Bonfiglioli Active 401/201 Inverter Selection and Application Guide

1. Key points of bus configuration

Set node ID (900) to 0 to indicate that the local machine is the master station, set it to -1 to shut down the bus, and 1 to 63 to indicate the slave station.

The baud rate (903) can be selected from 50~1000 kBaud, corresponding to a maximum line length of 1000~25 m.

The terminal resistor is activated through the DIP switch on the module (S1/S2), and the physical head and tail nodes must be enabled.

2. PDO virtual link

Each node has 3 sets of TxPDO and 3 sets of RxPDO, each with 8 bytes of data, and can freely map boolean/word/long integer variables (through source numbers such as control word 740, status word 741, and actual frequency 62).

By parameterizing data links across frequency converters (such as sending master control words to slave control word inputs), electronic gears, master-slave synchronization, or angle synchronization can be achieved.

3. Synchronization and timeout monitoring

The master station can generate SYNC messages (identifier 918, period 919) to synchronize the PDO processing of all slave stations.

Timeout (939/941/942/945) can be set separately for SYNC and each RxPDO, and faults F2200~F2203 will be reported upon timeout to ensure communication reliability.

Software Function and Configuration Architecture

The Active series has rich built-in control and application functions, which can be configured through KP500 or VPlus software.

1. Control mode selection (parameter P030)

110 (simple sensorless): suitable for low dynamic or multi motor parallel drive.

111 (with PI adjustment): Suitable for constant pressure/constant current applications such as pumps and fans.

210 (with speed sensor FOC): highest accuracy, zero speed full torque, suitable for elevators and winding.

410 (Extended Tuned Sensorless): High dynamic encoder free control, suitable for high response scenarios.

460 (with brake control and load detection): Suitable for vertical movements such as elevators and cranes.

510 (sensorless synchronous motor): Supports permanent magnet synchronous motors and achieves high precision with EM-RES.

2. Built in functional blocks

Brake control: For lifting applications, mechanical delay is compensated through timers (P790~P795) to prevent rolling.

Motor chopper (P507): Utilizing the motor winding to consume braking energy without the need for an external braking resistor.

Positioning function (P458~P464): Based on the reference point positioning of external proximity switches, suitable for automated workstations.

Timer and Logic Function: Built in two programmable timers with a delay range of 10ms~650 hours, enabling sequential control.

3. VPlus engineering software

Provide parameterization, monitoring, oscilloscope (KP232 required), remote diagnosis, and XPI file import (for advanced system bus configuration).

The oscilloscope supports 4 channels, with a sampling interval of 2-32 ms, a storage depth of 1 MB, and a recording time of 60 minutes.

EMC filtering and peripheral accessories

1. Input filtering and reactor

≤ 9.2 kW models have built-in EMI filters (EN 61800-3 Class A Group 2).

Line chokes are recommended for use in the following situations:

Short circuit power of power grid<1%;

Power transformer capacity ≤ 500 kVA;

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

There are two types of external EMI filters: "backplane type" (FTV007B/018B/040B) and "book type" (FTV007A~FTV250A), which are suitable for different powers and installation spaces.

2. Output filter

DV/dt filter: used for suppressing voltage spikes in long cables (>50 m) or motors with high insulation requirements.

Sine wave filter: suitable for ultra long cables or situations requiring low harmonics.

3. Braking resistor

Provide BR series braking resistors with built-in thermal protection, fully tested and combined with Active drivers (such as ACT401-22 with BR 696/92).

When selecting, determine the resistance value and continuous power based on the braking power and cycle.

Engineering selection process and common problems

Selection steps:

Determine the motor power, voltage level (230V/400V), and number of phases.

Select control mode based on load characteristics (V/f, sensorless vector, FOC with encoder).

Assess whether I/O, encoder, fieldbus, or system bus expansion is necessary and select the appropriate EM/CM module.

According to the power grid conditions and EMC requirements, select incoming line reactors and EMI filters.

If frequent braking occurs, select a suitable specification of braking resistor.

Common troubleshooting:

Overcurrent (OC): Check the motor cable and parameter settings, extend the acceleration time, and confirm that the motor rated current matches.

Communication failure (F21nn or F220x): Check the bus wiring, terminal resistance, baud rate, and node ID settings to confirm that the SYNC message is normal.

Temperature alarm: Check the ambient temperature and heat dissipation space, confirm if the derating is sufficient, and check if the built-in fan is running.