Selection and Configuration of Bonfiglioli Active Series Inverter

Selection and Configuration of Bonfiglioli Active Series Inverter

In the field of industrial automation, the selection and system integration of frequency converters directly affect equipment performance, energy efficiency, and long-term operation and maintenance costs. The Bonfiglioli Active series (ACT 210/410), as a one-stop drive solution for mid to high performance applications, has become the preferred component for industries such as packaging, material handling, textiles, and lifting machinery due to its wide power coverage, flexible modular architecture, and rigorous compliance design. This article is based on the technical core of this series, providing an engineering level application guide from hardware selection, installation adaptation, peripheral filtering, braking energy consumption to extended communication.

Product Family and Model Decoding

The Active series is divided into two voltage platforms: ACT210 (1-phase/3-phase 230V level, power 0.55~9.2 kW) and ACT410 (3-phase 400V level, power 0.55~132 kW). Its model naming follows clear rules, making it easy for engineers to quickly identify the required specifications:

Series: ACT210 or ACT410

Power level: Two digits represent the rated motor power (e.g. 05=0.55kW, 22=9.2kW, 49=132kW)

Mechanical dimensions: frames 1-7, increasing with power

Version suffix: A (standard air-cooled), C (cold plate installation), L (liquid cooled, suitable for high-power)

Braking options: S (built-in braking transistor), X (no braking transistor, only available in sizes 6/7)

EMC filtering: F (built-in C3 level filter, small power standard) or reserved position

For example, ACT410-27-A-S-F represents 400V class 22kW, size 5, standard air-cooled, with braking, and built-in EMC filter. Understanding this coding system can significantly reduce selection ambiguity.

Core electrical and environmental parameters

2.1 Input/output characteristics

Main power supply adaptation: ACT210 allows 184-264V (-0%/+10%), ACT410 covers 320-528V (-0%/+10%), with a frequency of 45-66Hz, suitable for most global power grids.

Overload capacity: 150% of rated current for 60 seconds, 200% peak for 1 second (most models), meeting heavy-duty starting and intermittent impact conditions.

Switching frequency: default 4kHz, adjustable through parameters between 2-16kHz (low power) or 2-8kHz (high power) to balance noise and loss.

Output frequency: 0~599Hz, higher frequencies can be customized, suitable for high-speed spindle applications.

2.2 Environment and Protection

Operating temperature: 0~40 ℃ rated, 40~55 ℃ needs to be downgraded for use.

Humidity and Pollution: Relative humidity of 15%~85% without condensation, pollution level 2, overvoltage category III (main circuit).

Protection level: IP20 (standard cover plate), suitable for cabinet installation.

Altitude: 0~1000m without derating, 1000~4000m needs to be derated proportionally.

2.3 Safety and Compliance

The entire series meets CE (low voltage, EMC, RoHS) and UL/CSA (UL508c) certifications, and complies with EN 61800-5-1 safety standards and EN 61800-3 EMC industrial environment requirements. Built in short-circuit and ground fault protection, and coated with protective coating (optional) to enhance corrosion resistance.

Mechanical installation and cooling scheme

Active offers a variety of installation kits to accommodate different cabinet structures and heat dissipation requirements:

Installation type, applicable size, purpose

Standard (MSTD) direct backplate installation for all sizes, standard configuration

MPSV 1-7 radiators pass through cabinet openings to achieve external heat dissipation and enhance protection level

Vibration isolation (MNVIB) 1-6 is designed for vibration equipment (such as punching machines) to reduce mechanical stress through elastic damping

DIN rail (MDIN) 1-2 quick card mounting, suitable for low-power distributed layout

Cold plate/liquid cooling 1-5 (cold plate), 5-7 (liquid cooling) fanless design, suitable for closed or high temperature environments, requires customized heat dissipation circuit

It is worth noting that the power terminals with sizes 1 to 4 adopt a pluggable design, which facilitates quick wiring and maintenance; For sizes 6-7, bolt terminals are used to ensure the reliability of high current connections.

Peripheral filtering and EMC compliance design

The frequency converter itself is an EMI source, and the Active series can meet different EMC levels (C1~C3) by combining internal or external filters and reactors, while suppressing harmonic pollution to the power grid.

4.1 Line Choke

Necessity: When the capacity of the power supply transformer is greater than 500kVA or the short-circuit power ratio (RSC) is high, a reactor must be used to protect the rectifier bridge and electrolytic capacitor. For ACT210 single/two-phase power supply and all size 7 models, reactors are mandatory requirements.

Selection recommendation: Bonfiglioli suggests using a reactor with a relative short-circuit voltage of 4%, which can reduce harmonic reactive current by about 20%. The table lists the complete matches from 6A to 250A (LCVS/LCVT series), such as ACT410-37 (55kW) paired with LCVT115 (115A, 0.25mH).