Bonfiglioli Vectron EM-RES-01 Expansion Module Rotary Transformer Interface Configuration Guide

X410A.1 REF+excitation signal positive pole

X410A. 2 REF - excitation signal negative pole

X410A.3 SIN - sine signal negative pole

X410A.4 SIN+sine signal positive pole

X410A.5 COS cosine signal negative pole

X410A.6 COS+cosine signal positive pole

3.2 Repetitive frequency output (simulated incremental encoder)

EM-RES-01 can convert the Resolver signal into an incremental encoder signal output for speed monitoring of external devices (such as PLC high-speed counting modules):

Terminal signal description

X410A.7 A+Track A positive pole

X410B. 1 A-Track A negative pole

X410B. 2 B+positive pole of track B

X410B. 3 B-Track B Negative

Specifications:

Maximum frequency: 512 kHz

Output type: TTL (push-pull), compliant with RS-422A/RS-485

Maximum output voltage: 5V

Maximum current: ± 60mA (minimum load resistance 150 Ω)

Fixed division mark: 1024 (no parameterization required)

3.3 Shielding and Wiring Requirements

To ensure signal integrity, the manual explicitly requires:

Use shielded twisted pair cables (SIN+paired with SIN -, COS+paired with COS -, two excitation wires paired)

The shielding layer is connected to the PE (protective earth) over a large area at both ends

Control and communication cables are physically separated from power cables

Offset setting of rotary transformer - core link of on-site debugging

The offset setting of the rotary transformer is the most critical and complex step in the on-site debugging of EM-RES-01. The accuracy of Offset directly affects the starting performance, smooth operation, and output torque of synchronous motors.

4.1 The Physical Meaning of Offset

In permanent magnet synchronous motors, there is a fixed angular deviation between the rotor position of the rotary transformer and the magnetic pole position of the motor rotor, known as Offset. This deviation is due to the mechanical installation position of the rotary transformer on the motor shaft. If the Offset is not accurate, the frequency converter will not be able to correctly determine the position of the rotor magnetic poles, resulting in:

The motor cannot start (only shaking without rotation)

Motor reversal or acceleration loss of control

Excessive current triggers overcurrent protection

Parameter 382 (Offset) is used to compensate for this deviation, with a range of -360.0 °~360.0 ° and a factory value of 0.0 °.

4.2 Safety Preparation Before Offset Setting

Before performing Offset tuning, the following security measures must be taken:

Release load coupling: If possible, disconnect the motor from the load machinery to ensure that the motor shaft can rotate freely.

Release mechanical brake: If the motor is equipped with a brake, ensure that it has been released.

Set frequency limit: Set parameter 417 (Switch Off Limit) to a lower value (such as 5-10Hz) to prevent motor runaway in case of Offset error.

Set current limit: Set parameter 728 (Current Limit) to about 10% of the rated current of the motor to prevent overcurrent when Offset error occurs.

Warning: If the load cannot be disconnected, make sure that the motor is running at low speed and will not cause equipment or personnel injury.

4.3 Data Input and Preliminary Verification

Exit automatic SETUP: When powered on for the first time, the operating unit displays "SETUP", press the ESC key to exit.

Input motor nameplate data: Enter the PARA menu and input the rated voltage, current, frequency, speed, and pole pairs of the motor (parameter 373).

Set the parameters of the rotary transformer:

Parameter 380=Select excitation frequency (e.g. 10kHz)

Parameter 381=Set the number of poles of the rotary transformer

Manually rotate the motor shaft: Rotate the motor shaft manually and observe the displayed value of parameter 219 (Frequency Speed Sensor 2).

When rotating clockwise, a positive value should be displayed.

If a negative value is displayed, swap the wiring of X410A.3 (SIN -) and X410A.4 (SIN+).

4.4 Offset coarse adjustment - judged based on motor behavior

Set a low speed setpoint (such as 10% below Switch Off Limit 417) and start the motor through digital input. Observe motor behavior:

Scenario 1: The motor does not rotate or only stops after shaking

Check if parameters 373 (motor pole pairs) and 381 (rotary transformer pole pairs) are correct.

If the parameters are correct, switch the wiring of any two phases of the motor (such as U and V), as the rotation direction of the motor and the rotating transformer do not match.

Power on again and try to start.

Scenario 2: Still not starting after exchanging phase lines

Increase Offset (parameter 382) by 90 °/motor pole pairs.

If it still does not start, switch the motor phases (such as U and W) again.

Scenario 3: Motor accelerates until frequency limit (runaway)

Check if there is an open circuit or poor contact in the wiring of the rotary transformer.

If the fault code is F1100 (overclocking), increase the Offset by 180 ° per motor pole pair.

4.5 Offset Fine Adjustment - Based on the Voltage Formed by Magnetic Flux

After the motor can run stably at the set speed, perform fine adjustment of Offset:

Observe the displayed value of parameter 235 (Flux Forming Voltage).

Adjust parameter 382 with a small step size (such as 2.5 °) and observe the change in 235: