BONFIGLIOLI Vectron Syn10 S115 01 User manual

www.bonfiglioli.com
Bonfiglioli Riduttori S.p.A.
Via Giovanni XXIII, 7/A
40012 Lippo di Calderara di Reno
Bologna, Italy
tel: [phone]
fax: [phone]
bonfiglioli@bonfiglioli.com
www.bonfiglioli.com
VEC 114 R1
SYNTHESIS
Operations Manual
single phase 115 V 0.2 - 0.75 kW
single phase 230 V 0.2 - 2.2 kW
three phase 400 V 0.75 - 2.2 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.

Operations Manual
Table of Contents
Foreword........................................................................................1
Examination before installation......................................................2
Chapter 1 Safety Precautions
1. Precautions for Operation........................................3
2. Environmental Precautions......................................6
Chapter 2 Hardware Instruction and Installation
1. Operational Environment.........................................7
2. Sample Model No. Identification..............................8
3. Specifications...........................................................9
4. Wiring diagram.......................................................15
5. Dimensions & Location of terminal block...............19
Chapter 3 Software Index
1. Keypad Operating Instructions ..............................29
2. Parameters List......................................................30
3. Parameter Function Description............................31
4. Malfunction Indication and Countermeasure.........43
5. General Malfunction Examination Method.............46
Chapter 4 Maintenance and Examination
1. Maintenance and Examination.............................48
Chapter 5 Option and accessories
1. Class B Emi filter...................................................50
2. Braking resistors ...................................................51

1
1
1. Foreword
To fully employ all functions of this AC Drive, and to ensure the safety for its users, please read
through this operations manual in detail. Should you have any further questions, please feel
free to contact your local distributor or regional representative.

Please use Precaution with this product
The AC Drive is a power electronic device. For safety reasons, please read carefully those
paragraphs with “WARNING” or “CAUTION” symbols. They are important safety precautions to
be aware of while transporting, installation, operating or examining the AC drive. Please follow
these precautions to ensure your safety.
WARNING Personnel injury may be resulted by improper operation.
CAUTION The AC Drive or mechanical system may be damaged by improper operation.
WARNING
z Do not touch the PCB or components on the PCB right after turning off the power before the
charging indicator went off.
z Do not attempt to wire circuitry while power is on. Do not attempt to examine the components
and signals on the PCB while the inverter operating.
z Do not attempt to disassemble or modify internal circuitry, wiring, or components of the
inverter.
z The grounding terminal of the inverter must be grounded properly with 200V class type III
standard.
z This is a product of the restricted sales distribution class according to EN61800-3.
In a domestic environment this product may cause radio interference in which case the user
may be required to take adequate measures.
CAUTION
z Do not attempt to perform dielectric strength test to internal components of the inverter. There
are sensitive semiconductor-devices vulnerable to high voltage in the inverter.
z Do not connect the output terminals: T1 (U), T2 (V), and T3 (W) to AC power input
z The CMOS IC on the primary PCB of the inverter is vulnerable to static electrical charges. Do
not contact the primary PCB of the inverter.

2
2
2. Examination before installation
Every inverter has been fully tested and examined before shipment. Please carry out the
following examination procedures after unpacking your AC inverter.
z Check to see if the model number of the AC inverter matches the model number of the AC
inverter that you ordered.
z Check to see whether any damage occurred to the AC inverter during shipment. Do not
connect the AC inverter to the power supply if there is any sign of damage.
Report this to a regional sale representative if you find any abnormal condition as mentioned
above.

