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BONFIGLIOLI Vectron Manual

Active cube expansion module em-res-03 230 v/400 v
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ACTIVE CUBE
Expansion Module EM-RES-03
Frequency Inverter 230 V / 400 V

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  • Page 1 ACTIVE CUBE Expansion Module EM-RES-03 Frequency Inverter 230 V / 400 V...
  • Page 3 The documentation and additional information can be requested via your local repre- sentation of the company BONFIGLIOLI. The following pictograms and signal words are used in the documentation: Danger! means a directly threatening danger.

  • Page 4: Table Of Contents

    Server SDO1/SDO2 ....................27 5.10 Communication channels, SDO1/SDO2.............. 29 5.10.1 SDO telegrams (SDO1/SDO2) ................. 29 5.10.2 Communication via field bus connection (SDO1) ............31 5.10.2.1 Profibus-DP ....................31 5.10.2.2 RS232/RS485 with VECTRON bus protocol ............31 EM-RES-03 10/07 EM-RES-03 10/07...
  • Page 5 5.11 Process data channels, PDO ................33 5.11.1 Identifier assignment process data channel.............. 33 5.11.2 Operation modes process data channel..............34 5.11.3 Timeout monitoring process data channel ..............35 5.11.4 Communication relationships of the process data channel ......... 36 5.11.5 Virtual links ......................

  • Page 6: General Safety And Application Information

    General information Warning! BONFIGLIOLI VECTRON frequency inverters have high voltage levels dur- ing operating, depending on their protection class, drive moving parts and have hot surfaces.

  • Page 7: Proper Use

    Proper use Warning! The frequency inverters are electrical drive components intended for in- stallation in industrial plant or machines. Commissioning and start of in- tended operation are not allowed until it has been established that the machine corresponds to the provisions of the EC machine directive 98/37/EEC and EN 60204.

  • Page 8: Electrical Connection

    Electrical connection Warning! Before any assembly or connection work, de-energize the frequency in- verter. Make sure that the frequency inverter is de-energized. Do not touch the sockets, because the capacitors may still be charged. Comply with the information given in the operating instructions and on the frequency inverter label.

  • Page 9: Introduction

    The EM-RES-03 expansion module differs in the resolver evaluation from Note: the expansion modules EM-RES-01 and EM-RES-02. The frequency of the excitation signal is set to the fixed value 8 Hz. This module is applicable for BONFIGLIOLI motor types BCR and BTD. 10/07 EM-RES-03 10/07...

  • Page 10: Technical Data Of The Expansion Module Em-Res-03

    Warning! The PTC input is not insulated. Only PTC thermistors with safe insulation from the motor winding acc. to EN61800-5-1 may be connected. Note: BONFIGLIOLI servomotors of types BCR and BTD are designed with safe insulation from the motor winding. Technical data of the control terminals Digital inputs (X410B.2) …...

  • Page 11: Installation Of The Em-Res-03 Expansion Module

    Installation of the EM-RES-03 expansion module General The mechanical and electrical installation of the EM-RES-03 expansion module is to be carried out by qualified personnel according to the general and regional safety and installation directives. Safe operation of the frequency inverter requires that the documentation and the device specification be complied with during installation and start of operation.
  • Page 12 The EM-RES-03 expansion 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-RES-03 expansion module becomes accessible. The EM-RES-03 expansion module (2) is pre-fitted in a housing. Do NOT Caution! touch the PCB visible on the back, as modules may be damaged.

  • Page 13: Electrical Installation

    Electrical installation If the following instructions are not complied with, there is direct danger Danger! with the possible consequences of death or severe injury by electrical current. Further, failure to comply can lead to destruction of the frequency inverter and/or of the expansion module. Before electrical installation of the EM-RES-03 expansion module, the frequency •...

