Bonfiglioli Vectron EM-RES-02 Expansion Module Installation and Configuration Guide

Explanation of socket terminal number and signal name

X410A 1 REF+positive terminal of rotary excitation

X410A 2 REF - Rotary converter excitation negative terminal

X410A 3 SIN - Rotating sine signal negative

X410A 4 SIN+spiral sine signal positive

X410A 5 COS spiral cosine signal negative

X410A 6 COS+spiral cosine signal sine

X410A 7 RFOUT A+frequency output A-phase positive (RS-422)

X410B 1 RFOUT A-frequency output A-phase negative

X410B 2 RFOUT B+frequency output B phase positive

X410B 3 RFOUT B-frequency output B-phase negative

X410B 4 S1INA Analog Input (Voltage/Current)

X410B 5 RFOUT R+zero position reference signal positive

X410B 6 RFOUT R-zero reference signal negative

X410B 7 GND analog input ground (reference ground)

Key wiring points:

The rotary transformer cable adopts twisted pair shielding, and SIN+/SIN - and COS+/COS - are independently twisted, and the excitation line (REF+/REF -) also needs to be twisted. The shielding layer is grounded at both ends, with the grounding impedance as low as possible.

If the analog input adopts current type (4-20mA), the internal switch S3 of the module needs to be turned to the "ON" position (upward), and a 250 Ω resistor should be connected in parallel between terminal X410B. 4 and GND (built-in in the module, no external connection required). Set the voltage mode (± 10V) to "OFF" (downward), with an input impedance of 100k Ω.

The frequency output is differential RS-422/RS-485 level, with a maximum load current of ± 60mA and a minimum load impedance of 150 Ω. It can be directly connected to the PLC high-speed counting module or motion controller.

Detailed configuration of analog input (EM-S1INA)

5.1 Input Mode and Feature Settings

After selecting voltage or current through switch S3, the input-output characteristic curve needs to be defined by parameters. Using a two-point linear mapping, the two feature points (X1, Y1) and (X2, Y2) correspond to the input percentage and output percentage (relative to the maximum frequency or maximum percentage), respectively. The four key parameters are:

564 feature point X1 (default -98.00%): Input percentage of the first point;

565 feature point Y1 (default -10.000%): Output percentage of the first point;

566 feature point X2 (default 98.00%): Input percentage of the second point;

567 feature point Y2 (default 100.00%): Output percentage of the second point.

Among them, the input percentage is 100% at full scale (10V or 20mA), and the output percentage is 100% at 419 maximum frequency or 519 maximum reference percentage. For example, if the maximum frequency is set to 50Hz, then Y=100% corresponds to 50Hz.

5.2 Four working modes (parameter 562)

According to application requirements, the following feature transformations can be selected:

Mode 1- Bipolar: Direct mapping, allowing negative input to generate negative frequency (inversion).

Mode 11- Unipolar: Clamp the negative input to zero, suitable for situations where only forward rotation is required.

Mode 21- Monopolar 2... 10V/4... 20mA: Forcefully compresses the 0-20% input range to zero output, commonly used for industrial sensors with "active zeros" to ensure that the signal is not driven below the threshold.

Mode 101- Bipolar Absolute Value: Absolute value is taken for the output, negative input generates positive speed, but input polarity still affects direction judgment.

In practical engineering, if a 4-20mA signal is used and forward and reverse rotation is required, mode 1 can be combined with current type input. The characteristic point X1 is set to 20% (corresponding to 4mA), which corresponds to the negative maximum, and X2 is set to 100% (corresponding to 20mA), which corresponds to the positive maximum, with a linear transition in the middle.

5.3 Dead zone/hysteresis and filtering

560 Tolerance Band: default 2.00%, used to define the dead zone range near zero crossing to prevent speed jitter caused by signal noise. For example, 2% of the voltage signal corresponds to 0.2V, and the output remains at zero or minimum frequency when the input is within ± 0.2V.

561 filtering time constant: optional 0-5000ms (15 levels), using first-order low-pass filtering to smooth out reference value mutations caused by interference or measurement fluctuations. For tension control with fast response requirements, it is recommended to set it to below 4ms; For slow temperature regulation, it can be increased to several hundred milliseconds.

5.4 Fault Monitoring and Adjustment

Parameter 563 error/warning behavior configurable response to input signal too low (<1V or<2mA):

0: Do not monitor;

1: Only issue warnings;

2: Warning and slow down to stop the machine (according to stopping method 1);

3: Warning+malfunction, free parking.

This monitoring is independent of the enable status of the frequency converter and is particularly important for safety critical applications.

Due to component errors, it may be necessary to make 568 adjustments to the analog signal: first short-circuit the input to ground and select "Adjust 0V/0mA"; Connect to precise 10V (or 20mA) and select "Adjust 10V/20mA". Automatically saving adjustment values can greatly improve measurement accuracy.