Bonfiglioli Active series high-end frequency converter

Bonfiglioli Active series high-end frequency converter

The complete product catalog of the Active (ACT201/ACT401) Solution Drive frequency converter from the Vectron department of Bangfeili. ACT201 is rated at 230V and ACT401 is rated at 400V, with a power coverage of 0.55-132 kW. The hardware is modular, with built-in PLC application functions, supports rich fieldbus and expansion boards, and is compatible with asynchronous and synchronous servo motors. It is designed for industrial automation, lifting, conveying, positioning and multi axis synchronization scenarios. The document includes enterprise introduction, model naming, electrical specifications, expansion modules, software functions, installation kits, peripheral accessories (reactors, filters, braking resistors), and a global service network.

Enterprise and Product Positioning

Background of Bonfly Group: Headquartered in Bologna, Italy, established in 1956; Acquiring the Vectron brand to form a complete electromechanical integration solution of reducer, motor, and frequency converter; The business is divided into three major sectors: industrial, mobile engineering machinery, and wind power; Annual production capacity of 1.6 million transmission products, with DNV and T Ü V quality certifications, and multiple production bases and service outlets worldwide.

Active positioning: Solution Drive system driver

ACT201: Input 200-240V, single-phase/three-phase, power 0.55-9.2 kW;

ACT401: Input 360-480V three-phase, power 0.55-132 kW;

Perfectly matched with the power level of Bangfeili motor;

8   kHz switching frequency without derating, low operating noise; Hardware modularization, automatic recognition of hot swappable expansion modules when powered on; Built in PLC function, capable of implementing complex processes without the need for an additional PLC; Compatible with TN and IT power supply grids.

Model Naming Rules

Taking ACT 401-15 F A MPSV as an example:

ACT201/ACT401: Series;

Number: power specification;

F: Built in EMI filter (blank=no built-in filter);

A: Standard air cooling; C: Cold plate heat dissipation;

Installation kit:

MPSV: Through type fanless installation;

MDIN: DIN rail installation;

MNVIB: Anti vibration installation kit;

Optional accessory fields: Human Machine Unit KP500, Communication CM-Xxx, IO/Encoder/Rotary Transformer EM-Xxx Expansion Board.

Basic hardware and electrical specifications

1. Basic hardware configuration

Overload capacity: 150% rated current for 60 seconds; 200% peak value for 1 second;

Switching frequency: 2-16 kHz; Size6-7 high power (37-132 kW) upper limit 2-8 kHz;

Output frequency 0-1000 Hz; built-in braking transistor, supporting external braking resistor; Equipped with DC bus parallel interface;

Local IO: 6DI+1 multifunctional input; 1DO+1 multifunctional output; 1 relay output; Support motor temperature monitoring; The terminal with a power of ≤ 4kW can be plugged and unplugged.

Protection level IP20, vertically installed.

2. Reduction rules (corresponding curve chart provided in the document)

Environmental temperature:>40 ℃, with a 2.5% decrease in output for every 1K increase, and a maximum environmental temperature of 55 ℃;

Altitude: ＞ 1000   m, with a 5% reduction for every 1000   m increase, and a maximum allowable value of 4000   m;

Input voltage: When the voltage is higher than 400V, the voltage will decrease by 0.22% for every 1V increase, with an upper limit of 480V.

3. Environmental conditions

Working temperature 0-40 ℃; Humidity 15-85% without condensation; Storage follows EN50178; Equipped with short-circuit and ground fault protection; CE, UL508c certification, compliant with EN61800-3 electromagnetic compatibility standard.

Hardware modular system (three slot positions A/B/C)

Conflict: CM-CAN and EM-SYS cannot be installed simultaneously, CAN functions are mutually exclusive.

Slot A: Human computer/serial port interface

KP500: Detachable operation panel, supports parameter copying and replication, supports local start stop and parameter modification; Can be remotely installed with KPCMK kit cabinet door (3-meter cable).

KP232: RS232 adapter, the only one that supports VPlus software oscilloscope function.

