Bonfiglioli ACT/ACU Cold Plate Inverter Installation Instructions

Bonfiglioli ACT/ACU Cold Plate Inverter Installation Instructions

Scope of Supply

The cold plate version cancels the ordinary cooling fan cooling components, and accessories are divided into three major groups according to power:

ACT/ACU 201 (≤ 3.0 kW, 230V), ACT/ACU 401 (≤ 4.0 kW, 400V)

host; X1 power/DC networking terminal; X2 brake resistor/motor terminal; X10 relay output terminal; X210A/X2210B control terminals; Paper manual+CD material CD.

ACT/ACU 201 (4.0-9.2 kW, 230V), ACT/ACU 401 (5.5-15.0 kW, 400V)

host; X10 relay terminal; X210A/X2210B control terminals; Manual CD.

ACT/ACU 401（18.5‑30.0 kW，400V）

host; X10 relay terminal; X210A/X2210B control terminals; Manual CD.

Within 7 days of receiving the goods, the appearance and packaging must be inspected for damage. Any damage must be reported to the supplier for insurance claims.

Technical parameters

The protection level is all IP20, and the installation posture requires vertical installation; The parameters are based on a switching frequency of 2 kHz; The size, weight, and standard air-cooled frequency converter are different; The allowable temperature of the coolant is 0-40 ℃ (3K3 environmental level).

Voltage level, power segmentation, loss at 2kHz, Pv weight

230V ACT/ACU201 0.55‑3.0 kW 43‑170 W 1.2‑1.6 kg

230V ACT/ACU201 4.0‑9.2 kW 200‑420 W 2.2‑3.1 kg

400V ACT/ACU401 0.55‑4.0 kW 40‑130 W 1.2‑1.6 kg

400V ACT/ACU401 5.5‑15.0 kW 145‑310 W 2.2‑3.1 kg

400V ACT/ACU401 18.5‑30.0 kW 420‑750 W 8.0 kg

The total loss is divided into two parts: Pv (conducted to the cold plate base); Pvint (dissipated into the interior of the cabinet, accounting for about 30% of the total loss, which must be included in the cabinet thermal calculation).

Application Scenarios

The maximum temperature of the cold plate base during operation can reach 75 ℃, and it remains high for a period of time after power failure. Touch is prohibited. The cold plate model is suitable for the following working conditions:

High protection level cabinet is required, but the limited space inside the cabinet cannot achieve internal heat dissipation;

Severe dust and oil pollution in the ambient air, and ordinary fans are prone to damage;

Multiple frequency converters are installed in a centralized manner, sharing a liquid cooled collection plate;

Directly assembled onto the machine body structure, utilizing the device body for heat dissipation.

For models with an output power greater than 15 kW, additional fans or liquid cooling must be added to enhance heat dissipation.

Thermal characteristics of heat dissipation

The heat from the power components of the frequency converter is conducted to the external heat dissipation substrate through the contact surface of the cold plate.

4.1 Thermal resistance calculation formula

(R_{th}=frac{T_{k max }-T_{u}}{P_{v}})

(T {kmax} ): Maximum allowable temperature of the inverter cold plate; 0.55-3 kW, maximum 75 ℃; 4-18.5 kW, maximum 70 ℃

(T_u ): Environmental temperature of the cold plate heat dissipation substrate;

(P_v ): Loss power transmitted to the cold plate;

(R_ {th} ): Maximum allowable thermal resistance (K/W).

Installation requirements:

External heat dissipation substrate contact area ≥ frequency converter cold plate contact surface;

Smooth contact surface and high thermal conductivity;

Recommend black anodized heat dissipation substrate, which has a thermal resistance 5-10% lower than ordinary substrates under convective conditions;

When multiple devices share a cooling plate, sum up the power losses of all devices and calculate the allowable thermal resistance.

The document provides a table of the maximum allowable thermal resistance for equipment in the full power range at the factory; The thermal resistance test conditions are: no forced air blowing, with a reserved gap of 300   mm above and below the equipment, and a gap of 100   mm on both sides.

4.2 Forced air cooling/liquid cooling

Forced cooling can allow for greater thermal resistance, formula: (R_ {th forced}= frac {R_ {th}} { alpha} )

(R_ {th} ): Allowable thermal resistance for natural convection;

( alpha ): Wind speed related proportional coefficient; The higher the wind speed, the smaller the alpha, allowing for greater thermal resistance. Taking ACT401-27 (18.5 kW) as an example, the document provides a reference table for α and allowable thermal resistance corresponding to different wind speeds.

Mechanical installation

General requirements for installation

Vertical installation; Reserve a gap of ≥ 300mm above and below the device, and a gap of ≥ 100mm on both sides;

Fix with 6 M6 bolts, with a minimum length of 20mm and a maximum tightening torque of 3.4Nm. Tighten the bolts evenly;

Installation steps: ① Clean the contact surface between the cold plate and the external heat dissipation substrate; ② Apply thermal conductive silicone grease evenly and thinly on the surface of the cold plate to compensate for surface micro roughness and reduce contact thermal resistance; ③ Vertically fix the frequency converter and evenly tighten 6 M6 screws;

The terminal cover must be fully installed before power can be turned on, otherwise it does not meet IP20 protection. The document provides detailed installation hole size drawings for three levels of power.

Temperature monitoring function

The frequency converter continuously monitors the temperature of the cooling base and the internal temperature of the cabinet.

Cut off fault threshold: The radiator is at 80 ° C, and the internal temperature of the equipment is at 65 ° C. When the limit is reached, the machine will immediately shut down due to a fault;

Alarm threshold: The factory default setting is the highest temperature of -5 ℃; When the threshold is reached, the red LED flashes and the screen displays a Warning. The alarm signal can be output externally through the digital output terminal;

The temperature of the radiator and the internal temperature of the equipment can be read in the VAL actual value menu, and the alarm threshold can be customized for early warning, avoiding direct fault shutdown.