Bonfiglioli EM-ENC-02 Expansion Module

Safety and Fundamentals

safety requirements

The disassembly and assembly module must be completely powered off and wait for the DC bus capacitor to fully discharge; ESD electrostatic protection: 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; Do not plug or unplug terminals when they are live.

This manual is a supplementary manual and needs to be accompanied by the ACT/ACU machine operation manual; The KP500 panel is unable to access the system bus PDO mapping parameters and requires VPlus software to load a dedicated XPI configuration file.

All hardware resources of the module

EM-SYS CAN system bus (ISO 11898 high-speed CAN)

EM-ENC incremental encoder/speed sensor input (A+/A -, B+/B -, maximum 300kHz)

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

EM-S1OUTA: Analog current output (0-20mA)

EM-S1IOD: configurable single channel digital input/output (24V)

EM-MPTC: Motor PTC thermistor/bimetallic normally closed contact temperature detection

Terminal: Pluggable Wieland terminals X410A and X410B, with a tightening torque of 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, and restore the cover plate; Prohibit live operation.

X410A terminal

Terminal signal description

1 A+Encoder Phase A+

2 A Encoder Phase A

3 B+Encoder B Phase+

4 B-Encoder B-Phase

5+5V 5V output, maximum 200mA

6 GND5V 5V Ground

7 EM-S1IOD configurable DI/DO digital ports

X410B terminal

Terminal signal description

1-2 EM-MPTC Motor Temperature Sensor

3 EM-S1OUTA analog current output 0-20mA

4 EM-S1INA analog input ± 10V/± 20mA

5 CAN-L system bus

6 CAN-H system bus

7 GND CAN Ground

Module dip switch S1-S4

Rules for setting dialing purposes

S1/S2 CAN bus terminal S1=ON, S2=OFF: Passive terminal (recommended); S1&S2 are both ON: active terminals; Open the terminal at the beginning and end nodes of the bus, and turn off in the middle; The entire bus can only have one active terminal

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

S4 encoder 150 Ω terminal resistor ON enabled (only for 5V RS422 encoder); The 24V single ended encoder must be turned off

EM-SYS system bus CAN interface

This part of the function is completely consistent with the independent module EM-SYS; When the CM-CAN module is inserted into Slot-B, the CAN bus is taken over by CM-CAN, causing the CAN of this module to fail, and the IO/encoder is not affected.

Key bus parameters

Parameter 900 Node ID: -1 disabled; 0=System Bus Master Station; From station 1 to 63; A single bus can have a maximum of 1 master station and 63 slave stations.

Parameter 903 baud rate, all nodes must have the same baud rate; 50k‑1M， Corresponding to different maximum cable lengths.

network status

Pre Operational: SDO available, PDO invalid; Default power on state.

Operational operation: All SDO and PDO are available for data exchange.

Stopped: SDO and PDO are all disabled.

Main station (Node-ID=0) functions: NMT network management, generation of SYNC synchronization messages, processing of slave station Emergency fault messages, gateway transparent transmission: The local Profibus DP/RS232 485 can directly access all slave station parameters on the CAN bus.

Parameter 989 Emergency Reaction: Received slave station fault message, 0=master station shutdown message F21nn; 1=Only alarm without stopping the machine.

SDO Service Data Object

SDO1: Used for accessing parameters of PLC/main station frequency converter; SDO2: Reserve visualization tools.

Expedited fast transmission; Support int/uunt/long; String parameters are inaccessible; Index=frequency converter parameter number, Sub Index=dataset number; Write EEPROM for dataset 0-4; 5-9 RAM only to avoid EEPROM wear.

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 Object and Virtual Links (Core)

TxPDO: Fill in the internal source number Source Number of the local machine, and put the local control word, frequency, IO, etc. into the sent message.

RxPDO: The received data generates new source numbers (700-729), which are directly referenced by the local control input and given source.

The 8-byte payload can be mixed with Bool (2B)/Word (2B)/Long (4B).

Each frequency converter has 3 sets of RxPDO/TxPDO, with a fixed load of 8 bytes per set.

Trigger modes: time triggered, SYNC synchronous triggered; Configurable PDO timeout monitoring, with timeout reporting F22-xx fault.

Virtual Links: No need for upper level PLC, data can be directly exchanged between frequency converters.

Bus load calculation: The recommended total load is ≤ 80%, and the official Excel calculation tool Load_Systembus.xls is provided.

bus fault

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.

Expand IO hardware functionality

4.1 EM-S1INA 12 bit analog input

Dial S3 to switch voltage (-10V~+10V)/current (-20mA~+20mA); Maximum input impedance: voltage Ri=100k Ω; current Ri=250 Ω.

Parameter 562 working mode:

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

Two point calibration: X1/Y1, X2/Y2 percentage coordinates, custom input-output mapping curve; Parameter 560 dead zone hysteresis loop; 561 filtering time constant 0-5000ms low-pass filtering.

Parameter 563 fault behavior: off/warning/ramp stop/free stop, used for wire breakage detection (signal<1V/2mA).

Support zero point and full-scale hardware calibration.

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

4.2 EM-S1OUTA Analog Output

Current output 0-20mA, maximum load 500 Ω; Parameter 590: Select output source; Support offset (585) and amplification (586); Support zero full-scale calibration.

4.3 EM-ENC incremental speed/encoder input

Interface: A+A-B+B -, maximum input frequency 300kHz; Supports 5V RS-422 push-pull and 24V single ended HTL signal; Dial S4 to activate the 150 Ω terminal resistor, which is only used for 5V differential encoders and cannot be activated for 24V.

Parameter 493 working mode: quadruple frequency decoding, supports inversion; Parameter 494: Encoder line count 1-8192; 495 level mode: push-pull 5V/single ended 24V.

Parameter 766 actual speed source: You can choose to use the motherboard’s native encoder or switch to the EM-ENC encoder of this module as the speed closed-loop feedback source.

Monitoring parameters: 219 (frequency Hz), 220 (speed rpm).

Related faults: F14-30 encoder signal fault; F14-31 phase deficiency; F14-32 phase direction error.

4.4 EM-S1IOD Single Channel Configurable Digital Port

Parameter 558 setting: 0=digital input DI; 1=digital output DO.

DI mode: can be used for fixed frequency switching (extended FF5-FF8 with a total of 8 fixed frequencies); DO mode maps various internal state signals; Actual value parameter 250/254 reads port status.

4.5 EM-MPTC Motor PTC Temperature Input

Compatible with DIN44081 standard PTC thermistor and also compatible with bimetallic normally closed contacts.

Parameter 570+modes: warning only, immediate fault shutdown, 1/5/10 minute delayed shutdown; Fault code F0400 motor overheating.

Independent of the hardware enable terminal S1IND, overheating will still trigger protection and the panel fault LED will light up.

4.6 Expanding Given and Comparing Devices

Analog input and encoder speed can be used as frequency/percentage given sources, superimposed with the motherboard given.

Expand the comparator function to perform threshold comparison between the analog input of this module and the actual speed of the encoder, and output an internal Boolean source.

Parameters and Monitoring

VAL actual value menu (can be read by KP500)

219: Encoder 2 frequency; 220 encoder 2 speed; 253% expanded analog input percentage; 267 Extended Analog Output mA;

978 Node State bus node status; 979 CAN State physical layer status.

PARA parameter menu: All PDO, SDO, and virtual link mapping parameters KP500 of the system bus are not visible; The XPI configuration file must be loaded by VPlus software before it can be modified.

Appendix Fault List: IO Fault, Encoder Fault, CAN System Bus Fault.