Bonfiglioli ACTION 401/201 Inverter Engineering Integration Guide

1. Selection of Communication Module (CM)

CM-232 (RS232): Used for point-to-point PC debugging and parameter monitoring, supporting VPlus software (excluding oscilloscope function).

CM-485 (RS485): Supports multi station networks with up to 30 nodes, suitable for protocols such as Modbus RTU, with a maximum communication distance of 1200 m (at 9.6 kbps).

CM-PDP (Profibus DP): Supports PPO1~PPO4 types, configured through GSD files, suitable for high-speed data exchange with PLCs such as Siemens.

CM-CAN (CANopen): Compliant with DS-301 V4.02, supporting up to 127 nodes, suitable for distributed automation systems.

2. Speed sensor and I/O expansion module (EM)

EM-ENC-01~05: Supports incremental encoders (5V/24V line drive, including Z-pulse), providing encoder signal frequency division output (pulse repetition), facilitating master-slave synchronization or electronic gear.

EM-RES-01/02: Supports rotary transformer interface for high dynamic and high-precision servo control, providing absolute position information even at zero speed.

EM-I/O-01~04: Provides additional digital/analog I/O and PTC/KTY temperature probe inputs to meet different application requirements.

EM-SYS: System bus module (based on CANopen), supporting up to 64 frequency converters for high-speed data exchange through PDO and SDO, achieving complex master-slave synchronization and distributed control.

3. Module installation restrictions

When installing CM-CAN in slot C, EM-SYS cannot be installed in slot B at the same time (both share system bus resources).

KP232 and CM-232 are both RS232 interfaces but installed in different locations. KP232 supports VPlus oscilloscope function (115 kbps), while CM-232 only supports up to 19.2 kbps and does not include oscilloscope function.

Software Configuration and Core Function Application

The ACTION series has rich built-in software functions that can be configured through the KP500 control unit (with parameter copying function) or VPlus Windows software.

1. Control mode selection (parameter P030)

Configuration 110 (simple sensorless control): default mode, suitable for parallel motor drive or low dynamic requirements.

Configuration 111 (sensorless control with PI regulation): Suitable for turbomachinery such as pumps and fans that require constant pressure/constant current control.

Configuration 210/215/216 (magnetic field orientation control with speed sensor): requires an external encoder to achieve zero speed full torque, high-precision speed and torque control, suitable for elevators, winding, and synchronous transmission.

Configuration 410/430/460 (Extended Tuned Sensorless Control): Through motor parameter identification and self-tuning, high dynamic performance is achieved without sensors, suitable for applications without encoders but requiring fast response.

2. Brake control and motor chopper

Brake control: For suspended loads such as elevators and cranes, provide logical output to control mechanical brake, and compensate for mechanical action delay through timers (P790~P795) to prevent rolling.

Motor chopper (P507): Using the motor itself as a braking resistor, the braking energy is consumed in the motor winding, especially suitable for high inertia flywheel loads, which can save the cost and space of external braking resistors.

3. Positioning and timer function

Positioning from reference point (P458~P464): By defining the reference point through external sensors (such as proximity switches), relative positioning can be achieved without the need for an absolute value encoder.

Timer logic: Equipped with 2 programmable timers with a delay range of 10ms to 650 hours, it can achieve complex timing control (such as sequential start, delayed stop, and fault delay confirmation), reducing the I/O occupation of external PLCs.

Electromagnetic Compatibility (EMC) and Harmonic Suppression Engineering

The electromagnetic environment in industrial sites is complex, and the ACTION series provides both internal and external filtering solutions.

1. Scope of application of built-in filter

All ACT201 series and ACT401 9.2 kW and below models are equipped with EMI filters that comply with EN 61800-3 standards.

The built-in filter can meet the Class A Group 2 radiation limit under standard configuration (motor cable ≤ 10m).

2. Combination strategy of external filter and reactor

For models with a power output greater than 7.5 kW, an external EMI filter (such as FTV007B/018B/040B) is required.

Line Choke: It is recommended to use it in the following situations:

When the ratio of short-circuit power to inverter power is less than 1%.

When the capacity of the power transformer is ≤ 500 kVA.

ACT201 must be used during single-phase/two-phase operation.

It is recommended to choose 4% for the voltage drop of the reactor, which can effectively reduce harmonic currents and extend the life of the DC bus capacitor.

Installation sequence: It must be connected in the order of mains power → incoming reactor → EMI filter → frequency converter, otherwise the filtering effect will be greatly reduced.

Dv/dt filter and sine wave filter: used for long motor cables (>50m) or in situations where motor insulation requirements are stringent, they can suppress overvoltage spikes and protect motor windings.