BONFIGLIOLI Active Cube User manual
AND AUTOMATION SOLUTIONS
INDUSTRY PROCESS
ACTIVE Cube
Expansion Module EM-ABS-01
GB
Frequency Inverter 230 V / 400 V
03/12 EM-ABS-01 for ACU 3
TABLE OF CONTENTS
1General Information about the Documentation ........................................................................7
1.1Instructions ............................................................................................................. 7
1.2Pictograms and signal words used.......................................................................... 8
1.3Copyright ................................................................................................................. 8
2General Safety Instructions and Information on Use ................................................................9
2.1General Information................................................................................................ 9
2.2Designated use ........................................................................................................ 9
2.3Transport and Storage........................................................................................... 10
2.4Handling and installation....................................................................................... 10
2.5Electrical Installation............................................................................................. 10
2.6Information on Use................................................................................................ 11
2.6.1Operation with products from other manufacturers................................................... 11
2.7Maintenance and service....................................................................................... 11
2.8Disposal ................................................................................................................. 11
3Introduction ....................................................................................................................... 12
3.1Restrictions for operation of standard functions .................................................. 13
3.2Range of applications of encoders......................................................................... 14
3.2.1Asynchronous motor .............................................................................................. 14
3.2.2Synchronous motor................................................................................................ 14
4Technical data .................................................................................................................... 15
5Installation......................................................................................................................... 17
5.1General .................................................................................................................. 17
5.2Mechanical Installation ......................................................................................... 17
5.3Electrical Installation............................................................................................. 19
5.3.1Block diagram ....................................................................................................... 19
5.3.2Control terminals ................................................................................................... 21
5.3.2.1Cable assembly SinCos .................................................................................... 23
5.3.2.2Cable assembly EnDat 2.1................................................................................ 24
5.3.2.3Cable assembly Hiperface ................................................................................ 25
5.3.3Power supply......................................................................................................... 26
5.3.3.1Internal power supply...................................................................................... 26
5.3.3.2Looping via terminals X410A ............................................................................ 27
5.3.3.3Direct connection of external power supply to the encoder ................................. 28
6Commissioning the encoder ................................................................................................ 29
6.1General Information.............................................................................................. 29
6.1.1Information on use ................................................................................................ 30
6.2SinCos encoders..................................................................................................... 31
6.3Hiperface encoders................................................................................................ 32
6.4EnDat 2.1 encoders................................................................................................ 33
6.5SSI encoders.......................................................................................................... 34
6.6Commissioning of linear encoders......................................................................... 36
6.6.1Checking the settings............................................................................................. 41
6.6.2Initialize counting direction..................................................................................... 43
6.6.3Initializing home position........................................................................................ 43
4 EM-ABS-01 for ACU 03/12
7System bus interface........................................................................................................... 44
7.1Bus termination ..................................................................................................... 44
7.2Cables .................................................................................................................... 45
7.3Control terminal X410B ......................................................................................... 45
7.4Baud rate setting/line lengths .............................................................................. 46
7.5Setting the node address....................................................................................... 46
7.6Functional overview .............................................................................................. 47
7.7Network management........................................................................................... 47
7.7.1SDO channels (parameter data) .............................................................................. 48
7.7.2PDO channels (process data) .................................................................................. 48
7.8Master functionality............................................................................................... 49
7.8.1Control boot-up sequence, network management..................................................... 49
7.8.2SYNC telegram, generation..................................................................................... 51
7.8.3Emergency message, reaction................................................................................. 52
7.8.4Client SDO (system bus master).............................................................................. 53
7.9Slave functionality................................................................................................. 54
7.9.1Implement boot-up sequence, network management................................................ 54
7.9.1.1Boot-up message ............................................................................................ 54
7.9.1.2Position control ............................................................................................... 54
7.9.2Process SYNC telegram .......................................................................................... 55
7.9.3Selecting the synchronization source ....................................................................... 55
7.9.3.1Settings for electronic gear in configuration x40................................................. 57
7.9.3.2Scope sources................................................................................................. 57
7.9.4Emergency-Message, fault shutdown....................................................................... 58
7.9.5Server-SDO1/SDO2................................................................................................ 59
7.10Communication channels, SDO1/SDO2.............................................................. 61
7.10.1SDO telegram (SDO1/SDO2)................................................................................... 61
7.10.2Communication via field bus actuation (SDO1) ......................................................... 63
7.10.2.1Profibus-DP .................................................................................................... 63
7.10.2.2RS232/RS485 with VECTRON bus protocol ........................................................ 63
7.11Process data channels, PDO ............................................................................... 65
7.11.1Identifier assignment process data channel.............................................................. 65
