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BONFIGLIOLI Act 201 User Manual

BONFIGLIOLI Act 201
218 pages
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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 211 R4
ACTIVE
Operating Instructions
Frequency Inverter 230 V / 400 V
0.55 kW ... 132.0 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.

Table of Contents

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BONFIGLIOLI Act 201 Specifications

General IconGeneral
BrandBONFIGLIOLI
ModelAct 201
CategoryDC Drives
LanguageEnglish

Summary

General Information about the Documentation

Quick Start Guide

Basic steps for mechanical and electrical installation. Guided commissioning supports parameter selection.

Operating Instructions

Describes all functions and parameters for adapting the inverter to specific applications.

General Safety Instructions and Information on Use

Purpose of the Frequency Inverters

Electrical drive components for industrial plants. Compliance with directives and standards required.

Handling and Installation

Warning about damaged components. Careful handling to avoid mechanical stress and electrostatic discharge.

Electrical Connection

Warning to discharge inverter before work. Compliance with standards and directives is mandatory.

Information on Use

Warning about potential unexpected motor start after power failure. Install protective equipment.

Maintenance and Service

Warning about unauthorized opening leading to injury. Repairs only by authorized personnel.

Technical Data

General technical data

Covers CE conformity, EMC directive, UL approval, ambient temperature, climate class, degree of protection, storage, functions, and parameterization.

Technical data of control electronics

Details technical specifications for control terminals X210A and X210B, and relay output X10.

Mechanical Installation

ACT 201 (up to 3.0 kW) and ACT 401 (up to 4.0 KW)

Describes vertical mounting and provides dimensions for installation in electrical cabinets.

Electrical Installation

Connection conditions

Discusses connection to public/industrial mains, commutating chokes, EMC filter compliance, and unearthed mains connection.

EMC Information

Provides measures for electromagnetic interference reduction, including panel installation, bonding, cable management, and components.

Connection of the device

Dimensioning of the conductor cross section

Guidelines for selecting conductor cross sections for mains, protective, and motor cables based on current and standards.

Typical conductor cross sections

Provides tables with typical conductor cross sections for 230V and 400V connections.

Mains Connection

Specifies selection of mains fuses and cable cross-sections according to EN 60204 and DIN VDE 0298 Part 4.

Motor connection

Permissible length of motor cable, without filter

Table detailing maximum permissible motor cable lengths for unshielded and shielded cables without output filters.

Permissible length of motor cable with output filter dU/dt

Table showing maximum permissible motor cable lengths when using output filters.

Connection of the construction sizes

ACT 201 (up to 3.0 kW) and ACT 401 (up to 4.0 kW)

Explains mains, motor, and brake resistor connections via plug-in terminals X1 and X2.

ACT 201 (4.0 up to 9.2 kW) and ACT 401 (5.5 up to 15.0 kW)

Details mains power connection for these models, including cable cross-sections and connection types.

ACT 401 (18.5 up to 30.0 kW)

Describes mains power connection for these models, including cable cross-sections and connection types.

ACT 401 (37.0 up to 65.0 kW)

Details mains power connection for these models, including wire cross-section and bolt size.

ACT 401 (75.0 up to 132.0 kW)

Describes mains power connection for these models, including terminal layout and bolt size.

Control Terminals

Control terminal X210A

Lists terminal assignments and descriptions for control terminal X210A.

Control terminal X210B

Lists terminal assignments and descriptions for control terminal X210B.

Control Terminals – Terminal Diagram

Explains terminal assignments for sensorless control, including supply voltage and ground.

Configuration 110 – Sensorless Control

Describes terminal assignments for sensorless control, including supply voltage and ground.

Configuration 111 – Sensorless Control with Technology Controller

Details terminal assignments for sensorless control with a technology controller for various applications.

Configuration 410 – Sensorless Field-Oriented Control

Describes terminal assignments for sensorless field-oriented control of 3-phase machines.

Configuration 411 – Sensorless Field-Oriented Control with Technology Controller

Outlines terminal assignments for sensorless field-oriented control with a technology controller.

Configuration 430 – Sensorless Field-Oriented Control, speed or torque controlled

Details terminal assignments for sensorless field-oriented control with speed/torque control.

Configuration 210 – Field-Oriented Control, speed controlled

Describes terminal assignments for field-oriented control with speed sensor feedback.

Configuration 211 – Field-Oriented Control, with Technology Controller

Explains field-oriented control extended with a technology controller.

Configuration 230 – Field-Oriented Control, speed and torque controlled

Details terminal assignments for field-oriented control with speed and torque control.

Control Unit KP500

Keys

Explains the function of each key on the KP500 control unit: RUN, STOP, J, ENT, ESC, FUN.

Display

Describes the different display elements: 7-segment displays, menu branches, status messages.

Menu Structure

Main Menu

Explains how to navigate the menu structure and return to the main menu using arrow keys and ENT/ESC keys.

Actual Value Menu (VAL)

Parameter Menu (PARA)

C Use the arrow keys to adjust the parameter value or to select an operation mode.

Describes how to adjust parameter values and select operation modes.

Copy Menu (CPY)

Reading the Stored Information

Describes how to read stored data, handle initialization errors, and format memory.

Menu Structure

Outlines the three main functions within the copy menu: FOR, ALL, and Act.

Selecting the Source

Explains how to select the data source (Src.) for the copy operation.

Selecting the Destination

Details how to select the destination (dSt.) for the copy operation and start the copy process.

Copy Operation

Describes the copy process, parameter checks, progress indication, and handling of errors or interruptions.

Error Messages

Code Meaning

Lists error codes and their meanings related to copy operations, memory issues, and parameter transmission.

