Bonfiglioli EM-RES-01 Expansion Module

Overview of Hardware Resources

Power off plug-in option board, inserted into the lower slot of the frequency converter, automatically recognized when powered on. Hardware List:

CAN HighSpeed system bus (ISO DIS 11898, up to 1 Mbaud), without optoelectronic isolation

Complete interface of EM-RES rotary transformer (excitation REF ±, SIN ±, COS ±)

Excitation output effective value 4V, maximum 60mA; supports excitation frequencies of 5 kHz/10 kHz/20 kHz;

Suitable for rotary transformers with up to 24 pole pairs, with a maximum speed of 30000rpm (pole pair=1 condition);

EM-S1INA: 1-channel 12 bit bipolar analog input, switch by dialing S3: ± 10V voltage/± 20mA current;

EM RFOUT: RS-422 (A+/A -, B+/B -) repetitive frequency output, maximum 512kHz, analog incremental encoder AB phase signal output, short-circuit overload protection;

Hardware conflict: If other CAN controller options (CM-CAN) are installed at the same time, the CAN bus of this module will be automatically disabled.

Terminal definition (Wieland DST85/RM3,5, tightening torque 0.2-0.3 Nm)

X410A

Pin function

1. Rotational excitation EM-RES REF+

2. Rotational excitation EM RES REF

3 Rotary SIN –

4 Rotary SIN+

5 Rotation COS –

6 Rotating COS+

7 repetition rate output A+EM RFOUT A+

X410B

Pin function

1. Repetitive frequency output A – EM – RFOUT A –

2 Repetitive frequency output B+EM RFOUT B+

3 Repetitive frequency output B-EM RFOUT B

4 Analog inputs EM-S1INA

5 CAN‑Low

6 CAN‑High

7 CAN‑GND

Onboard dip switch S1/S2/S3

S1, S2: CAN bus terminal resistance; Passive terminal S1=ON, S2=OFF; Active terminals S1&S2 are simultaneously turned on; only one module in the entire network is allowed to enable active terminals; All products are turned off at the factory.

S3: Analog input mode; OFF=voltage ± 10   V; ON=current ± 20   mA.

Safety, storage and transportation, mechanical and electrical installation

Safety red line: When disassembling and assembling modules, the entire machine must be powered off and wait for the DC bus capacitor to fully discharge; Static sensitive components, do not touch PCB with bare hands; Only licensed professional electricians are allowed.

Storage: Original factory packaging, dry and dust-proof, no electricity storage for up to 1 year, in accordance with EN50178 standard.

Mechanical installation: Remove the lower cover plate of the frequency converter, insert the module directly into the lower slot, restore the cover plate, and prepare for power on.

Key points of wiring:

Rotary signal: Twisted shielded cables (SIN paired, COS paired, excitation paired) must be used, and PE should be widely connected at both ends of the shielding layer;

The CAN bus adopts braided shielded twisted pair cables; Physical isolation between power cables and signal communication cables;

Plug and unplug all control lines in a power-off state to avoid chip damage.

CAN System Bus

Following CANopen CiA DS301, linear topology, supporting master/slave mode.

1. Core configuration parameters

900 Node – ID Node Address: -1=Bus shutdown; 0=This machine serves as the main station; From station 1 to 63; A single network can have a maximum of 63 slave stations and 1 master station.

903 Baud Rate Baud Rate

Maximum baud rate bus length

50 kBaud 1000 m

100 kBaud 800 m

125 kBaud 500 m

250 kBaud 250 m

500 kBaud 100 m

1000 kBaud 25 m

2. Communication channel model

SDO channel (parameter read-write, Client Server)

SDO1: The upper/master frequency converter accesses all slave parameters; Supports Profibus DP and RS232/485 transparent transmission to access bus nodes.

SDO2: Left for visual debugging tools, can be parameter disabled to avoid compatibility conflicts.

Only supports uint/int/long data types, string parameters are not readable or written; Expedited SDO protocol.

PDO channel (real-time process data): 3 sets of TxPDO transmission and 3 sets of RxPDO reception for each frequency converter

Trigger mode: time triggered/SYNC synchronization message triggered;

Virtual links: Source Number source numbering mechanism; Multi frequency converters can directly exchange real-time data without the need for a PLC; Support one-to-one and one to many broadcasting; Equipped with PDO and SYNC message timeout monitoring.