7.11.2Operation modes process data channel.................................................................... 66
7.11.3Timeout monitoring process data channel................................................................ 67
7.11.4Communication relationships of the process data channels........................................ 68
7.11.5Virtual links ........................................................................................................... 69
7.11.5.1Input parameters of the TxPDOs for data to be transmitted ................................ 72
7.11.5.2Source numbers of the RxPDOs for received data .............................................. 74
7.11.5.3Examples of virtual links .................................................................................. 75
7.12Control parameters............................................................................................. 76
7.13Handling of the parameters of the system bus.................................................. 77
7.14Ancillaries ........................................................................................................... 79
7.14.1Definition of the communication relationships........................................................... 80
7.14.2Production of the virtual links.................................................................................. 81
7.14.3Capacity planning of the system bus........................................................................ 82
8Control inputs and outputs .................................................................................................. 84
8.1Analog input EM S1INA ......................................................................................... 84
8.1.1General................................................................................................................. 84
8.1.2Characteristic ........................................................................................................ 84
8.1.3Operation modes ................................................................................................... 85
8.1.3.1Examples........................................................................................................ 85
03/12 EM-ABS-01 for ACU 5
8.1.4Scaling.................................................................................................................. 88
8.1.5Tolerance Band and Hysteresis ............................................................................... 89
8.1.6Error and warning behavior .................................................................................... 90
8.1.7Adjustment ........................................................................................................... 91
8.1.8Filter time constant................................................................................................ 91
8.2Digital outputs EM-S1OUTD and EM-S2OUTD....................................................... 92
8.2.1General................................................................................................................. 92
8.2.2Operation modes ................................................................................................... 92
8.2.3Repetition frequency output via EM-S1OUTD and EM-S2OUTD................................... 92
8.3Digital inputs EM-SxIND........................................................................................ 93
8.3.1Fixed reference value and fixed value change-over ................................................... 93
8.4Encoder input EM-ABS-01...................................................................................... 94
8.4.1Division marks....................................................................................................... 94
8.4.2Tracks/Protocol ..................................................................................................... 95
8.4.3Power supply......................................................................................................... 98
8.4.4Supply voltage..................................................................................................... 101
8.4.5Speed filter ......................................................................................................... 102
8.4.6Offset ................................................................................................................. 102
8.4.7Bits/Turn............................................................................................................. 104
8.4.8Bits Multiturn....................................................................................................... 105
8.4.9SSI: error/additional bits ...................................................................................... 106
8.4.9.1Example 1 .................................................................................................... 107
8.4.9.2Example 2 .................................................................................................... 107
8.4.9.3Example 3 .................................................................................................... 107
8.4.9.4Example 4 .................................................................................................... 107
8.4.10SSI: Sampling interval.......................................................................................... 108
8.4.11Gear factor speed sensor 2................................................................................... 108
8.4.11.1Example ....................................................................................................... 109
8.4.12Instructions on speed-controlled configurations (“Not x40”) .................................... 109
8.4.13Instructions on positioning (configuration x40)....................................................... 110
8.4.13.1Example ....................................................................................................... 111
8.4.13.2Homing ........................................................................................................ 112
8.4.14Warning Dig. Encoder .......................................................................................... 112
8.4.15Act. speed source ................................................................................................ 113
8.4.16Actual position source .......................................................................................... 113
8.5Reference frequency and percentage value channel .......................................... 114
8.6Actual value display............................................................................................. 114
8.6.1Absolute value encoder - raw data ........................................................................ 115
8.6.2Actual position..................................................................................................... 115
8.7Status of digital signals ....................................................................................... 116
8.8Motor temperature .............................................................................................. 117
9List of parameters............................................................................................................. 118
9.1Actual value menu (VAL)..................................................................................... 118
9.2Parameter menu (PARA) ..................................................................................... 118
10Annex.............................................................................................................................. 121
10.1Recommended encoder settings ...................................................................... 121
10.1.1SinCos encoders: ................................................................................................. 121
10.1.2Hiperface encoders:............................................................................................. 122
10.1.3EnDat2.1 encoders: ............................................................................................. 122
10.1.4SSI encoders, rotary: ........................................................................................... 123
10.1.5SSI encoders, linear encoders:.............................................................................. 123
10.2Compatibility list .............................................................................................. 124
6 EM-ABS-01 for ACU 03/12
10.2.1Module Firmware 1.0.1.0...................................................................................... 124
10.2.2Module-Firmware 2.0.1.0...................................................................................... 124
10.3Error messages................................................................................................. 125
Index ..................................................................................................................................... 128
03/12 EM-ABS-01 for ACU 7
1General Information about the Documentation
The present supplement to the operating instructions is valid for the frequency inverters of the ACU
series of devices. The information necessary for the assembly and application of the EM-ABS-01 ex-
tension module is documented in this guidance.
