals for the relay output

Standard fixtures with fixing bolts (M4x20, M4x60)

for vertical assembly

Brief Instructions and manuals on CD

Control terminals X210A / X210B (Wieland DST85 / RM3.5)

Plug-in terminal for connection of the control signals

Note: 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.

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