Selection and Configuration of Bonfiglioli Active Series Inverter

4.2 EMC Filter

Built in solution: Size 1-2 (≤ 9.2kW) comes standard with an internal C3 level filter; Size 3 can be selected as internal or external; Sizes 4 and above are only available externally.

External filters: divided into "backplane type" (FTV series, 18A/40A, compatible with size 3/4) and "book type" (HLD series, 8-250A, compatible with all sizes). According to EN 61800-3, in order to achieve C2 or C1 level, external filters and/or reactors need to be used, and the length of motor cables needs to be limited (such as C2 level typically ≤ 10m, C1 level requires additional external filters).

Installation sequence: main power supply → line reactor → EMC filter → frequency converter, all three need to be installed on the metal base plate together to ensure the shortest high-frequency circuit.

Selection of Braking Resistors and Energy Consumption Calculation

When the motor decelerates or the potential load decreases, energy is fed back to the DC bus, and the built-in braking transistor (default standard) directs excess energy to the external braking resistor. The selection should be based on the load cycle (% ED) and braking power.

Bonfiglioli offers BR series resistors (IP20, panel mounted), with some models integrated with thermal protection switches. The following table shows common matching examples:

Inverter model Resistance model Resistance value (Ω) Continuous power (W) Duty cycle (based on rated power)

ACT210-05 (0.55kW) BR160/100 100 160 10%

ACT210-18 (4kW) BR667/24 24 667 10%

ACT410-15 (3kW) BR471/136 136 471 10%

ACT410-22 (11kW) BR1330/48 48 1330 10%

If the braking is frequent or lasts for a long time, the power should be converted according to the actual cycle and a higher rated resistor should be selected. The wiring terminals are located at Rb1 and Rb2 of power terminal block X2, with small sizes being plug-in and large sizes being bolt type.

Control terminals and expansion modules

6.1 Standard I/O

X210A/X210B (low-power) provides: 6 digital inputs (configurable), 2 digital outputs, 1 analog input (0~10V), 1 analog output (± 10V), relay output (5A/240V), and 20V/10V auxiliary power supply.

The terminal function of X410A/X410B (high power) varies with the expansion module, and flexible interfaces are reserved for the basic unit.

6.2 Option Modules

Active provides 3 expansion slots and supports the following functional modules:

Main functions of module model

EM-IO-01/02 adds digital I/O, analog I/O, PTC input, and system bus (CAN)

EM-ENC-01~05 encoder interface (HTL/TTL/differential), supports zero pulse, analog output

EM-RES-01/02 Rotary Transformer Evaluation with Repetitive Frequency Output and System Bus

EM-SYS system bus node, realizing high-speed data exchange among multiple machines (based on CANopen, 64 nodes, 3 PDO channels)

All modules are plug and play, automatically recognized, and share a platform with the Bonfiglioli Agile series to reduce spare parts inventory.

6.3 Communication module

Integrated into mainstream fieldbus:

CM-CAN（CANopen）

CM-PDP（Profibus DP）

CM-485（Modbus RTU）

CM-232（RS232）

The communication module occupies the front-end slot and comes with DSUB-9 interface, making it easy to connect to PLC or upper computer.

Human computer interaction and debugging tools

KP500 operation panel: graphical display, supporting parameter copying, diagnosis, and local control. Optional remote installation kit (KPCMK) for cabinet door installation or handheld operation.

KP-USB adapter: Connect directly to PC via USB, and use VPlus engineering software to complete parameter settings, oscilloscope waveform monitoring, fault log analysis, and motor self-tuning (supporting asynchronous/synchronous/servo motors). VPlus provides a guided process with built-in preset parameters for Bangfeili motors, significantly reducing the debugging cycle.

Software Features and Advanced Applications

The Active firmware has built-in rich functional modules to meet complex process requirements:

Control modes: V/f, sensorless vector (SVC), closed-loop vector (with encoder/transformer), and servo synchronous control.

Application macros: brake control (lifting type), spindle positioning, electronic gear, index positioning (sensorless synchronization), load detection, intelligent current limiting.

Power failure management: Implement controlled deceleration shutdown in case of voltage drop to avoid equipment damage.

Logic programming: Built in simple PLC function, customizable digital/analog logic relationship, reducing external PLC nodes.

Multiple datasets: 4 independent parameter sets, suitable for different process switching.

Application scenarios and selection suggestions

The Active series is optimized for the following industries:

Material handling and lifting: advanced brake release, anti sway, overload detection to ensure safety and efficiency.

Packaging and Textile: High speed positioning, electronic cam, synchronous tracking to ensure production rhythm.

Automated warehousing: Multi machine system bus synchronization enables precise positioning of stacker cranes.

Machine tool and spindle: high-frequency output (up to 599Hz) and tool replacement function.