For better clarity, the documentation is structured according to the customer-specific requirements
made on the frequency inverter.
1.1 Instructions
For better clarity, the documentation is structured according to the customer-specific requirements
made on the frequency inverter.
Quick Start Guide
The Quick Start Guide describes the basic steps required for mechanical and electrical installation of
the frequency inverter. The guided commissioning supports you in the selection of necessary parame-
ters and the configuration of the frequency inverter by the software.
User manual
The Operating Instructions describe and document all functions of the frequency inverter. The para-
meters required for adapting the frequency inverter to specific applications as well as the wide range
of additional functions are described in detail.
Application Manual
The application manual supplements the documentation for purposeful installation and commissioning
of the frequency inverter. Information on various subjects connected with the use of the frequency
inverter are described specific to the application.
If you need a copy of the documentation or additional information, contact your local representative
of BONFIGLIOLI.
The present documentation was prepared with great care and it was subjected to extensive and re-
peated reviews. For reasons of clarity, it was not possible to include all details of all types of the prod-
uct in the documentation. Neither was it possible to consider all conceivable installation, operation or
maintenance situations. If you require further information or if you meet with specific problems which
are not dealt with in sufficient detail in the documentation, contact your local BONFIGLIOLI agent.
We would also like to point out that the contents of this documentation do not form part of any pre-
vious or existing agreement, assurance or legal relationship. Neither are they intended to supplement
or replace such agreements, assurances or legal relationships. Any obligations of the manufacturer
shall solely be based on the relevant purchase agreement which also includes the complete and solely
valid warranty stipulations. These contractual warranty provisions are neither extended nor limited by
the specifications contained in this documentation.
The manufacturer reserves the right to correct or amend the specifications, product information and
omissions in these operating instructions without notice. The manufacturer shall not be liable for any
damage, injuries or costs which may be caused by the aforementioned reasons.
The present instructions were issued in German language. Other language versions are translations of
the German document.
8 EM-ABS-01 for ACU 03/12
1.2 Pictograms and signal words used
The following pictograms and signal words are used in the documentation:
Danger!
Danger refers to an immediate threat. Non-compliance with the precaution described may
result in death, serious injury or material damage.
Warning!
Warning refers to a possible threat. Non-compliance with the warning may result in death,
serious injury or material damage.
Caution!
Caution refers to an indirect threat. Non-compliance may result in personal or material
damage.
Attention!
Attention refers to a possible operational behavior or an undesired condition that can occur in accor-
dance with the reference text.
Note
Note marks information that facilitates handling for you and supplements the corresponding part of
the documentation.
1.3 Copyright
This user manual is protected by copyright. It is solely intended for use by operating staff and must
not be copied nor disclosed to third parties.
03/12 EM-ABS-01 for ACU 9
2General Safety Instructions and Information on Use
Warning!
The specifications and instructions contained in the documentation must be complied with
strictly during installation and commissioning. Before starting the relevant activity, read the
documentation carefully and comply with the safety instructions. The term “Qualified Staff”
refers to anybody who is familiar with the installation, assembly, commissioning and opera-
tion of the frequency inverter and has the proper qualification for the job.
2.1 General Information
Warning!
The DC-link circuit of the frequency inverter is charged during operation, i.e. there is al-
ways the risk of contact with high voltage. Frequency inverters are used for driving moving
parts and they may become hot at the surface during operation.
Any unauthorized removal of the necessary covers, improper use, wrong installation or op-
eration may result in serious injuries or material damage.
In order to avoid such injuries or damage, only qualified technical staff may carry out the
transport, installation, commissioning, setup or maintenance work required. The standards
DIN EN 50178, IEC 60364 (Cenelec HD 384 or DIN VDE 0100), IEC 60664-1 (Cenelec HD
625 or VDE 0110-1), BGV A2 (VBG 4) as well as the applicable national regulations must
be complied with. The term „Qualified Staff“ refers to anybody who is familiar with the in-
stallation, assembly, commissioning and operation of the frequency inverter as well as the
possible hazards and has the proper qualification for the job.