  • Page 14: Control Terminals

    Communication interface system bus CAN actuation of the system bus according to ISO-DIS 11898 (CAN High Speed) Resolver- and PTC thermistor input (SubD9) The resolver interface is suitable for the connection of standard resolvers with the following specifications: Input impedance > 95 Ω at 8 kHz, number of pole pairs up to 7, 30 000 rpm at number of pole pairs = 1 Excitation voltage U = 3.5 V, I...
  • Page 15 Excitation voltage If a synchronous motor should be connected to the resolver input which is Note: not from BONFIGLIOLI it can be necessary to change the sign of the sinus Evaluation Mode track. This can be set via parameter 492. Refer to chapter 6.4.3.

  • Page 16: System Bus Interface

    System bus interface The CAN connection of the system bus is physically designed according to ISO-DIS 11898 (CAN High Speed). The bus topology is the line structure. The frequency inverter supports a CAN protocol controller, which may exist in either the CM-CAN communication module with CANopen interface OR in an extension module for the system bus, such as the EM-RES-03 extension module.

  • Page 17: Cables

    Cables For the bus line, use twisted a cable with harness shield (no foil shield). Attention: The control and communication lines are to be laid physically separate from the power lines. The harness screen of the data lines is to be con- nected to ground (PE) on both sides on a large area and with good con- ductivity.

  • Page 18: Baud Rate Setting/Line Length

    Baud rate setting/line length The setting of the baud rate must be identical in all subscribers on the system bus. The maximum possible baud rate is based on the necessary overall line length of the Baud-Rate system bus. The baud rate is set via the parameter 903 and thus defines the possible line length.

  • Page 19: Functional Overview

    Functional overview The system bus produces the physical connection between the frequency inverters. Logical communication channels are produced via this physical medium. These chan- nels are defined via the identifiers. As CAN does not possess a subscriber-oriented, but a message-oriented addressing via the identifiers, the logical channels can be displayed via it.

  • Page 20: Sdo Channels (Parameter Data)

    5.7.1 SDO channels (parameter data) Each frequency inverter possesses two SDO channels for the exchange of parameter data. In a slave device, these are two server SDO's, in a device defined as a master a client SDO and a server SDO. Attention must be paid to the fact that only one master for each SDO channel may exist in a system.

  • Page 21: Master Functionality

    Master functionality An external control or an frequency inverter defined as a master (node ID = 0) can be used as a master. The fundamental tasks of the master are controlling the start of the network (boot-up sequence), generating the SYNC telegram and evaluating the emergency messages of the slaves.
  • Page 22 Power on Initialization any state Pre-Operational Stopped Operational After Power On and the initialization, the slaves are in the Pre-Operational state. The transition (2) is automatic. The system bus master (frequency inverter or PLC/PC) triggers the transition (3) to Operational state. The transitions are controlled via NMT telegrams.

  • Page 23: Sync Telegram, Generation

    5.8.2 SYNC telegram, generation If synchronous PDO’s have been created on the system bus, the master must send the SYNC telegram cyclically. If an frequency inverter has been defined as a system bus master, the latter must generate the SYNC telegram. The interval for the SYNC tele- gram of an frequency inverter defined as the system bus master is adjustable.

  • Page 24: Emergency Message, Reaction

    5.8.3 Emergency message, reaction If a slave on the system bus suffers a fault, it transmits the emergency telegram. The emergency telegram marks the node ID for the identification of the failed node via its identifier and the existing fault message via its data contents (8 bytes). After a fault has been acknowledged on the slave, the latter again transmits an emer- gency telegram with the data content zero.

  • Page 25: Client Sdo (System Bus Master)

    5.8.4 Client SDO (system bus master) Each subscriber on the system bus can be addressed via the SDO channels. In this way, each subscriber can be addressed and parameterized by one master via its cli- ent SDO1. All the parameters of the data types uint/int/long are accessible. String parameters can not be processed.

