Bonfiglioli EM-ENC-05 Expansion Module

Bonfiglioli EM-ENC-05 Expansion Module

Safety and Overview

Mandatory safety requirements

The disassembly and assembly module must be completely powered off and wait for the DC bus capacitor to fully discharge; Static electricity sensitivity, do not touch the components on the back of the PCB; Only licensed electricians are allowed to operate.

Storage without power for up to 1 year; Terminals are prohibited from being plugged in or unplugged while live.

This manual is a supplement to the overall operation manual and does not repeat the basic operations of the inverter body.

Complete Hardware Resource Inventory

EM-SYS high-speed CAN system bus (ISO-DIS 11898, up to 1Mbaud)

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

EM-S1INA: 12 bit bidirectional analog input, dip code switching ± 10V voltage/± 20mA current

EM-S1OUTA: Bidirectional analog voltage output -10V~+10V, maximum output 2mA, short-circuit overload protection

Terminal: pluggable Wieland X410A (encoder), X410B (CAN+analog IO); Tightening torque 0.2-0.3 Nm.

Mechanical and Electrical Installation

Mechanical installation: Remove the lower cover plate of the frequency converter when the power is turned off, insert the module into the lower slot, restore the cover plate, and it is strictly prohibited to disassemble and assemble while the power is on.

X410A (encoder interface)

Terminal signal description

1 A+A phase+

2 A-A phase

3 B+B phase+

4 B-B phase

5 Z+Z phase zero mark+

6 Z-Z phase zero marking

7+5V encoder power supply, maximum 200mA

X410B (analog IO+CAN system bus)

Terminal signal description

1+20V auxiliary power supply output maximum 180mA

2 GND power supply ground

3 EM-S1OUTA analog output ± 10V

4 EM-S1INA Analog Input (Voltage/Current)

5 CAN‑Low CAN‑L

6 CAN‑High CAN‑H

7 GND CAN signal ground

Dial switch S1-S4

Rules for setting up dialing function

S1/S2 CAN bus terminal S1=ON, S2=OFF Passive terminal (recommended); S1&S2 simultaneously turn on as active terminals; The beginning and end nodes of the bus are turned on, and the middle nodes are all turned off; There can be no more than one active terminal on the entire bus; All factory products are turned off

S3 analog input mode OFF=± 10V voltage; ON=± 20mA current

S4 encoder 150 Ω terminal resistance 5V differential RS-422 open S4=ON; 24V HTL single end must be turned off to prevent hardware damage

Wiring requirements: CAN bus uses twisted pair shielded cables, with large areas of PE at both ends of the shielding layer; power cables are physically separated from communication/analog signal lines.

EM-SYS CAN system bus interface

The protocol, functional logic, and EM-SYS independent module are completely consistent; If CM-CAN is inserted into Slot-B, CAN will fail.

Core bus parameters

Parameter 900 Node ID: -1=disabled (factory); 0=System Bus Master Station; 1-63=slave station; A bus can have up to 1 master station and up to 63 slave stations.

Parameter 903 Baud Rate: The baud rate of all nodes on the bus must be consistent.

Maximum cable length for baud rate

50kBaud 1000m

100kBaud 800m

125kBaud 500m

250kBaud 250m

500kBaud 100m

1000kBaud 25m

Three working states of nodes

Pre Operational: SDO parameters can be read and written, PDO does not work; Default power on state.

Operational operation: SDO and PDO are all available, and data exchange is normal during the process.

Stopped: SDO and PDO are all disabled.

Master master station (Node-ID=0) capability

0: Received a fault message, the main station stopped and reported fault F21nn, where nn is the hexadecimal ID of the faulty slave station;

1: Only set the warning position, the main station will not shut down.

NMT network management: Boot Up Delay parameter 904 power on delay, automatically issuing NMT to start all slave stations.

Generate SYNC synchronization message (parameter 918 identifier, 919SYNC cycle; 0 disable SYNC), used for multi axis synchronous sampling PDO.

Receive Emergency fault messages from slave stations; Parameter 989 Emergency Reaction:

Gateway transparent transmission function: The master station's Profibus DP/CM-232-485 serial port allows direct access to all slave SDO parameters on the CAN bus.

