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).

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.

Suggested selection steps:

Confirm the main power supply voltage (230V or 400V) and number of phases.

According to the rated current and overload requirements of the motor, refer to the technical data sheet to select the power level (if the rated current needs to be greater than the motor current and the overload current meets the starting peak).

Determine the installation method (air-cooled/cold plate/liquid cooled) and mechanical dimensions.

Evaluate whether it is necessary to have built-in EMC filtering and braking transistors.

Select communication modules according to the fieldbus protocol and expansion modules according to the number of I/O points.

Peripheral configuration: reactors, filters, braking resistors, and ensure cable shielding and grounding standards.