Persons not familiar with the operation of the frequency inverter or children must not have
access to the device.
2.2 Designated use
Warning!
The frequency inverters are electrical drive components intended for installation in indus-
trial plants or machines. Commissioning and start of operation is not allowed until it has
been verified that the machine meets the requirements of the EC Machinery Directive
2006/42/EEC and DIN EN 60204. In accordance with the CE marking requirements, the
frequency inverters comply with the Low Voltage Directive 2006/95/EEC as well as DIN
EN 61800-5-1. The user shall be responsible for making sure that the requirements of the
EMC Directive 2004/108/EEC are met. Frequency inverters are only available at specialized
dealers and are exclusively intended for professional use as per DIN EN 61000-3-2.
Any use other than the use described above, will be considered as not in accordance with
the specified purpose and may result in the warranty becoming null and void.
The frequency inverters are also marked with the UL label according to UL508c, which
proves that they also meet the requirements of the CSA Standard C22.2-No. 14-95.
The technical data, connection specifications and information on ambient conditions are
indicated on the rating plate and in the documentation and must be complied with in any
case. Anyone involved in any kind of work at the device must have read the instructions
carefully and understood them before starting the work.
10 EM-ABS-01 for ACU 03/12
2.3 Transport and Storage
The frequency inverters must be transported and stored in an appropriate way. During transport and
storage the devices must remain in their original packaging.
The units may only be stored in dry rooms which are protected against dust and moisture and are
exposed to little temperature deviations only. Observe the conditions as per DIN EN 60721-3-1 for
storage, DIN EN 60721-3-2 for transport and the labeling on the packaging.
The duration of storage without connection to the permissible nominal voltage may not exceed one
year.
2.4 Handling and installation
Warning!
Damaged or destroyed components must not be put into operation because they may be a
health hazard.
The frequency inverters are to be used in accordance with the documentation as well as the applica-
ble directives and standards.
It must be handled carefully and protected against mechanical stress.
Do not bend any components or change the isolating distances.
Do not touch electronic components or contacts. The devices are equipped with components which
are sensitive to electrostatic energy and can be damaged if handled improperly. Any use of damaged
or destroyed components shall be considered as a non-compliance with the applicable standards.
Removal of seals from the housing can result in invalidation of warranty.
Do not remove any warning signs from the device.
2.5 Electrical Installation
Warning!
Before any assembly or connection work, discharge the frequency inverter. Verify safe iso-
lation from power supply.
Do not touch the terminals because the capacitors may still be charged.
Comply with the information given in the operating instructions and on the frequency in-
verter label.
Follow the safety rules applying to work on electrical equipment.
Follow the safety rules applying to work on electrical equipment:
•Isolate: Isolate the installation from all possible sources of electrical power.
•Secure against reconnection. Only the persons working on the installation may re-commission the
relevant part of the installation.
•Verify there is no electrical power: Using a measuring instrument or voltage tester, ensure there is
no voltage against ground on the relevant plant component.
•Ground and short-circuit: Starting from the ground terminal, connect all conductors to one anoth-
er.1)
•Cover und shield neighboring live parts: By covering, shielding or isolation of energized plant com-
ponents contact with such parts is to be prevented.
1) Deviations from this are possible in certain circumstances.
When working at the frequency inverters, comply with the relevant accident prevention regulations,
the applicable standards BGV A2 (VBG 4), VDE 0100, standards governing work on systems with dan-
gerous voltages (e.g. DIN EN 50178) and other national directives.
03/12 EM-ABS-01 for ACU 11
Comply with the electrical installation instructions given in the documentation as well as the relevant
directives.
Responsibility for compliance with and examination of the limit values of the EMC product norm DIN
EN 61800-3 for variable-speed electrical drive mechanisms is with the manufacturer of the industrial
plant or machine. The documentation contains information on EMC-conforming installation.
The cables connected to the frequency inverters may not be subjected to high-voltage insulation tests
unless appropriate circuitry measures are taken before.
Do not connect any capacitive loads.
2.6 Information on Use
Warning!
The frequency inverter may be connected to power supply every 60 s. This must be consi-
dered when operating a mains contactor in jog operation mode. For commissioning or after
an emergency stop, a non-recurrent, direct restart is permissible.