Slave slave (Node ID 1-63)

Power on and send Boot Up message; Waiting for NMT command to enter Operational; Automatically send Emergency messages for local faults.

SDO service data object (read-write parameters)

SDO1 is used for upper/main station access parameters; SDO2 reserves visual debugging tools.

Expedited fast transfer, supporting int/uunt/long; The string parameter is inaccessible.

Index=Variable frequency drive parameter number; Sub Index=dataset number; Write dataset 0-4 to EEPROM; 5-9 RAM only, avoiding EEPROM erase life loss.

Gateway transparent transmission: Fill in the target CAN slave Node ID in byte 3 of Profibus DP PKW; Fill in the Node ID in the VABus serial port packet header to access all slave stations across the bus.

PDO process data+Virtual Links (core)

TxPDO: Fill in the internal source number Source Number of the device and map the local signal to the message being sent.

RxPDO: Receive message and generate new source number (700-729); The internal function input of the drive directly references the source number.

8-byte payload supports mixing: Bool (2 bytes)/Word (2 bytes)/Long (4 bytes).

Each driver has 3 sets of RxPDO/TxPDO; Each group has a fixed 8-byte payload.

PDO triggering mode: time triggered/SYNC synchronous triggered; Support SYNC and RxPDO timeout monitoring, and report faults when exceeded.

Virtual Links: Control words, given values, and actual values are directly exchanged between frequency converters without the need for a higher-level PLC relay.

Bus load planning: The official Load_Systembus.xls calculation table is provided; The recommended total bus load is ≤ 80%; 90% of the system is unreliable.

Bus fault code

F21nn: The master station has received a fault from the slave station nn;

F2200: SYNC timeout; F2201-03 RxPDO1-3 timeout; F2210 CAN Bus OFF bus is turned off.

Parameter access restrictions

PDO mapping, virtual link configuration parameters: KP500 panel is not visible; VPlus software must load XPI configuration file for modification;

The KP500 panel can directly read the bus status monitoring parameters (978 Node State node status, 979 CAN State physical layer bus status).

Expand IO hardware functionality

4.1 EM-S1INA 12 bit bidirectional analog input

S3 dial-up switch voltage/current mode; Support two-point custom calibration of X1/Y1, X2/Y2 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 (input<1V/<2mA triggered: shutdown/warning/ramp stop/free stop fault);

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, read input in percentage form.

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

Parameter 584 Operation mode selects the output signal source; Support local simulation input of absolute values and internal actual values of various drivers.

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

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

4.3 EM-ENC with Z-phase incremental encoder input

Hardware specifications: Maximum input frequency of 300kHz; Supports 5V differential RS-422 (A/B/Z), 24V HTL single ended; S4 dialing controls a 150 Ω terminal resistor.

Parameter 493 Operation mode speed sensor2, supports Z-phase working mode:

0 closed; 4 times the fourth harmonic; 104 fourth harmonic inversion;

1004 fourth harmonic+Z-phase reference pulse; 1104 quadruple frequency reverse+Z-phase reference pulse, used for zero return positioning at the origin.

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 speed closed-loop feedback source switching: 1 motherboard native encoder; Module 2 EM-ENC-05 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 faults (F14-xx)

F14-30 encoder signal fault; F14-31 phase deficiency; F14-32 phase sequence direction 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.

4.4 Given and comparator functions

Parameters 475 Reference frequency source and 476 Reference percentage source can be used to configure the EM-S1INA analog input and EM-ENC-05 second encoder as frequency/percentage settings, and to superimpose them 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, actual value monitoring and fault detection

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

978 Node State bus node status

979 CAN-State Physical Layer Bus Status

PARA parameter menu

The encoder is fully configured, analog input and output are calibrated, filtering and calibration parameters are calibrated, and all KP500 panels can be accessed.

The CAN system bus PDO and virtual link mapping parameter KP500 are not visible, and VPlus needs to load the XPI configuration file.

Module specific fault code

Meaning of fault code

F14-02 EM-S1INA analog input disconnection signal fault

F14-30~F14-35 Second encoder various signal and parameter setting faults

F21nn system bus master receives fault from slave nn

F22-00/01-03/10 CAN system bus SYNC timeout, RxPDO timeout BUS‑OFF