Bonfiglioli EM-ENC-02 Expansion Module Engineering Configuration Guide

3. Timeout monitoring

Timeout times (parameters 939, 941, 942, 945, in milliseconds) can be set for SYNC and each RxPDO. If no data is received after the timeout, the frequency converter will report a fault (F2200~F2203).

Virtual links and data mapping

EM-ENC-02 maps internal variables to various bytes of PDO through a "virtual linking" mechanism. Each TxPDO's 8 bytes can be configured as boolean, word, or long integer data.

1. Selection of TxPDO data source

The input parameters corresponding to each byte are 946-977 (for example, bytes 1-4 of TxPDO1 correspond to Boolean1-4, bytes 5-8 correspond to Word1-4, or Long1-2).

Enter the 'source number' during setup. Example of commonly used source numbers:

Control word: 740

Status word: 741

Actual output frequency value (reference channel): 62

Output percentage actual value: 138

Digital input status (including expansion port): 250

If a certain byte is not used, set it to fixed source 9 (zero value) or 7 (False).

2. RxPDO data target

The received data will be mapped to the corresponding source numbers (700~729), and then these sources can be referenced internally through parameters in the frequency converter (for example, using 704 as the control word input, connected to parameter 99).

For example, sending the control word of another device through TxPDO, the local RxPDO receives it, and links the source 704 to its own control word input parameter 99 to achieve remote synchronous control.

Engineering example: Two frequency converters need to synchronize start stop and speed setting. Place the control word (740) and output frequency (62) of the host into bytes 1-2 and 5-8 of TxPDO1, respectively; After receiving from RxPDO1, bytes 1-2 are mapped to the control word input (parameter 99 is set as source 704), and bytes 5-8 are mapped to the frequency setting value input (parameter 137 is set as source 709). This way, the slave follows the host to run.

Analog input/output configuration

1. Analog input (EM-S1INA)

Hardware switching: Select voltage (OFF) or current (ON) mode by dialing code S3 on the module.

Characteristic curve: Define two linear points in percentages (corresponding to ± 10 V or ± 20 mA) using parameters 564~567 (X1, Y1, X2, Y2).

Operation mode 562:

1: Bipolar (full range mapping)

11: Unipolar (negative value returns to zero)

21: Monopolar 2~10 V/4~20 mA (for use with offset signal)

101: Bipolar takes absolute value (negative signal converted to positive)

Dead zone and hysteresis: 560 (tolerance band) can set the dead zone width near the zero position to prevent signal jitter from causing misoperation.

Fault response: 563 sets the behavior when the signal is below 1 V/2 mA (warning, deceleration shutdown, or immediate fault shutdown).

Filtering: 561 can choose a filtering time constant (0-5000 ms) to suppress noise.

Calibration: 568 can perform zero point calibration for 0 V and 10 V (or 0 mA and 20 mA) respectively.

2. Analog output (EM-S1OUTA)

The output is 0-20 mA current, and the output signal source (such as analog input absolute value, actual frequency, actual percentage, etc.) can be selected through 590 (Operation mode).

Offset and gain: 585 (Offset) and 586 (Amplification) can adjust output characteristics (such as mapping 0-100% to 4-20 mA for wire breakage detection).

Calibration: 599 is used to adjust the output zero point and full current, and is calibrated in conjunction with the operating modes of "0 mA" and "20 mA".

Encoder input interface configuration

EM-ENC-02 supports incremental encoders (TTL/HTL), which can be used as speed loops or position references.

1. Hardware connection

Wiring terminals X410A.1~4 correspond to A+, A -, B+, B - respectively.

If using a 5V differential signal (RS-422), the terminal resistor can be enabled (S4 switch ON); If using a 24V single ended signal, there is no need for a terminal (S4 OFF).

2. Parameter settings

493 (Operation mode speed sensor 2): Select 0=off, 4=fourth harmonic (bidirectional counting, direction recognition), 104=reverse fourth harmonic.

494 (Division Marks Speed Sensor 2): Set the number of pulses per revolution of the encoder (1~8192).

495 (Level): 0=push-pull (5V), 2=single ended (10-24V).

766 (Actual speed source): Select the actual speed source, 1=built-in encoder (basic unit), 2=encoder of this extension module.

3. Speed calculation

The maximum input frequency is 300 kHz, and based on this, the maximum speed can be calculated as follows: nmax=(300k × 60)/(number of pulses per revolution × 4) (fourth harmonic).

To maintain low-speed stability, it is recommended to have at least one pulse edge every 2 ms, with a minimum pulse frequency of 500 Hz, to calculate the minimum number of pulses required.

4. Application examples

When the encoder is used as speed feedback, set 766 to 2 and point the feedback source of the speed controller (such as PI) to this actual value.

If you need to use the encoder frequency as the frequency reference source, you can select operation mode 34 (absolute value of speed sensor 2) or 35 (speed sensor 2+MF11A) in the 475 (Reference frequency source).

Digital port and motor temperature protection