Bonfiglioli EM-ENC-04 Expansion Module

Bonfiglioli EM-ENC-04 Expansion Module

Safety and Fundamentals

Safety Specifications

The entire disassembly and assembly module must be powered off and wait for the DC bus capacitor to fully discharge; ESD electrostatic protection, prohibit touching the components on the back of the PCB; Only licensed electricians are allowed to operate.

Storage without power for up to 1 year; Terminals must not be plugged or unplugged with power on, otherwise the hardware will be damaged.

This manual is a supplementary manual and needs to be used in conjunction with the ACT/ACU machine operation manual.

Complete hardware resources for the module

EM-S1INA: 12 bit bidirectional analog input (± 10V/± 20mA, dial switching)

EM-S1OUTA: Bidirectional analog voltage output (-10V~+10V)

EM-S1OUTD: Relay normally open contact output (24V AC/DC, maximum 1A resistive load)

EM-ENC second incremental encoder input: A+/A -, B+/B -, Z+/Z - (Z-phase zero mark), maximum input frequency 300kHz; Supports 5V RS-422 push-pull and 24V single ended HTL signals.

Terminal: pluggable Wieland connectors X410A, X410B; Tightening torque 0.2-0.3Nm.

Mechanical and Electrical Installation

Mechanical installation: Remove the lower cover plate of the frequency converter when powered off, insert the module into the dedicated slot on the lower level, restore the cover plate, and prohibit live disassembly.

X410A (encoder interface, with Z-phase)

Terminal signal description

1 A+Encoder Phase A+

2 A Encoder Phase A

3 B+Encoder B Phase+

4 B-Encoder B-Phase

5 Z+Z phase zero mark+

6 Z-Z phase zero marking

7+5V 5V power output, maximum 200mA

X410B (analog IO, relay output)

Terminal signal description

1+20V 20V auxiliary power output, maximum 180mA

2 GND power supply ground

3 EM-S1OUTA analog output ± 10V, maximum load 2mA

4 EM-S1INA analog input 12 bits; Voltage Ri=100k Ω; Current Ri=250 Ω

5-6 EM-S1OUTD relay normally open NO contact; 24V AC/DC 1A resistive load

7 GND signal ground

Dial switch S1/S2

Rules for setting dialing purposes

S1 analog input mode OFF=voltage ± 10V; ON=current ± 20mA

S2 encoder 150 Ω terminal resistance only 5V differential RS-422 encoder S2=ON; 24V HTL single end must be turned off, otherwise the hardware will be damaged

Cable requirements: Analog signal lines, encoder signal lines, and power cables should be physically separated and routed; The shielding layer of the shielded cable is extensively connected to PE.

Control IO hardware functions

3.1 EM-S1INA 12 bit bidirectional analog input

Dial S1 to switch voltage/current mode; Support dual point custom calibration curves X1/Y1, X2/Y2, and percentage coordinate mapping.

Parameter 562 Operation mode has four working modes:

1. Bipolar; 11 unipolar; 21 industrial signal 2-10V/4-20mA; 101 Bipolar takes absolute value.

Supporting parameters:

560 Tolerance band zero crossing hysteresis loop;

561 Filter time constant Low pass filter time constant (0-5000ms);

563 Error/learning behavior disconnection fault monitoring: off/warning only/ramp stop/free stop fault; Triggered when input<1V/<2mA;

564-567 feature points X1 Y1 X2 Y2;

568 Adjustment Zero/Full Scale Hardware Calibration.

Usage: Can be configured as a frequency given source, percentage given source, limit source, comparator source.

Monitoring parameter: 253 Analog input EM-S1INA, displaying input as a percentage.

3.2 EM-S1OUTA bidirectional analog voltage output (-10V~+10V)

Parameter 584 Operation mode selects the output source (internal actual value, EM-S1INA input absolute value, fixed voltage, etc.).

585 Offset zero offset; 586 Amplification output amplification factor; 587 Adjustment Hardware output calibration.

Monitoring parameter: 266 Analog output EM-S1OUTA, in volts.

3.3 EM-S1OUTD relay normally open output

Pure normally open NO relay contact, resistive load 24V AC/DC maximum 1A; response time is about 40ms.

Parameter 533 Operation mode EM-S1OUTD can map various internal status signals of the drive (running, fault, reaching given, overheating warning, etc.).

3.4 EM-ENC Second Incremental Encoder (supports Z-phase zero marking, a unique feature of this module)

Hardware specifications: Maximum input frequency of 300kHz; Supports 5V differential RS-422 (A/B/Z) and 24V single ended HTL; Dial S2 to control a 150 Ω terminal resistor.

Parameter 493 Operation mode speed sensor 2, compared to EM-ENC-03, adds Z-phase working mode:

0: Close; 4: Four fold frequency; 104: Four fold inversion;

1004: Four fold frequency+Z-phase reference pulse; 1104: Four fold frequency inversion+Z-phase reference pulse (used for zeroing positioning)

494 Division Marks Speed Sensor2 Encoder Line Count 1-8192;

495 Level level mode: 0=5V push-pull; 2=24V single ended;

766 Actual Speed Source Feedback Source Switching: 1 motherboard native encoder; Module 2: EM-ENC-04 Encoder (with Z-phase).

Monitoring actual value: 219 Frequency speed sensor2 (Hz); 220 Speed, speed sensor2(rpm)。

Functional purpose

As an actual feedback source for speed closed-loop;

Z-phase pulse is used for origin positioning;

As a frequency/percentage given source;

Connect the comparator for overspeed detection.

Encoder related fault codes:

F14-30 encoder signal fault; F14-31 phase deficiency; F14-32 phase sequence error; F14-33 line number setting error; The number of F14-34 lines is too low; The number of F14-35 lines is too high.

3.5 Given Source Configuration

The parameters 475 Reference frequency source and 476 Reference percentage source can configure the EM-S1INA analog input and EM-ENC-04 second encoder as frequency/percentage settings, which can be overlaid with other settings on the motherboard. Parameter 540/543 comparator can perform threshold comparison on the analog input and second encoder speed of this module, generating an internal Boolean source.

Parameter list and fault information

VAL actual value menu (readable on KP500 panel)

Parameter description

219 Speed sensor2 frequency Hz

220 Speed sensor2 RPM

253 EM-SINA Analog Input Percentage

266 EM-S1OUTA analog output voltage V

PARA parameter menu: Simulate input calibration, filtering, and fault behavior; Analog output offset amplification calibration; Relay output mode; All encoder configuration parameters; Selection of speed feedback source. All parameters of KP500 panel can be accessed, and this module has no CAN bus or XPI file dependency.

Module specific fault code (F14-xx)

Meaning of fault code

F14-02 EM-S1INA analog input signal fault disconnection

F14-30 second encoder signal fault

F14-31 encoder is missing one phase

F14-32 encoder phase sequence direction error

F14-33 encoder line number parameter error

F14-34 encoder line count set too low

F14-35 encoder line number set too high