  • Page 26: Slave Functionality

    Slave functionality 5.9.1 Implement boot-up sequence, network management 5.9.1.1 Boot-up message After the initialization, each slave on the system bus transmits its boot-up message (heartbeat message). Note: The boot-up telegram has the identifier 1792 + node ID and a data byte with contents = 0x00.

  • Page 27: Process Sync Telegram

    5.9.2 Process SYNC telegram If synchronous PDO’s have been created in an frequency inverter, their processing is synchronized with the SYNC telegram. The SYNC telegram is generated by the system bus master and is a telegram without data. The identifier is 128 according to the Predefined Connection Set. If a PC or PLC is used as a master, the identifier of the SYNC telegrams can be adapted by parameterization on the frequency inverter.

  • Page 28: Emergency Message, Fault Switch-Off

    Bytes 6/7 contain the product specific VECTRON error code. Error-Code = 0x1000 = general error Error-Register = 0x80 = manufacturer-specific error The explanation and description of the product-specific VECTRON error code can be found in the annex "Error messages". EM-RES-03 10/07 EM-RES-03 10/07...

  • Page 29: Server Sdo1/Sdo2

    5.9.4 Server SDO1/SDO2 The communication channel for the exchange of parameter data is the SDO channel. Communication works according to the client/server model. The server is the sub- scriber holding the data (here the frequency inverter), the client the subscriber re- questing or wanting to alter the data (PLC, PC or frequency inverter as system bus master).
  • Page 30 If a PC or a PLC is used as a master, the identifiers of the Rx/Tx-SDO1 can be adapted by parameterization on the frequency inverter. Attention: In free assignment of identifiers, there may not be any double occu- pancy ! The identifier range 129...191 may not be used as the emergency tele- grams can be found there.

  • Page 31: Communication Channels, Sdo1/Sdo2

    5.10 Communication channels, SDO1/SDO2 5.10.1 SDO telegrams (SDO1/SDO2) The service used for the exchange of parameter data is SDO Segment Protocol Expedited. The data (type uint, int, long) are exchanged in a telegram. Access to the parameters in the frequency inverters with a statement of parameter number and data set is displayed via the addressing defined for object access pursu- ant to the specifications of CANopen via Index/Sub-Index.
  • Page 32 BCC error in VECTRON bus protocol unknown error system bus subscriber not available only in access via field bus connection string parameter not admissible only in access via VEC-...

  • Page 33: Communication Via Field Bus Connection (Sdo1)

    3 = 0, the master inverter of the system bus is addressed. The display is binary (0...63). 5.10.2.2 RS232/RS485 with VECTRON bus protocol In the VECTRON bus protocol, there is a byte in the telegram header that is always transmitted with 0 as a standard feature. ENQUIRY...
  • Page 34 Display of node ID system bus in the VECTRON bus protocol: System bus Node-ID System bus (ASCII-) HEX value System bus (ASCII-) HEX value address character address character EM-RES-03 10/07 EM-RES-03 10/07...

  • Page 35: Process Data Channels, Pdo

    5.11 Process data channels, PDO 5.11.1 Identifier assignment process data channel The process channel for the exchange of process data under CANopen is the PDO channel. Up to three PDO channels with differing properties can be used in one device. The PDO channels are defined via identifiers according to the Predefined Connection Set to CANopen: Identifier 1.

  • Page 36: Operation Modes Process Data Channel

    5.11.2 Operation modes process data channel The transmit/receive behavior can be time controlled or controlled via a SYNC tele- gram. The behavior can be parameterized for each PDO channel. Tx-PDO’s can work time controlled or SYNC controlled. A time controlled TxPDO transmits its data at the interval of time set.

  • Page 37: Timeout Monitoring Process Data Channel

    5.11.3 Timeout monitoring process data channel Each frequency inverter monitors its received data for whether they are updated within a defined time window. The monitoring is done onto the SYNC telegram and the RxPDO channels. Monitoring SYNC / RxPDO‘s Parameter Setting Description Min.