3
3
Chapter 1: Safety Precaution
1. Precautions for operation
Before turning ON power
CAUTION
Choose the appropriate power source with correct voltage settings for the input voltage
specification of the AC inverter.
WARNING
Special care must be taken while wiring the primary circuitry panel. The L1 and L2
terminal must be connected to the input power source and must not be mistakenly
connected to T1, T2 or T3 out put terminals. This may damage the inverter when the
power is turned on.
CAUTION
z Do not attempt to transport the inverter by the front of the cover. Securely hold the
inverter by the heat-sink mounting chassis to prevent the inverter from falling, this
may cause personnel injury or damage to the inverter itself.
z Install the inverter onto a firm metal base plate or another non-flammable type
material. Do not install the inverter onto or nearby any flammable material.
z An additional cooling fan may need to be installed if several inverters are installed
into one control panel. The inside temperature inside an enclosed panel should be
below 40 degrees to avoid overheating.
z Turn off the power supply before proceeding to remove or perform any work on any
panel. Carry out installation procedures according to instructions given in order to
avoid a situation resulting in an operational malfunction.
z Suitable for use on a circuit capable of delivering not more than 5000 RMS
symmetrical amperes. 240 Volts maximum.
z This product is not provided with over speed protection.
z Only intended for use in a pollution degree 2 macro environment or equivalent

4
4
When power is applied
WARNING
z Do not attempt to install or remove input or out put connectors of inverter when the
power supply is turned on. Otherwise, the inverter may be damaged due to the
surge peak caused by the insertion or removal of power.
z When momentary power loss is longer than 2 seconds (the large of horse power,
the longer of time), the inverter does not have enough storage power to control the
circuit; Therefore, when power is regenerated, the operation of the inverter is
based on the setup of F_10 and the condition of external switch, this is considered
to berestartin the following paragraphs.
z When the momentary power loss is short, the inverter still has enough storage
power to control the circuit; therefore, when power is regenerated, the inverter will
automatically start operation again depends on the setup of F_23.
When restart the inverter, the operation of the inverter is based on the setup of
F_10 and the condition of external switch (FWD/REV button). Attention: the
restart operation is irrelevant with F_23/F_24.
(1) When F_10=0, the inverter will not start after restart.
(2) When F_10=1 and the external switch (FWD/REV button) is OFF, the inverter
will not start after restart.
(3) When F_10=1 and the external switch (FWD/REV button) is ON, the inverter
will start automatically after restart. Attention: Base on safety reason, please
turn off the external switch (FWD/REV button) after power loss to avoid
possible damage to the machine and the human body after sudden
regeneration of power.

5
5
Under Operation
WARNING
Do not use a separate device to switch ON or OFF motor during operation. Otherwise,
the inverter may experience an over-current breakdown.
WARNING
z Do not remove the front cover of the inverter when the power is ON to avoid
personnel injury caused by electrical shock.
z When the automatic restart function is enabled, the motor and machinery will be
restarted automatically.
CAUTION
z Do not touch the heat-sink base during operation.
z The inverter can be easily operated from a low-speed to high-speed range. Please
reconfirm the operating range of motor and the machinery you are controlling.
z Do not examining the signals on the PCB of the inverter when it is under operation.
z All inverters are properly adjusted and set before delivery.
CAUTION
Do not proceed with disassemble or examination procedure before ensuring that the
power is off and the Power LED extinguished.
When performing an examination or maintenance
CAUTION
Inverter environment should be within temp: –10 °C ~ +40 °C, humidity under 95% RH
without condensing.
CAUTION
After the removal of shield sticker, the environment temperature should be within
–10 °C ~ +50 °C and humidity under 95% RH without condensing. Besides, the inverter
should be free from water dripping or metal dust.

6
6
2. Precautions of operation environment
Avoid any direct sunlight Keep away from
corrosive gas or liquid
Keep away from oil
grease and gas
Keep away from salty
environments
Keep away from rain or
where dripping water may
get into the inverter
Avoid metal dust and
dusty environments
Avoid massive vibration
Avoid excessive direct heat
Avoid where
environmental
temperatures are too high
Keep away from high
electrical-magnetic waves or
Keep away from
radioactive matter
Keep away from
flammable material
oil