After a failure and restoration of the power supply, the motor may start unexpectedly if the
AutoStart function is activated.
If staff is endangered, a restart of the motor must be prevented by means of external cir-
cuitry.
Before commissioning and the start of the operation, make sure to fix all covers and check
the terminals. Check the additional monitoring and protective devices according to DIN EN
60204 and applicable the safety directives (e.g. Working Machines Act, Accident Prevention
Directives etc.).
No connection work may be performed, while the system is in operation.
2.6.1 Operation with products from other manufacturers
Please note that Bonfiglioli Vectron will not accept responsibility for compatibility with products from
other manufacturers (e.g. motors, cables, filters, etc.).
In order to achieve optimum system compatibility, Bonfiglioli Vectron offers components which ensure
easy commissioning and are perfectly adjusted to one another in operation.
Use of the device with products from other manufacturers will be at your own risk.
2.7 Maintenance and service
Warning!
Unauthorized opening and improper interventions can lead to personal injury or material
damage. Repairs on the frequency inverters may only be carried out by the manufacturer
or persons authorized by the manufacturer.
Check protective equipment regularly.
Any repair work must be carried out by qualified electricians.
2.8 Disposal
The components of the frequency inverter must be disposed of in accordance with the applicable local
and national laws, regulations and standards.
12 EM-ABS-01 for ACU 03/12
3Introduction
This document describes the possibilities and the properties of the EM-ABS-01 exten-
sion module for the frequency inverters of the ACU series of devices.
Note:
T
his document exclusively describes the
EM-ABS-01 extension module. It is not to be understood as fundamental
information for the operation of the frequency inverters of the ACU series
of devices.
The EM-ABS-01 extension module is an optional hardware component to extend the
functionality of the frequency inverter. It enables the data exchange within the net-
work and between the components which have been directly connected, for example
control and regulation elements.
A
n absolute value encoder or a SinCos encoder and an external DC 24 V power source
can be connected to the extension module EM-ABS-01. The connected volta
g
e source
can power the encoder. To that end, the encoder power supply must be set to “Via
X410A” via a parameter (Parameter Power Supply 1186, see chapter 8.4.3 Power
supply). The voltage level for encoder power supply can be set via a parameter (Pa-
rameter Supply voltage 1187, see Chapter 8.4.4 “Supply voltage”). The volta
g
e value
can be controlled via a measuring cable (often referred to as “sense” cable).
The EM-ABS-01 extension module extends the functionality of the frequency inverters
of the ACU series of devices by the following functions:
−System bus CAN
(Can interface ISO-DIS 11898, CAN High Speed, max. 1 MBaud).
See chapter 7 “System bus”.
−Analog input DC -10…+10 V or DC 0…+10 V.
See chapter 8.1 “Analog input EM S1INA”.
−Encoder interface including PTC evaluation via HD-Sub-D female connector.
Supported encoder types:
oSinCos (optionally with commutation tracks for synchronous motors)
oEnDat 2.1 (encoder type with SinCos track required)
oHiperface
oBeing prepared: SSI encoder (optionally with TTL [RS-422]- or SinCos
track)
See chapter 8.4 “Encoder input EM”.
−Three digital inputs.
See chapter 8.3 “Digital inputs EM-SxIND”.
−Two digital outputs, can also be used as repetition frequency output.
See chapter 8.2 “Digital outputs EM-S1OUTD and EM-S2OUTD”.
−Adjustable voltage output for encoder supply.
See chapter 8.4.3 “Power supply” and 8.4.4 “Supply voltage”.
−DC 24 V voltage input for connection of external power supply. Via this input a
connected encoder can be powered.
See chapter 5.3.3 “Power supply” 8.4.3 “Power supply”.
Note: Dependin
g
on the motor and encoder type used there are restrictions as
to usability in applications. See chapter 3.2 “Range of applications of en-
coders”.
Note: The EM-ABS-01 extension module has been enclosed with the frequenc
y
inverter as a separate component and must be fitted by the user. This is
described in the chapter 5.2 “Mechanical Installation”.
03/12 EM-ABS-01 for ACU 13
T
he extension module is assembled simply by plu
gg
in
g
on without tools bein
g
needed
thanks to the modular set-up of the frequency inverters of the ACU series of devices.
Caution! Carry out the assembly of the extension module before the frequency
inverter is put into operation, and only in a voltage-free state.
The plug-type terminals of the extension module enable economical overall fittin
g
with
a safe function.