  • Page 38: Communication Relationships Of The Process Data Channel

    5.11.4 Communication relationships of the process data channel Regardless of the process data to be transmitted, the communication relationships of the process data channels must be defined. The connection of PDO channels is done via the assignment of the identifiers. The identifiers of Rx-/Tx-PDO must match in each case.

  • Page 39: Virtual Links

    5.11.5 Virtual links A PDO telegram contains 0 ...8 data bytes according to CANopen. A mapping for any kind of objects can be done in these data bytes. For the system bus, the PDO telegrams are firmly defined with 8 data bytes. The mapping is not done via mapping parameters as with CANopen, but via the method of sources and links.
  • Page 40 For the system bus, the input data of the TxPDO’s are also displayed as input pa- rameters and the output data of the RxPDO’s as sources. Example 2: Function A TxPDO Inverter 1 Inverter 1 Parameter 977 Source-No. 27 system bus Function B Inverter 1 Parameter 972...
  • Page 41 The virtual links with the possible sources are related to the Rx/TxPDO channels. For this purpose, the eight bytes of the Rx-/TxPDO’s are defined structured as inputs and sources. This exists for each of the three PDO channels. Each transmit PDO and receive PDO can be occupied as follows: 4 Boolean variables 4 uint/int variables 2 long variables...

  • Page 42: Input Parameters Of The Txpdo's For Data To Be Transmitted

    5.11.5.1 Input parameters of the TxPDO’s for data to be transmitted The listed parameters can be used to stipulate the data that are to be transported there for each position in the TxPDO telegrams. The setting is done in such a way that a source number is entered for the required data in the parameters.
  • Page 43 With this method, there are up to three possibilities for a meaning of the contents of the individual bytes. Each byte may only be used for one possibility. To ensure this, the processing of the input links is derived from the setting. If an input link has been set to the fixed value of zero, it is not processed.

  • Page 44: 5.11.5.2 Source Numbers Of The Rxpdo's For Received Data

    5.11.5.2 Source numbers of the RxPDO’s for received data Equivalent to the input links of the TxPDO’s, the received data of the RxPDO’s are displayed via sources or source numbers. The sources existing in this way can be used in the frequency inverter via the local input links for the data targets. RxPDO1 Source No.

  • Page 45: 5.11.5.3 Examples Of Virtual Links

    5.11.5.3 Examples of virtual links Example 1: Frequency inverter 1 Frequency inverter 2 Source Input link TxPDO1 RxPDO1 Source Target - No. Byte Byte - No. Control Control in- word put, Control word Output Ramp input, reference Line set frequency value 137 channel 62 Parameter 950 = Source-No.

  • Page 46: Control Parameters

    5.12 Control parameters For the monitoring of the system bus and the display of the internal states, two con- trol parameters are provided. There is a report of the system bus state and a report of the CAN state via two actual value parameters. Node-State The parameter 978 gives information about the Pre-Operational, Opera-...

  • Page 47: Handling Of The Parameters Of The System Bus

    All the setting parameters for the configuration of the system bus are not directly ac- cessible for the user. For defined customer applications, pre-defined XPI files can be generated by VECTRON for the VPlus PC program, with which the necessary parame- ters are visible for the user. The application-relevant variables are then available in these XPI files.
  • Page 48 The display of the parameters when using the XPI file is according to the following structure: System bus 900 Node-ID Basic Settings 903 Baud-Rate 904 Boot-Up Delay Master Functions 919 SYNC-Time SYNC-Identifier 918 SYNC-Identifier 921 RxSDO1-Identifier SDO1-Identifier 922 TxSDO1-Identifier 923 SDO2 Set Active SDO2 Set Active PDO-Identifier 924 RxPDO1-Identifier...

  • Page 49: Ancillaries

    5.14 Ancillaries For the planning of the system bus according to the drive tasks in question, there are ancillaries in the form of tables. The planning of the system bus is done in three steps: 1. Definition of the communication relationships 2.