7
7
Chapter 2: Hardware Instructions and Installation
1. Operational Environment
The installation site of the inverter is very important. It relates directly to the functionality and the
life span of your inverter. Please carefully choose the installation site to meet the following
requirements:
z Mount the unit vertically
z Environment temperature: -10°C ∼+40°C (with cover removed: -10°C ∼+50°C)
z Avoid placing close to any heating equipment
z Avoid water dripping or humid environment
z Avoid direct sunlight
z Avoid oil or salty corrosive gas
z Avoid contacting corrosive liquid or gas
z Prevent foreign dusts, flocks, or metal scraps from entering interior
z Avoid electric-magnetic interference (soldering or power machinery)
z Avoid vibration, if vibration cannot be avoided, an anti-rattle mounting device should be
installed to reduce vibration.
z If the inverter is installed in an enclosed control panel, please remove the shield sticker
located at the top of the inverter. This will allow additional airflow and cooling.
z For proper Installation of the inverter you must place the front side of the inverter facing
front and the top of the inverter in the up direction for better heat dissipation.
z Installation must be compliant to the following requirements.
External Fan Placement needs to be over the top of the inverter
Correct Alignment Wrong Alignment Correct Alignment Wrong Alignment

8
8
Note: Maximum temperature in the enclosure 50 
2. Sample Model No. Identification
SYN10 S 220 05 AF - -
Series
Input phases S = single phase, T = three phases
Input voltage 115, 230, 400V
Size/Power 01 = 0.2kW 03 = 0.4kW 05 = 0.75kW
07 = 1.5kW 09 = 2.2kW
Filter _= no EMI filter, AF = class ””
Degree of protection _= IP20, IP65 = IP65
Switch (only for IP65) _= no switch, S = integrated switch
Ventilation & Installation
Direction
Front View
SYN10
5cm(min) 5cm(min)

9
9
3. Specification:
Basic specification:
Model: SYN10
   
   
   
   



   
 
 
 
 
     
     
     
     



     

 
  
 
   
   
   
   



   
 
 
 
 
Model: SYN10
S 115 01 S 115 03 S 115 05
S 220 01 AF S 220 03 AF S 220 05 AF S 220 07 AF S 220 09 AF
Model: SYN10 T 400 05 AF T 400 07 AF T 400 09 AF
Single phase 200-240V (+10%,-15%),
50 / 60 Hz (+/-5%)
Single/Three phase
200-240V 50 / 60 Hz

10
10
Functional specification:
Item Specification
Input Signal Type PNP type (SOURCE) input (External 24VDC Input is allowed)
Control Method Sinusoidal wave PWM control
Freq. Range 1~200 Hz
Resolution Setting Digital: 0.1 Hz (1 ~ 99.9 Hz); 1 Hz (100 ~ 200 Hz)
Analog: 1Hz/ 60 Hz
Keyboard Setting Directly setup by and buttons.
External Signal Setting 0~10V, 4 ~ 20mA, 0 ~ 20mA
Freq.
Control
Other function Frequency upper and lower limit
Carrier frequency 4~16KHz
Accelerate/Decelerate time 0.1~ 999 Sec
V/F Pattern 6 Patterns
Torque control Torque boost level adjustable (manual torque boost)
Multi-Functional input 2 point, to be used as multi-speed 1(Sp.1) / multi-speed 2(Sp.2) /
Jog / External quickstop / External bb / Reset
Multi-Functional output 1a Relay terminal, to be setup as Fault / Running / Frequency.
Braking Torque S115, S220 01,03 and 05: about 20%
S220 07, 09 and T400: 20%~100% built-in braking transistor
General
Control
Other function Decelerate or free run stop, Auto reset, DC braking frequency /
Voltage / Time can be setup by constants.
Display Three digital LED display frequency / inverter parameter / fault
record / program version.
Operating temperature -10OC~ +40OC (with cover removed: -10OC ~ +50OC)
Humidity 0~95% RH non-condensing.
Vibration Under 1 G (9.8 m/s2)
EMC specification EN50081-1, EN50081-2, EN50082-2, EN50178, EN61800-3+A11
UL UL508C
Overload protection 150% for 1 min.
Over-voltage DC voltage > 410V(200 series); DC voltage > 800V(400 series)
Under voltage DC voltage < 200V(200 series); DC voltage < 400V(400 series)
Momentary Power-loss 0 ~ 2 sec: the inverter can be restarted using speed search
feature.
Stall Prevention During Acceleration / Deceleration/ Constant speed
Output Short-circuit Electronic circuitry protection
Grounding fault Electronic circuitry protection
Protection
Function
Other function Heat sink overheat protection, Current limit
Installation Mounting screw or DIN rail (Option).