B slot - CM communication module

CM‑232：RS232；

CM‑485：RS485， Supports Modbus RTU/Modbus ASCII;

CM‑CAN：CANopen；

CM‑PDP：Profibus‑DP。

C-Slot EM Expansion Board Series (Key)

Module Core Capability

EM-IO-01 DI/Relay, ± 10V AI/AO, Systembus System Bus

EM-IO-02 adds PTC motor temperature measurement, the rest is the same as 01

EM-IO-03 increases 0-20mA analog output and PTC temperature measurement

EM-IO-04 2DI+1 configurable DI/DO; Choose one of PTC/KTY for temperature measurement; Systembus (the previous documentation for this module has been parsed)

EM-ENC-01~05 incremental TTL/HTL encoder interface, some with zero position Z signal, analog IO, PTC, Systembus; Among them, EM-ENC-02 is a commonly used model (as analyzed in the previous document)

EM-RES-01/02 Rotary Transformer Resolver Feedback Interface, Frequency Reproduction Output, Analog Input

EM-SYS independent Systembus system bus board

Systembus (Bangfeili based on CANopen private bus)

Up to 64 active frequency converters can be connected;

2-channel SDO (parameter read-write), 3-channel PDO high-speed process data channel;

Support virtual links to achieve master-slave, electronic gear, and multi axis synchronization; The master station issues the speed and phase, and the slave follows; Can monitor master-slave current deviation alarm;

It can be led out by CM-CAN or EM-SYS/EM-IO-xx/EM-ENC-xx modules.

Software control capability (built-in firmware, no need for additional PLC)

1. Motor control mode (parameter P030 selection configuration set)

Scalar V/F;

Sensorless vector (suitable for fans, water pumps, and ordinary drives);

Feedback magnetic field oriented FOC with encoder (high-precision, zero speed with torque);

Synchronous motor sensorless control;

The factory default configuration is 110 simple sensorless mode; We also provide a preset configuration set specifically for lifting, electronic gears, positioning, and synchronous following (216 electronic shaft, 460 lifting brake mode, etc.).

2. Built in application functions

Brake control: lifting conditions, timing control of mechanical brake+motor circuit breaker, compensation for mechanical action delay, suspended load;

Motor chopper braking: high inertia load, does not rely on external braking units to achieve braking;

Zero return positioning: relying on an external proximity switch to achieve origin positioning, the target position and positioning action can be set;

Programmable timer with 2 channels, 10ms-650 hours, binding IO and internal events;

S-curve acceleration and deceleration (suppressing impact, acceleration and deceleration plus vibration limitation);

PI closed-loop regulator: pressure, flow, and speed closed-loop;

Automatic fault reset and power-off ride through (using motor inertia to maintain short-term operation);

Master slave electronic gear: supports online modification of speed ratio and phase offset; Multi axis synchronization of conveyor belt; Support phase shift and current deviation monitoring alarm.

PC debugging software VPlus

Windows platform, connect the frequency converter through KP232/CM-232/CM-485;

Function: parameter upload and download, online monitoring, fault recording; 4-channel virtual oscilloscope, capable of collecting voltage, current, and internal control variables; Record waveform for up to 60 minutes;

The oscilloscope must use KP232 hardware, CM-232 does not support oscilloscopes.

Mechanical installation plan

4 installation methods, each size corresponding to different installation kit drawings:

Installation of standard cabinet backboards;

MPSV: Through type cold plate installation, with the radiator extending outside the cabinet to enhance heat dissipation;

MDIN: DIN rail installation (small power models);

MNVIB: Anti vibration installation, used for strong vibration mechanical equipment.

Complete set of optional peripheral accessories

1. Line choke for incoming reactor

Suppress power grid harmonics and protect the electrolytic capacitors of frequency converters; When the short-circuit capacity of the power grid is insufficient, it must be configured; The document provides the reactor model, size, and power consumption corresponding to each power level.

2. EMI filter

≤ 7.5kW models can have built-in EMI filters; High power models use external bottom plate FTV-B and book type FTV-A filters;

Meets EN61800-3 Class A/B electromagnetic compatibility; Provide the maximum allowable length for motor cables.

3. Output filter

DV/dt filter; Sine wave filter, suitable for long-distance motor cables.

4. BR series braking resistor

The ACT series is equipped with a built-in brake chopper, and an external BR series brake resistor consumes regenerative energy;

Sample complete table: Each inverter model is matched with resistance value, continuous power, and working duty cycle; Equipped with built-in thermal protection.

5. PFC energy feedback unit: feeds back the regenerated energy to the grid.