Note: Chapter 10.2 contains a compatibility list of the EM-ABS-01 modules in
combination with the ACU inverter firmware versions.
3.1 Restrictions for operation of standard functions
Note: If an EM-ABS-01 module is used with an ACU device, the following func-
tions of the basic device can no longer be used:
•Repetition frequency mode via MFO1 of base device.
Instead, repetition frequency mode can be realized via digital out-
puts of the EM-ABS-01 module.
•Repetition frequency mode (also PWM frequency input) via di
g
ital
inputs of basic device
Instead, the speed sensor 1 input of the basic device can be used.
14 EM-ABS-01 for ACU 03/12
3.2 Range of applications of encoders
Depending on the motor and encoder type used there are restrictions as to usability in
applications. The following sections describe the range of applications.
Note: The EM-ABS-01 module supports, in the case of EnDat 2.1 encoders, a
baud rate of 100 kBit/s. Other baud rates will not be supported.
3.2.1 Asynchronous motor
SinCos,
Hiperface,
EnDat 2.1 with SinCos track,
SSI with incremental track (TTL [RS-422] or SinCos)
can be used on asynchronous motors as:
•Motor encoders for speed feedback (e.g. Configuration 210)
•Motor encoders for speed feedback and parallel position feedback in non-slip
systems (e.g. Configuration 240)
•Application encoder for position feedback with parallel speed feedback either
via motor model (sensorless e.
g
. Confi
g
uration 440) or via HTL encoder (via
terminals on ACU basic device e.g. Configuration 240).
SSI encoders without incremental track
can be used on asynchronous motors as:
•Application encoder for position feedback with speed feedback either via mo-
tor model (sensorless e.g. Configuration 440) or via HTL encoder (via termin-
als on ACU basic device e.g. Configuration 240).
EnDat 2.1 without SinCos track
cannot be used.
3.2.2 Synchronous motor
SinCos with commutation tracks,
Hiperface,
EnDat 2.1 with SinCos track,
SSI with incremental track (TTL [RS-422] or SinCos)
can be used on synchronous motors as:
•Motor encoders for speed feedback (e.g. Configuration 510).
•Motor encoders for speed feedback and parallel position feedback in non-slip
systems (e.g. Configuration 540).
•Application encoder for position feedback with parallel speed feedback via mo-
tor model (sensorless e.g. Configuration 640) .
SinCos without commutation track,
SSI encoders without incremental track
can be used on synchronous motors as:
•Application encoder for position feedback with parallel speed feedback via mo-
tor model (sensorless e.g. Configuration 640) .
EnDat 2.1 without SinCos track
cannot be used.
03/12 EM-ABS-01 for ACU 15
4Technical data
When using the EM-ABS-01 extension module, the technical data of the frequency
inverter must be considered.
Control terminal X410A Control terminal X410B
X410A.1 Voltage input DC 24 V X410B.1 Ground
X410A.2 Ground DC 24 V X410B.2 Digital input EM-S1IND1)
X410A.3 Digital output EM-S1OUTD1), 2) X410B.3 Digital input EM-S2IND1)
X410A.4 Digital output EM-S2OUTD1), 2) X410B.4 Digital input EM-S3IND1)
X410A.5 Voltage output DC 5…12 V3) X410B.5 System bus, CAN low
X410A.6 Analog input EM-S1INA1) X410B.6 System bus, CAN high
X410A.7 Ground DC 10 V X410B.7 Ground
1) The control electronics parameters can be configured as required.
2) Can be used as repetition frequency output. The repetition frequency output can
withstand external voltage in a range from -5 V to +10 V.
3) The max. power available is reduced by the other control outputs of the frequency
inverter and extension module.
Caution! The input for external DC 24 V voltage supply can withstand external vol-
tage up to DC 30 V. Avoid higher voltage levels. Higher voltages may de-
stroy the module.
Caution! The power output on terminal X410A.1 may be loaded with a maximum
power of 2 W. Higher power levels can damage components of the mod-
ule.
Encoder and PTC input X412 (HD-Sub-D)
Encoder input: PTC input
Internal resistance <100 ΩTrigger resistance = 2.4 kΩaccording
to
DIN 44081
A/B and C/D track:
sine-shaped differential signal 0.6…1.2 Vss
Hysteresis = 1.3 kΩ
PTC or bimetal temperature sensor
(NC)
R-track:
Differential signal 0.2…1.7 Vss
Clock and data (alternative to C/D track)
Signal: V =DC 2.5 V ±0.5 V
Power supply encoder:
VENC track: Supply DC 5…12 V
VENC
,
Sense track: encoder sensor cable
Warning! The PTC input is not insulated. Only PTCs which feature a safe isolation
from the motor winding as per EN61800-5-1 may be connected.