Read data from the KP 500 control unit

Activation of the KP 500 control unit for Parameter transfer mode

Explains how to activate parameter transfer mode via parameter Program(ming) 34.

Activation via keyboard of the control unit

Step-by-step guide to activate parameter transfer mode using the KP500 unit's keyboard.

Transfer data

Outlines the procedure for transmitting files from the control unit to the frequency inverter.

Reset to Normal Mode

Control Menu (CTRL)

Controlling the Motor via the Control Unit

Details how to control the motor using the control unit, including necessary connections and parameters.

Commissioning of the Frequency Inverter

Switching on Mains Voltage

Safety checks before switching on mains voltage and inverter self-test procedure.

Setup Using the Control Unit

Explains the guided commissioning procedure for parameter settings relevant to the application.

Configuration

Machine Data

Rated Motor Parameters

Details setting rated parameters of the 3-phase asynchronous machine from the name plate or data sheet.

Plausibility check

Check direction of rotation

Speed sensor

Set-up via the Communication Interface

Inverter Data

Set Password

Explains setting a password for protection against unauthorized access.

Control Level

Speed sensor 1

Operational Behavior

Starting Behavior

Explains parameterizing start and stop behavior, including Auto Start, synchronization, and positioning.

Starting Behavior of Sensorless Control System

Details starting behavior operation modes (0-Off, 1-Magnetization, 2-Magnetization + current impression) for sensorless control.

Flux Formation

Explains flux formation in field-oriented control, including magnetization current and maximum flux-formation time.

Stopping Behavior

Stopping Behavior

Table showing different stopping behaviors based on Operation Mode 630 and start signals.

Direct current brake

Auto Start

Search Run

Positioning

Reference Positioning

Explains feedback of current position relative to motor revolutions and reference signal accuracy.

Axle Positioning

Explains axle positioning requiring a feedback system and expansion module for evaluation.

Error and warning behavior

Overload Ixt

Explains admissible load behavior and parameters for warning limits of short and long-term Ixt.

Temperature

Discusses frequency inverter heating and parameters for warning limits of heat sink and inside temperatures.

Controller Status

Phase Failure

Automatic Error Acknowledgment

Frequency Reference Channel

Reference Percentage Channel

Fixed Reference Values

Frequency ramps

Motor Potentiometer

Controlling the Motor via the Control Unit

Repetition frequency input

Control Inputs and Outputs

Multi-function input MFI1

Configures MFI1 as voltage, current, or digital input, linking to software functions.

Error and warning behavior

Multi-function output MFO1

Digital Outputs

Open brake

Enables activation of a brake unit via digital control output based on start/stop behavior.

Warning Mask

Digital Inputs

Start command

3-Wire-Control

Data Set Change-Over

Comparator

Logic Modules

V/f - Characteristic

Dynamic Voltage Pre-Control

Control Functions

Intelligent current limits

Discusses current limits to avoid inadmissible loading and prevent fault switch-off.

Voltage controller

Technology Controller

Functions of Sensorless Control

Current limit value controller

Ensures drive system is not overloaded by reducing acceleration ramp.

Functions of Field-Orientated Control

Motor Chopper

Implements generator energy into heat function for dynamic speed changes.

Torque Controller

Speed controller

Limitation of Speed Controller

Acceleration Pre-Control

Field Controller

Limitation of field controller

Modulation Controller

Special Functions

Pulse Width Modulation

Reduces motor noises by changing switching frequency, with automatic reduction adjusting frequency.

Brake Chopper and Brake Resistance

Trigger Threshold 506

Defines switch-on threshold of brake chopper based on DC link voltage.

Dimensioning of Brake Resistor

Motor Circuit Breaker

Temperature Adjustment

Encoder Monitoring

Error Protocol

Error List

Lists last 16 fault messages chronologically and shows the number of errors occurred.

Error Messages

Provides error codes (FXX) and their meanings, grouped by category like Overload, Heat Sink, etc.

Error Environment

Operational and Error Diagnosis

Status Display

Explains status indications via green/red LEDs and display elements RUN, WARN, FAULT.

Warning Status

Controlled commissioning

Frequency ramps

Lists parameters for acceleration and deceleration ramps.

Technology Controller

Lists parameters for technology controller, including operation mode, fixed frequency, and P-component.

Positioning

Lists parameters for positioning operation mode, signal source, distance, signal correction, load correction, activity after positioning, and waiting time.

Speed controller

Current Limit

Lists parameters for current limit, torque limit, and power limit.

Speed controller

Lists parameters for Isq limit source and torque limit source.

Modulation Controller

Lists parameters for modulation controller: Reference Modulation, Integral Time, Operation mode, Ref. Imr Lower Limit, Control Deviation Limitation.

Encoder Monitoring

Lists parameters for encoder monitoring: Operation mode, timeouts.

Torque Controller

Lists parameters for frequency upper/lower limits and their sources.

Starting Behavior

Lists parameters for max flux-formation time and current during flux formation.

Search Run

Auto Start

Lists parameter for auto start operation mode.

Slip compensation

Lists parameters for slip compensation: operation mode, amplification, max. slip ramp, minimum frequency.

Voltage controller

Lists parameters for voltage controller: operation mode, mains failure threshold, reference mains support value, etc.

Current Controller

Lists parameters for current controller: amplification, integral time.

Field Controller

Lists parameters for field controller: Reference Flux, Amplification, Integral Time.

Frequency Limits

Lists parameters for slip frequency.

Speed controller

Lists parameters for speed controller: operation mode, amplification, integral time.

Acceleration Pre-Control

Lists parameters for acceleration pre-control: operation mode, minimum acceleration, mech. time constant.

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