  • Page 50: Definition Of The Communication Relationships

    5.14.1 Definition of the communication relationships The communication relationships are planned and documented with the help of the table. The table is available as a Microsoft Word document "kbl.doc" on the VECTRON product CD or upon request. EM-RES-03 10/07 EM-RES-03...

  • Page 51: Production Of The Virtual Links

    5.14.2 Production of the virtual links The virtual links are planned and documented with the help of the table. The table is available as a Microsoft Word document "vvk.doc" on the VECTRON product CD or upon request. 10/07 EM-RES-03 10/07...

  • Page 52: Capacity Planning Of The System Bus

    5.14.3 Capacity planning of the system bus Each PDO telegram possesses a constant useful data content of 8 Bytes. According to worst case, this results in a maximum telegram length of 140 bits. The maximum tele- gram run time of the PDO’s is thus stipulated via the set baud rate. Capacity planning Baud rate / Telegram run time /...
  • Page 53 The capacity planning are planned and documented with the help of the table. The work sheet is available as a Microsoft Excel document "Load_Systembus.xls" on the VECTRON product CD or by request. Load system bus Baud rate [kBaud]: 1000 50, 100, 125, 250, 500, 1000...

  • Page 54: Control Inputs And Outputs

    Control inputs and outputs Analog input EM-S1INA 6.1.1 General The analog input of the EM-RES-03 expansion module can optionally be configured as a voltage or a current input. Parameterization of the input signal is done by the defini- tion of a linear characteristic and assignment as a reference value source −...

  • Page 55: Operation Modes

    6.1.3 Operation modes The operation modes of the analog input characteristic enable application-related scal- ing as a supplement to the characteristic points stated. One of the four linear types of characteristic is selected for adaptation of the signal for the analog input signal via the Operation mode parameter 562.
  • Page 56 Operation mode "11 – unipolar" In operation mode "11 – unipolar“, the characteristic points are displaced to the origin of the characteristics with a negative value for the X-axis. Characteristic point 1: X1 = -70.00% · 10 V = -7.00 V (X2=80% / Y2=85%) Y1 = -50.00% ·...
  • Page 57 Operation mode "21 – unipolar 2…10 V / 4…20 mA" This operation mode limits the input characteristic to the range between 20% and 100% of the analog signal. If the value for a characteristic point of the X-axis is out- side 0%, it is mapped to the characteristic point (2 V / 0 Hz).

  • Page 58: Scaling

    Operation mode "101 – bipolar absolute value" The operation mode "101 – bipolar absolute value“ maps the bipolar analog signal onto a unipolar input characteristic. The formation of the absolute amount takes the characteristic into account comparable to the "bipolar" operation mode, but the char- acteristic points are reflected on the X-axis with a negative value for the Y-axis.

  • Page 59: Tolerance Band And Hysteresis

    6.1.5 Tolerance band and hysteresis The analog input characteristic with change of sign of the reference value can be Tolerance band adapted by the parameter 560 of the application. The tolerance band to be defined extends the zero crossing of the speed relative to the analog control signal.

  • Page 60: Error And Warning Behavior

    6.1.6 Error and warning behavior The monitoring of the analog input signal necessary according to the application is to Error/Warning behavior be configured via the parameter 563. Operation mode Function 0 - Off The input signal is not monitored. If the input signal is less than 1 V or 2 mA, there 1 - Warning <...

  • Page 61: Adjustment

    6.1.7 Adjustment As a result of component tolerances, it can be necessary to adjust the analog input. Adjustment Parameter 568 is used for this purpose. Operation mode Function 0 - no adjustment Normal operation Adjustment of the measurement with an analog 1 - Adjustment 0 V / 0 mA signal of 0 V or 0 mA.

