BONFIGLIOLI Active Cube Manuale utente

AND AUTOMATION SOLUTIONS

INDUSTRY PROCESS

ACTIVE Cube

Expansion Module EM-ABS-01

Frequency Inverter 230 V / 400 V

03/12 EM-ABS-01 for ACU 3

TABLE OF CONTENTS

1General Information about the Documentation ........................................................................7

1.1Instructions ............................................................................................................. 7

1.2Pictograms and signal words used.......................................................................... 8

1.3Copyright ................................................................................................................. 8

2General Safety Instructions and Information on Use ................................................................9

2.1General Information................................................................................................ 9

2.2Designated use ........................................................................................................ 9

2.3Transport and Storage........................................................................................... 10

2.4Handling and installation....................................................................................... 10

2.5Electrical Installation............................................................................................. 10

2.6Information on Use................................................................................................ 11

2.6.1Operation with products from other manufacturers................................................... 11

2.7Maintenance and service....................................................................................... 11

2.8Disposal ................................................................................................................. 11

3Introduction ....................................................................................................................... 12

3.1Restrictions for operation of standard functions .................................................. 13

3.2Range of applications of encoders......................................................................... 14

3.2.1Asynchronous motor .............................................................................................. 14

3.2.2Synchronous motor................................................................................................ 14

4Technical data .................................................................................................................... 15

5Installation......................................................................................................................... 17

5.1General .................................................................................................................. 17

5.2Mechanical Installation ......................................................................................... 17

5.3Electrical Installation............................................................................................. 19

5.3.1Block diagram ....................................................................................................... 19

5.3.2Control terminals ................................................................................................... 21

5.3.2.1Cable assembly SinCos .................................................................................... 23

5.3.2.2Cable assembly EnDat 2.1................................................................................ 24

5.3.2.3Cable assembly Hiperface ................................................................................ 25

5.3.3Power supply......................................................................................................... 26

5.3.3.1Internal power supply...................................................................................... 26

5.3.3.2Looping via terminals X410A ............................................................................ 27

5.3.3.3Direct connection of external power supply to the encoder ................................. 28

6Commissioning the encoder ................................................................................................ 29

6.1General Information.............................................................................................. 29

6.1.1Information on use ................................................................................................ 30

6.2SinCos encoders..................................................................................................... 31

6.3Hiperface encoders................................................................................................ 32

6.4EnDat 2.1 encoders................................................................................................ 33

6.5SSI encoders.......................................................................................................... 34

6.6Commissioning of linear encoders......................................................................... 36

6.6.1Checking the settings............................................................................................. 41

6.6.2Initialize counting direction..................................................................................... 43

6.6.3Initializing home position........................................................................................ 43

4 EM-ABS-01 for ACU 03/12

7System bus interface........................................................................................................... 44

7.1Bus termination ..................................................................................................... 44

7.2Cables .................................................................................................................... 45

7.3Control terminal X410B ......................................................................................... 45

7.4Baud rate setting/line lengths .............................................................................. 46

7.5Setting the node address....................................................................................... 46

7.6Functional overview .............................................................................................. 47

7.7Network management........................................................................................... 47

7.7.1SDO channels (parameter data) .............................................................................. 48

7.7.2PDO channels (process data) .................................................................................. 48

7.8Master functionality............................................................................................... 49

7.8.1Control boot-up sequence, network management..................................................... 49

7.8.2SYNC telegram, generation..................................................................................... 51

7.8.3Emergency message, reaction................................................................................. 52

7.8.4Client SDO (system bus master).............................................................................. 53

7.9Slave functionality................................................................................................. 54

7.9.1Implement boot-up sequence, network management................................................ 54

7.9.1.1Boot-up message ............................................................................................ 54

7.9.1.2Position control ............................................................................................... 54

7.9.2Process SYNC telegram .......................................................................................... 55

7.9.3Selecting the synchronization source ....................................................................... 55

7.9.3.1Settings for electronic gear in configuration x40................................................. 57

7.9.3.2Scope sources................................................................................................. 57

7.9.4Emergency-Message, fault shutdown....................................................................... 58

7.9.5Server-SDO1/SDO2................................................................................................ 59

7.10Communication channels, SDO1/SDO2.............................................................. 61

7.10.1SDO telegram (SDO1/SDO2)................................................................................... 61

7.10.2Communication via field bus actuation (SDO1) ......................................................... 63

7.10.2.1Profibus-DP .................................................................................................... 63

7.10.2.2RS232/RS485 with VECTRON bus protocol ........................................................ 63

7.11Process data channels, PDO ............................................................................... 65