Note: BONFIGLIOLI servo motors of types BCR and BTD are provided with
safe isolation to the motor winding.
Note: BONFIGLIOLI VECTRON recommends connecting an external power
supply to the voltage input of the control terminal. This auxiliary voltage
enables powering an encoder via the voltage output of the control ter-
minal. Note the manufacturer's input power specifications of the encod-
er.
16 EM-ABS-01 for ACU 03/12
Technical data of control terminals
Digital inputs (X410B.2) … (X210B.4):
Low Signal: DC 0 V …3 V, High Signal: DC 12 V … 30 V, input resistance: 2.3 kΩ, PLC
compatible
Sample Times: 1 ms in configurations x40 (“Positioning”)
4 ms in all other configurations
Frequency signal: DC 0 to 30 V, 10 mA at DC 24 V, fmax = 150 kHz
Digital outputs (X410A.3), (X410A.4):
Low signal: DC 0 V to 3 V,
High signal: DC 12 V to 30 V, output current: 40 mA, PLC compatible,
Repetition frequency output: frequency signal , Fmax = 150 kHz, overload and short-
circuit proof, Imax = ±60 mA at min. permissible line termination 150 Ω, according to
specification EIA485
Analog input (X410A.6):
Analog signal: Input voltage: DC -10 V to 10 V / DC 0 V to 10 V (Ri = 100 kΩ),
Resolution 13 Bit
Voltage output DC 5 to 12 V for encoder supply (X410A.5):
Pmax = 2 W. Depending on the load on the digital outputs of the frequency inverter
and extension module, this value may be lower.
Voltage input DC 24 V for external power supply (X410A.1)
Input voltage range DC 24 V ±10%, Umax = DC 30 V,
Rated input current: max. DC 1.0 A (typical DC 0.45 A),
Peak inrush current: typical: < DC 20 A,
External fuse: standard fuse elements for rated current, characteristic: slow,
Safety: Safety extra low voltage (SELV) according to EN 61800-5-1
Conductor cross-section:
The control terminals are suitable for the following cable sizes:
with ferrule: 0.25 … 1.0 mm²
without ferrule: 0.14 … 1.5 mm²
03/12 EM-ABS-01 for ACU 17
5Installation
5.1 General
The mechanical and electrical installation of the EM-ABS-01 extension module must be
carried out by qualified personnel accordin
g
to the
g
eneral and re
g
ional safety and
installation directives. For a safe operation of the frequency inverter it is necessary
that the documentation and the device specifications be complied with during installa-
tion and commissionin
g
. In the case of special applications, you may also have to
comply with further guidelines and instructions.
T
he frequency inverters are desi
g
ned accordin
g
to the requirements and limit values
of product norm EN 61800-3 with an interference immunity factor (EMI) for operation
in industrial applications. The electroma
g
netic interference is to be avoided by expert
installation and observation of the specific product information.
For further information, refer to the chapter "Electrical Installation" of the frequency
inverter operating instructions.
Warning!
A
ll connection terminals where dan
g
erous volta
g
e levels may be present
(e.g. motor connection terminals, mains terminals, fuse connection ter-
minals, etc.), must be protected against direct contact.
5.2 Mechanical Installation
Danger! If the followin
g
instructions are not complied with, there is direct dan
g
er
with the possible consequences of death or severe in
j
ury by electrical
current. Further, failure to comply can lead to destruction of the frequency
inverter and/or of the extension module.
•Before assembly or disassembly of the EM-ABS-01 extension module, the frequen-
cy inverter must be de-energized. Take appropriate measures to make sure it is
not energized unintentionally.
•Make sure that the frequency inverter is discharged.
Danger! When the frequency inverter is disconnected from power supply, the
mains, DC-link volta
g
e and motor terminals may still be live for some
time. Wait for at least three minutes until the DC link capacitors have
discharged before starting to work at the unit.
18 EM-ABS-01 for ACU 03/12
The EM-ABS-01 extension module is supplied in a housing for assembly on the lower
slot of the frequency inverter.
•Remove the lower cover (1) of the frequency inverter.
The slot for the EM-ABS-01 extension module becomes accessible.
