Bonfiglioli Active 401/201 Inverter Selection and Application Guide

Bonfiglioli Active 401/201 System Inverter Selection and Engineering Application Guide

In the field of industrial drive, frequency converters are not only actuators for motor speed regulation, but also intelligent nodes in automation systems. The Active 401/201 series "system frequency converter" launched by Bonfiglioli provides a complete solution for system integrators, ranging from simple speed regulation to complex motion control, with a wide power coverage of 0.55 kW to 132 kW, built-in PLC function, flexible expansion module, and advanced vector control algorithm. This article is based on the official product manual, and systematically elaborates on the deployment points of this series of frequency converters in practical engineering from the dimensions of selection matching, hardware architecture, expansion modules, communication networks, software configuration, and peripheral accessories, providing engineers with a practical technical reference.

Product series and power selection

The Active series is divided into two sub series:

ACT201 (230V level): Supports single-phase or three-phase 200-240V input, with a power coverage of 0.55~9.2 kW, suitable for small machinery, light load transmission, and single-phase power supply scenarios.

ACT401 (400V level): Supports three-phase 360-480V input, with a power coverage of 0.55~132 kW (7 chassis sizes, Size 1~7), covering from micro drivers to heavy-duty industrial applications.

Selection principle: Each frequency converter model corresponds one-to-one with the Bonfiglioli motor power (e.g. 7.5 kW motor corresponds to ACT401-21), simplifying the selection process. Simultaneously supporting 150% overload for 60 seconds and 200% overload for 1 second, meeting the requirements of overload startup or impact load.

Hardware Features and Installation Engineering

1. Compact design and installation options

The size 1-2 models have a width of only 60mm and use foldable mounting brackets that support lateral installation and DIN rails (≤ 4 kW), greatly saving cabinet space.

Standard installation kit as standard, optional MPSV (through installation, enhanced heat dissipation), MNVIB (anti vibration installation, suitable for strong vibration environments), and MDIN (DIN rail installation).

All models come standard with IP20 protection, and the Cold Plate option can accommodate cabinets with higher protection levels (heat is exported through the backplane).

2. Electrical connection

≤ 4 kW models use plug-in power terminals for quick replacement and maintenance.

Built in DC bus terminal, supporting multiple frequency converters to share the DC bus and achieve energy sharing.

Built in braking transistor (except for optional 75~132 kW), energy efficient braking can be achieved by simply connecting an external braking resistor.

The control terminals also adopt a plug-in design for easy debugging and replacement.

3. Rating reduction and environmental adaptation

If the ambient temperature is above 40 ℃, the rating should be reduced by 2.5%/K, with a maximum of 55 ℃.

For altitudes above 1000 meters, the rating will be reduced by 5% per 1000 meters, with a maximum of 4000 meters.

The switching frequency can be adjusted from 2 to 16 kHz, and there is no need to derate at 8 kHz, balancing low noise and rated output.

Expansion module system and functional enhancement

The Active series adopts a three slot modular structure (slot A/B/C), supporting rich expansion options and achieving "on-demand configuration".

1. Control and Interface Module (Slot A)

KP500: Detachable control unit with parameter copying function (upload/download parameters to non-volatile memory) for batch debugging.

KP232: RS232 interface adapter, supporting VPlus software and oscilloscope functions (4-channel, 115 kbps).

2. Communication module (slot B)

CM‑232（RS232）、CM‑485（RS485/Modbus）、CM‑CAN（CANopen）、CM‑PDP（Profibus‑DP）。 CM-485 supports Modbus RTU/ASCII protocol, providing convenience for low-cost integration.

The correspondence between communication speed and line length is clear (for example, Profibus can reach 1200 m at 93.75 kbps).

3. I/O and Encoder Expansion Module (Slot C)

EM-IO-01/02/03/04: Provides additional digital/analog I/O, PTC temperature measurement, and KTY temperature sensor interfaces, with EM-IO-04 supporting digital port direction customization and optional PNP/NPN.

EM-ENC-01~05: Supports incremental encoders (TTL/HTL, with or without Z-pulse), providing 5V/24V power supply, signal division output, and system bus.

EM-RES-01/02: Rotary transformer interface, suitable for high-precision servo control.

EM-SYS: System bus extension (based on CANopen) for high-speed data exchange between multiple machines.

Attention: CM-CAN and EM-SYS cannot be installed simultaneously (they share the CAN controller); Although both KP232 and CM-232 are RS232, only KP232 supports oscilloscope function (high speed).

System bus and multi machine synchronization

The Active series system bus is based on the CANopen protocol (DS-301) and supports up to 64 nodes, achieving high-speed data exchange through PDO (Process Data Objects) and SDO (Service Data Objects).