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).

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.