1
Caution! The EM-ABS-01 (2) extension module is pre-fitted in a housin
g
. The PCB
visible on the back may not be touched, as modules can be dama
g
ed by
this.
•Plug the EM-ABS-01 (2) extension module onto the slot (3).
•Re-install the lower cover (1).
Assembly is complete.
When the supply voltage of the frequency inverter is switched on, the EM-ABS-01
ex-tension module is ready for operation.
1
2
3
03/12 EM-ABS-01 for ACU 19
5.3 Electrical Installation
Danger! If the followin
g
instructions are not complied with, there is direct dan
g
e
r
with the possible consequences of death or severe in
j
ury by electrical
current. Further, failure to comply can lead to destruction of the frequenc
y
inverter and/or of the extension module.
•Before electrical installation of the EM-ABS-01 extension module, the frequency
inverter must be de-energized. Take appropriate measures to make sure it is not
energized unintentionally.
•Make sure that the frequency inverter is discharged.
Danger! When the frequency inverter is disconnected from power supply, the
mains, DC-link volta
g
e and motor terminals may still be live for some
time. Wait for at least three minutes until the DC link capacitors have
discharged before starting to work at the unit.
5.3.1 Block diagram
Caution!
T
he di
g
ital inputs and the DC 24 V terminal of the electronic control
equipment can withstand external volta
g
e up to DC 30 V. Avoid hi
g
her
voltage levels. Higher voltages may destroy the module.
20 EM-ABS-01 for ACU 03/12
A
V
olta
g
e input, connection for external power supply of encode
r
Input voltage range DC 24 V ±10%, Umax = DC 30 V,
Rated input current: max. DC 1.0 A (typical DC 0.45 A),
Peak inrush current: typical: < DC 20 A,
External fuse: standard fuse elements for rated current, characteristic: slow,
Safety: Safety extra low voltage (SELV) according to EN 61800-5-1
B
Digital outputs EM-S1OUTD, EM-S2OUTD
Digital signal, DC 24 V, Imax = 40 mA, PLC compatible, overload and short-circuit proof
C
V
olta
g
e output for encoder suppl
y
DC 5 V … 12 V, according to configuration of parameter Supply voltage 1187 (factory
setting DC 5.0 V), Pmax = 2 W
Caution! The power output on terminal X410A.1 may be loaded with a maximum
power of 2 W. Higher power levels can damage components of the mod-
ule.
D
Analog input EM-S1INA
A
nalo
g
si
g
nal, resolution 13 bit, Umax= DC ±10 V (Ri = 100 kΩ)
E
Digital inputs EM-S1IND … EM-S3IND
Digital signal, response time 1 ms in configurations x40 (“Positioning”), 4 ms in all
other configurations, Umax= DC 30 V, 10 mA at DC 24 V,
PLC-compatible,
frequency signal, DC 0 ... 30 V, 10 mA at DC 24 V
Communication interface system bus
CAN-connection of system bus according to ISO-DIS 11898 (CAN High Speed), bus
termination can be activated via switch
Inputs for SinCos encoders and PTC (15-pin female connector HD-Sub-
D)
The encoder interface is designed for connection of standard commercial SinCos (op-
tionally with commutation tracks for synchronous motors), EnDat 2.1 (SinCoS trac
k
required), Hiperface and SSI encoders (optionally with TTL [RS-422] or SinCos track).
Depending on the encoder type, different signals are evaluated. The following signals
can be evaluated:
- A/B tracks and/or Sin/Cos tracks
- C/D tracks (commutation tracks) or Data/Clock tracks (absolute value encoders)
- R tracks (reference track)
- Measuring line for monitoring and control of encoder supply voltage
Input: sinusoidal incremental signals, internal resistance of source <100 Ω,
A
/B and C/D tracks: Direct portion V =DC 2.5 V ±0.5 V, peak value: 0.6 V,
R-track: Direct portion V =DC 2.5 V ±0.5 V, differential voltage: 1.8 V.
The encoder supply voltage at contacts X412.6 (VEnc) and X412.15 (0VL) can be ad-
j
usted throu
g
h parameter Supply voltage 1187 in between DC 5.0 … 12 V. See chap-
ter 8.4.4 “Supply voltage”. Max. load: 2 W.
PTC input:
Trigger resistance = 2.4 kΩ(PTC) as per DIN 44081,
PTC or bimetal temperature sensor (NC)
Use PTC resistors with safe isolation from motor winding according to EN 61800-5-1.
F
G
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