  • Page 62: Digital Outputs Em-S1Outd And Em-S2Outd

    Digital outputs EM-S1OUTD and EM-S2OUTD 6.2.1 General Parameterization of this digital output permits a linking to a variety of functions. The selection of functions depends on the parameterized configuration. 6.2.2 Operation modes The operation mode of the digital output EM-S1OUTD (terminal X410A.3) is selected Operation Mode EM-S1OUTD via the parameter 533.

  • Page 63: Digital Inputs Em-Sxind

    Digital inputs EM-SxIND The EM-RES-03 expansion module has three digital inputs. The assignment of the control signals to the available software functions can be adapted to the application in Configuration question. As a function of the selected 30, the factory-set assignment and the selection of the operation mode differ.

  • Page 64: Resolver Input Em-Res

    Resolver input EM-RES The resolver input is used for evaluating the position information from the resolver. The frequency of the field signal for the resolver is set to the fixed value of 8 kHz. If the no. of resolver pole pairs > 1, the measured electric angle runs through the range of 0°...360°...
  • Page 65 Before adjusting the offset, take the following safety precautions: • Disable the frequency inverter via the digital inputs for controller release. • If possible, uncouple the motor from the load so that the motor shaft turns freely. If installed, release the mechanical brake. If uncoupling is not possible, make sure that the motor is loaded as little as possi- ble.
  • Page 66 Depending on the behavior of the motor after start, carry out the following steps: Motor does not turn, or the motor shaft only turns to a new position and − stops again: No. of Pole Pairs No. of Pole Check if the parameters 373 for the motor and •...

  • Page 67: Actual Speed Source

    RES-03 expansion module. 6.4.3 Evaluation mode If a synchronous motor which is not from BONFIGLIOLI should be connected to the resolver input it can be necessary to change the sign of the sinus track. This can be set Evaluation Mode via parameter 492.

  • Page 68: Status Of The Digital Signals

    Status of the digital signals Digi- The status of the digital signals can be read in decimal coding via the parameters tal inputs Digital outputs 250 and 254. The display of the digital input signals enables checking the various control signals and their connections with the software functions in question, in particular in commissioning.

  • Page 69: Motor Temperature

    Motor temperature Temperature monitoring forms part of the configurable error- and warning behavior. The connected load can be monitored by connecting a measuring resistor (motor PTC) with temperature characteristics according to DIN 44081 or by means of a bimetal tem- perature sensor (break contact).

  • Page 70: Parameter List

    Parameter list The parameter list is structured according to the menu branches of the control unit. For better clarity, the parameters are marked with pictograms: The parameter is available in the four data sets The parameter value is adjusted by the SETUP routine if a control method for a onfiguration synchronous machine is selected for parameter C This parameter cannot be written in the operation of the frequency inverter...
  • Page 71 System bus Description Unit Display range Chapter 923 SDO2 Set Active Selection 5.9.4 924 RxPDO1-Identifier 0 ... 2047 5.11.1 925 TxPDO1-Identifier 0 ... 2047 5.11.1 926 RxPDO2-Identifier 0 ... 2047 5.11.1 927 TxPDO2-Identifier 0 ... 2047 5.11.1 928 RxPDO3-Identifier 0 ... 2047 5.11.1 929 TxPDO3-Identifier 0 ...

  • Page 72: Annex

    Annex Error messages The various control functions and methods and the hardware of the frequency inverter contain functions which continuously monitor the application. As a supplement to the messages documented in these operating instructions, the following failure keys are activated by the EM-RES-03 expansion module. Control connections Resolver synchronization not successful.
  • Page 74 Bonfiglioli has been designing and developing innovative and reliable power transmission and control solutions for industry, mobile machinery and renewable energy applications since 1956. www.bonfiglioli.com Bonfiglioli Riduttori S.p.A. VEC 546 R0 tel: +39 051 647 3111 fax: +39 051 647 3126 Via Giovanni XXIII, 7/A bonfiglioli@bonfiglioli.com...

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