11
11

Suitable optional and Wiring Specification
Molded-Case Circuit Breaker / Magnetic Contact
z Warrantee does not apply to damage caused by the following situations:
(1) Damage to the inverter caused by the lack of appropriate molded-case circuit breaker or
when a circuit breaker with too large of capacity is installed between the power supply
and the inverter.
(2) Damage to the inverter caused by the magnetic contact, phase advancing capacitor, or
surge-protector installed between the inverter and the motor.
Model Type SYN10 S 115 01/03
S 220 01/03 AF
S 115 05
S 220 05/07 AF
S 220 09 AF T 400
05/07/09 AF
Molded-case circuit breaker 15A 20A 30A 15A
Primary Circuit Terminal (TM1) Wire dimension
(#14AWG) 2.0mm2
Terminal screw M3
Wire dimension
(#14AWG)
2.0m m2
Terminal screw
M3/M4
Wire dimension
3.5mm2
Terminal screw
M4
Wire dimension
3.5mm2
Terminal screw
M4
Signal Terminal (TM2)
1~11
Wire dimension 0.75mm2 (#18 AWG), Terminal screw M3
Use copper conductors only size field wiring based on 80 degrees C wire only.
z Please utilize three-phase squirrel-cage induction motor with appropriate capacity.
z If the inverter is used to drive more than one motor, the total capacity must be smaller
than the capacity of the inverter. Additional thermal overload relays must be installed
in front of each motor. Use the Fn_18 at 1.0 times of the rated value specified on the
motor nameplate at 50Hz, 1.1 times of the rated value specified on the motor nameplate
at 60Hz.
z Do not install phase advancing capacitors, LC, or RC component between the inverter
and the motor.
T3
T1 T2
L1 L2

12
12
Application and precautions of Peripherals
From the Power Source:
z Apply the power source at the correct rated voltage to prevent from damaging the inverter.
z A Power Disconnect or Circuit breaker must be installed between the AC power supply and the
inverter.
Molded-case circuit breaker:
z Utilize an appropriate circuit breaker that’s suitable for the rated voltage and current ratings of the
inverter to switch ON/OFF the power supply to the inverter and as additional protection for the
inverter.
z Do not operate the circuit breaker to switch ON or OFF the inverter. The circuit breaker should be
used only to supply input power and should not be used for operational sequence.
Leakage circuit breaker:
z An earth leakage circuit breaker should be added to prevent false operation cause by leakage
current and to ensure personnel safety.
Magnetic Contact:
z The Magnetic Contact can be omitted at ordinary operation. To utilize external control, automatic
restart, or breaking controller the magnetic contact must be added at the primary side.
z Do not operate the magnetic contact to switch ON or OFF the inverter.
Power improvement AC Reactor:
z If large capacity power source is applied (over 600KVA), additional AC reactor may be added to
improve power factor.
Inverter:
z Power supply input terminals L1 and L2 are not differentiated on phase sequence. They can
be arbitrarily connected. Their connection may be interchanged.
z Output terminal T1, T2, and T3 should be connected to the U, V, and W terminals of the motor
respectively. If motor turns in opposite direction of the inverter command, simply exchanging two of
the three wire connections will correct this problem.
z Output terminal T1, T2, and T3 must not be connected to power source to prevent from damaging
the inverter.
z Grounding terminal: properly ground the grounding terminal in compliance to 200V class type
three grounding. (The 400V class type is special grounding.)
External wiring should be carried out in accordance with following requirement. Check and
reassure the wiring is correct after the wiring is complete.
(Do not utilize the control circuitry buzzer to check the wiring).