NMT network management: nodes in three states: Pre Operational, Operational, and Stopped; Only the Operational status PDO is effective.

SYNC synchronization message: The master station periodically sends and synchronizes all slave station PDOs.

Emergency message: Automatic reporting of slave station faults; Parameter 989 is configured to “stop” or “only alert” upon receiving an emergency message.

3. Bus planning tool

Supporting: Definition of kbl.doc communication relationship; VVK.doc virtual link configuration; Load_Systembus.xls bus load calculation; The total bus load is recommended to be ≤ 80%, and cannot be put into use if it exceeds 90%.

KP500 panel only displays bus status; CAN advanced configuration can only load XPI configuration files using VPlus software.

Detailed explanation of hardware functions

4.1 Analog Input EM-S1INA (12 bit)

Dial S3 to switch voltage/current mode; Can be used as a frequency setting, percentage setting, and limit source.

Four input characteristic modes: 1- Bipolar; 11- Monopolar; 21- Industrial sensor mode (2-10V/4-20mA); 101- Absolute bipolar.

Two point custom calibration X1/Y1, X2/Y2; Support tolerance bands, hysteresis, and low-pass filtering time constants.

Fault monitoring: If the signal is below 1V/2mA, warning, deceleration shutdown, and free shutdown can be configured; Hardware zero point and full-scale calibration.

4.2 Rotating Transformer EM-RES (Core Function of This Module)

Parameter 380 selects the rotational excitation frequency: 5 kHz/10 kHz/20 kHz;

Parameter 381 sets the number of rotation poles (1-24); The ratio of the number of motor poles to the number of rotor poles must be an integer for synchronous motors to correctly identify the rotor position.

Offset offset angle parameter 382 (-360 °~+360 °): a key debugging parameter for synchronous motors, used to align the detection angle of the rotary transformer and the true mechanical position of the motor rotor; The debugging goal is for the magnetic flux voltage parameter 235 to approach 0V.

Reduce the maximum output frequency and limit the current before debugging to prevent the risk of runaway;

If the direction is reversed, the SIN ± can be switched; if the motor does not start, the offset angle needs to be adjusted or the motor phases need to be switched.

Parameter 766 [Actual Speed Source], Speed Sensor2 can be selected to use the spiral as the closed-loop speed feedback source.

Monitoring parameters: 219 (Speed Sensor2 frequency Hz), 220 (speed rpm).

4.3 Repetitive frequency output EM-RFOUT (RS-422 differential AB phase)

Simulate the incremental encoder signal by analyzing the rotational speed obtained from the rotary converter; Fixed equivalent 1024 line encoder.

Parameter 555 selects the power source and outputs the frequency signal of Speed-Sensor2; Differential output A+/A -, B+/B -, maximum 512kHz.

Purpose: External upper controller and second frequency converter for speed synchronization.

Parameter Overview

Divided into VAL (Actual Value Monitoring Menu) and PARA (Parameter Setting Menu)

VAL actual monitoring

219 Speed Sensor2 frequency; 220 Speed Sensor2 RPM;

253% analog input percentage;

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

PARA setting parameters

Analog inputs: characteristic points, modes, filtering, tolerance bands, fault behavior, hardware calibration;

Rotation: 380 excitation frequency, 381 pole pairs, 382 rotor bias offset; 766 speed feedback source selection;

RFOUT repeated output mode;

CAN complete set of parameters: node ID, baud rate, SYNC, SDO/PDO identifier, PDO mode, timeout, virtual link source number mapping.

KP500 can only read basic status; CAN advanced parameters can only be accessed through VPlus software and XPI configuration files.

Fault code

Hardware related faults in the rotary converter

F14-21: Rotary synchronization failure, signal interference

F14-22: Rotation counting error, interference

F14-23: Invalid setting of the number of rotary pole pairs (the ratio of motor to rotary pole pairs is not an integer)

F14-24: Rotary converter circuit open circuit, check the wiring cable

CAN system bus fault

F21-nn: Report fault from station nn;

F22-00: SYNC message timeout;

F22-01~03: RXPDO1-3 received timeout;

F22-10: Bus BUS OFF; Module detection BUS OFF automatically reinitializes the CAN bus.