7.11.1Identifier assignment process data channel.............................................................. 65

7.11.2Operation modes process data channel.................................................................... 66

7.11.3Timeout monitoring process data channel................................................................ 67

7.11.4Communication relationships of the process data channels........................................ 68

7.11.5Virtual links ........................................................................................................... 69

7.11.5.1Input parameters of the TxPDOs for data to be transmitted ................................ 72

7.11.5.2Source numbers of the RxPDOs for received data .............................................. 74

7.11.5.3Examples of virtual links .................................................................................. 75

7.12Control parameters............................................................................................. 76

7.13Handling of the parameters of the system bus.................................................. 77

7.14Ancillaries ........................................................................................................... 79

7.14.1Definition of the communication relationships........................................................... 80

7.14.2Production of the virtual links.................................................................................. 81

7.14.3Capacity planning of the system bus........................................................................ 82

8Control inputs and outputs .................................................................................................. 84

8.1Analog input EM S1INA ......................................................................................... 84

8.1.1General................................................................................................................. 84

8.1.2Characteristic ........................................................................................................ 84

8.1.3Operation modes ................................................................................................... 85

8.1.3.1Examples........................................................................................................ 85

03/12 EM-ABS-01 for ACU 5

8.1.4Scaling.................................................................................................................. 88

8.1.5Tolerance Band and Hysteresis ............................................................................... 89

8.1.6Error and warning behavior .................................................................................... 90

8.1.7Adjustment ........................................................................................................... 91

8.1.8Filter time constant................................................................................................ 91

8.2Digital outputs EM-S1OUTD and EM-S2OUTD....................................................... 92

8.2.1General................................................................................................................. 92

8.2.2Operation modes ................................................................................................... 92

8.2.3Repetition frequency output via EM-S1OUTD and EM-S2OUTD................................... 92

8.3Digital inputs EM-SxIND........................................................................................ 93

8.3.1Fixed reference value and fixed value change-over ................................................... 93

8.4Encoder input EM-ABS-01...................................................................................... 94

8.4.1Division marks....................................................................................................... 94

8.4.2Tracks/Protocol ..................................................................................................... 95

8.4.3Power supply......................................................................................................... 98

8.4.4Supply voltage..................................................................................................... 101

8.4.5Speed filter ......................................................................................................... 102

8.4.6Offset ................................................................................................................. 102

8.4.7Bits/Turn............................................................................................................. 104

8.4.8Bits Multiturn....................................................................................................... 105

8.4.9SSI: error/additional bits ...................................................................................... 106

8.4.9.1Example 1 .................................................................................................... 107

8.4.9.2Example 2 .................................................................................................... 107

8.4.9.3Example 3 .................................................................................................... 107

8.4.9.4Example 4 .................................................................................................... 107

8.4.10SSI: Sampling interval.......................................................................................... 108

8.4.11Gear factor speed sensor 2................................................................................... 108

8.4.11.1Example ....................................................................................................... 109

8.4.12Instructions on speed-controlled configurations (“Not x40”) .................................... 109

8.4.13Instructions on positioning (configuration x40)....................................................... 110

8.4.13.1Example ....................................................................................................... 111

8.4.13.2Homing ........................................................................................................ 112

8.4.14Warning Dig. Encoder .......................................................................................... 112

8.4.15Act. speed source ................................................................................................ 113

8.4.16Actual position source .......................................................................................... 113

8.5Reference frequency and percentage value channel .......................................... 114

8.6Actual value display............................................................................................. 114

8.6.1Absolute value encoder - raw data ........................................................................ 115

8.6.2Actual position..................................................................................................... 115

8.7Status of digital signals ....................................................................................... 116

8.8Motor temperature .............................................................................................. 117

9List of parameters............................................................................................................. 118

9.1Actual value menu (VAL)..................................................................................... 118

9.2Parameter menu (PARA) ..................................................................................... 118

10Annex.............................................................................................................................. 121

10.1Recommended encoder settings ...................................................................... 121

10.1.1SinCos encoders: ................................................................................................. 121

10.1.2Hiperface encoders:............................................................................................. 122

10.1.3EnDat2.1 encoders: ............................................................................................. 122

10.1.4SSI encoders, rotary: ........................................................................................... 123

10.1.5SSI encoders, linear encoders:.............................................................................. 123

10.2Compatibility list .............................................................................................. 124

6 EM-ABS-01 for ACU 03/12

10.2.1Module Firmware 1.0.1.0...................................................................................... 124

10.2.2Module-Firmware 2.0.1.0...................................................................................... 124

10.3Error 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.

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