13
13
EMI
connections:
It is very important that the connections between the inverter, the shielded motor cable, and the EMI
filters are tested as follows.
z Use a metal grounding plate and place the frequency inverter and the EMI filter on the plate.
z Use a shielded motor cable with 4 connectors (U, V, W, & Earth), don’t use the shielding as
safety earth (shield is high frequency earth)
z Remove any paint around the two metal coupling nut holes. So that the metal coupling nuts
(and the shielding) make contact with the frequency inverter and the motor.
z Don't solder a conductor to the shielding.
z Use a metal clamp to connect the shielding from the motor cable with the metal grounding
plate. Now there is a perfect high frequency earth connection between frequency inverter,
grounding plate and EMI filter.
z Keep the distance between the frequency inverter and EMI filter as short as possible (< 30cm)
if longer use a shielded cable with a metal coupling nut and a metal clamp to connect the
shielded cable to the frequency inverter and metal grounding plate.
z The only earth connection between the LISN and the test plate should be via the EMI filter.
z Use a motor which equals the power rating or below of the inverter rating.
z Install a noise filter for inverter onto the output side of the primary circuitry can suppress
conducting noise.
Drive
Class B:

14
14
Class A:
When the distance between the inverter and motor is longer than 100 meters, cable wire should
be carefully chosen to reduce the wiring resistance below 3% and the voltage drop
(V) = √3 x Wire resistance (Ω/km) x wire length (m) x current x 10-3
(B) Control circuitry wiring must be separated terminated and away from the primary
power circuitry and other high-voltage or large-current power lines to avoid noise
interference.
z To reduce the noise interference and avoid possible operational problems, shielded
twisted pair cable should be used to wire the control circuitry. Please refer to following
diagram. Connect the shielding wire onto the grounding terminal. Only connect one end of
the shield.
Wiring distance must be under 50m.
(C) The grounding terminal of the inverter must be correctly grounded in compliance
with 200V class type three grounding.
z Grounding wire should be wired in accordance to electrical equipment (AWG) with the
length of the grounding wire as short as possible.
Shielding Glove
To Inverter terminal
Connect to system grounding terminal
Wrapped with
insulating tape
To control machine
Do not connect the shielding
wire at this end
Drive
Connect Shield

15
15
z The grounding wire of the inverter must not be grounded together with other large current
loads (such as soldering machines or large current motors). They should be grounded
separately.
z Grounding circuitry must not be formed when grounding several inverters together.
(a) good (b) good (c) not good
(D) Wire specification, apply appropriate wire with correct diameter for primary power circuitry and
control circuitry in accordance with electricity regulations.
4. Wiring Diagram
Wire Terminations to the Inverter must be made in compliance to the applicable standards.
P R
L1
L2
L3
F WD
REV
SP1
RST
12V
+10V
MVI
(0~10V/0~20/4~20mA)
0V(FM–)
FM+
* Braking Resister
(Option)
S W1
1
2
3
(U)T1
(V)T2
(W)T3
1
2
CON2
AC Input
I M
} Trip Relay
Test Points
Grounding
3
4
6
7
5
{
Multi-Function
Inputs
8
9
10
11
F
M
S
p
eed Pot 10kΩ
0~10V

16
16
(External 24V supply)
Primary Circuitry Terminal Block (TM1) descriptions
Terminal Symbol Function Description
L1 (R)
L2 (S)
L3 (T)
Primary power source input to Drive
Single phase: L1/L2 (for SYN10 S 115 01/03/05 and S 220 01/03/05) or L/N
Three phase: L1/L2/L3
P
R
External braking resistor terminal
(Only for models SYN 10 S 220 07/09 and T400 05/07/09)
T1 (U)
T2 (V)
T3 (W)
Inverter output to Motor
Tightening torque for TM1 is 1 Nm (in the S 115 and S 220 01/03/05 models).
Tightening torque for TM1 is 1.3 Nm (in the S 220 07/09 and T400 05/07/09 models).
* Wire voltage rating must be a minimum of 300V (200V series) and 600V (400V series)
TM2
FWD
REV
SP1
RST
0V
3
4
6
7
10
+
24V
–
Inverter terminal descriptions