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

Interface calibration and startup of rotary transformer

The interface of the rotary transformer is the core advantage of EM-RES-02, and its processing flow includes excitation frequency setting, pole pair matching, offset calibration, and speed source selection.

6.1 Basic parameter settings

380 working mode: Select excitation frequency (5kHz, 10kHz, 20kHz) that is consistent with the specifications of the rotary converter. The higher the frequency, the faster the position update rate, but the phase delay also increases (about 7 ° at 5kHz).

381 Rotary pole pairs: Set according to the rotary nameplate (1-24). It should be noted that if the number of motor pole pairs is P_motor and the number of rotary pole pairs is P_res, then P_motor/P_res must be integers, otherwise the mechanical absolute angle cannot be correctly resolved.

6.2 Offset Calibration Process

The offset parameter 382 (range -360 ° to+360 °) determines the phase relationship of the stator current vector relative to the rotor magnetic poles. Incorrect offset can cause the motor to fail to start, experience severe vibration, or overcurrent. The standard calibration steps are as follows:

Safety preparation: Release the load (disconnect the coupling), release the mechanical brake, set the upper limit of the frequency converter output frequency (417 switch frequency limit) to a low value (such as 5Hz), and set the current limit (728) to 10% of the rated current of the motor to prevent accidental runaway.

Check the rotation direction of the rotary transformer: manually rotate the motor shaft and observe the actual value of 219. Check the positive and negative of frequency sensor 2. If the displayed symbol is opposite to the direction of rotation, exchange the SIN+and SIN - connections of X410A.

Trial operation: Given a small positive speed reference (e.g. 2Hz), enable the frequency converter. Observe whether the motor rotates smoothly.

If the motor does not rotate or only shakes slightly: check whether the number of pole pairs (373) of the motor matches the number of pole pairs (381) of the rotary converter. If matched, power off and exchange any two-phase motor wires (such as U, V), as the direction of the motor magnetic field may be opposite to the direction of the rotation.

If the motor accelerates until the overclocking alarm (F1100) is triggered, it indicates that the offset difference is about 180 °. At this point, increase the 382 offset by 180 °/Pmotor (number of motor poles) and test drive again.

Fine adjustment: When the motor can stabilize at a given speed, fine tune the offset value online. Observing the actual value of 235 excitation forming voltage, this value should approach 0. If it is positive, increase the offset; If it is negative, reduce the offset. Step 2.5 ° each time until the absolute value of the excitation voltage is minimized. It is best to repeat this step for verification at 50% of the rated frequency.

Restore limiting: After tuning, restore 417 and 728 to their normal application values and perform a "SETUP" guided debugging (if used for the first time) to ensure that the current loop parameters match the transformer.

6.3 Selection of Speed Source

Parameter 766 determines the feedback source for the speed closed-loop based on the actual speed source. The default basic setting is "1- Speed Sensor 1" (i.e. the inverter body comes with an encoder or Hall sensor). If a rotary transformer is required as the main feedback, it should be set as "2- Speed Sensor 2".

Application of Repetitive Frequency Output (EM-RFOUT)

This output converts the rotated angle signal into differential orthogonal pulses, generating a fixed 1024 A/B pulses per revolution (i.e. 4096 lines after 4th multiplication), and outputs a zero position reference signal (R+/R -). This function facilitates the transmission of rotary signals to external PLCs, motion controllers, or synchronization cards, avoiding the need to purchase expensive third-party conversion modules.

In terms of electrical parameters, the output is at RS-422 level (maximum 5V), with overload and short circuit protection, and a maximum output frequency of 512kHz. When wiring, attention should be paid to terminal matching (usually a 120 Ω resistor), and the recommended cable length should not exceed 50 meters to ensure signal integrity.

Parameter List and Fault Diagnosis

8.1 Summary of Key Parameters

Parameter number name range description

219 frequency sensor 2 0.0~999.99Hz rotation actual frequency (proportional to speed)

220 speed sensor 2 0-60000rpm converted speed

253 Analog Input EM-SINA-100~+100% Current Input Percentage

380 Rotary Transformer Excitation Frequency Selection 5/10/20kHz

381 rotation pole pairs set from 1 to 24

382 offset angle -360.0~360.0 ° phase compensation

560 tolerance with 0-25% zero crossing dead zone

561 filtering time constant 0-5000ms optional range

562 analog input working mode 1/11/21/101 feature transformation

563 Error/Warning Behavior 0-3 Under Voltage Response

564-567 feature points X1/Y1/X2/Y2 ± 100% linear mapping

568 adjustment mode 0/1/2 calibration

766 actual speed source 1/2 feedback selection