Bonfiglioli EM-IO-03 Expansion Module

Overview of Hardware Resources

Pluggable option board, inserted into the lower slot of the frequency converter when powered off, automatically recognized when powered on. Hardware List:

CAN HighSpeed system bus (ISO DIS 11898, up to 1 Mbaud)

1-way bipolar analog input EM-S1INA (12 bit, ± 10   V voltage/± 20   mA current, switch mode by dialing S3)

Two analog outputs

EM-S1OUTA: Voltage output ± 10   V, maximum 2   mA, short circuit protection

EM-S2OUTA: Current output 0 (4) -20 mA, overload short circuit protection (EM-IO-01/02 has no current output)

2-channel digital input EM-S2IND/S3IND; Can be used as a second incremental encoder speed sensor (up to 150 kHz)

1 relay normally open output EM-S1OUTD (24V AC/DC, resistive load 1A)

EM-MPTC motor PTC thermistor interface (DIN44081, action threshold 2.85   k Ω; compatible with bimetallic normally closed hot contacts)

Hardware conflict: If other CAN controller options (CM-CAN) are installed at the same time, the CAN bus function of EM-IO-03 will be automatically disabled.

Terminal definition (Wieland DST85/RM3,5, tightening torque 0.2-0.3 Nm)

X410A

Pin function

1+20V output, maximum 180mA

2 20V‑GND

3 EM-S2OUTA current output 0 (4) -20 mA

4 DI2 EM‑S2IND

5 DI3 EM‑S3IND

6-7 relay output EM-S1OUTD (normally open)

X410B

Pin function

1-2 EM MPTC motor PTC temperature detection input

3 Analog inputs EM-S1INA (voltage/current)

4. Analog voltage output EM-S1OUTA ± 10V

5 CAN‑Low

6 CAN‑High

7 CAN‑GND

Onboard dip switch S1/S2/S3

S1, S2: CAN bus terminal resistance; Passive terminal S1=ON, S2=OFF; Active terminals S1&S2 are simultaneously turned on; only one module is allowed to turn on the active terminal in the entire network; All products are turned off at the factory.

S3: Analog input mode; OFF=voltage ± 10   V; ON=current ± 20   mA.

Safety, storage and transportation, mechanical and electrical installation

Safety red line: Disassembly and assembly of modules must be completely powered off and wait for the DC bus capacitor to fully discharge; Belonging to electrostatic sensitive devices, it is prohibited to touch the PCB circuit board with bare hands; Only licensed professional electricians are allowed to work.

Storage: The original packaging is dry and dust-proof, and can be stored for up to 1 year without electricity, following the EN50178 standard.

Mechanical installation: Remove the lower cover plate of the frequency converter, insert the module directly into the lower slot, and restore the cover plate; Ready to power on.

Electrical: Control lines must be unplugged and unplugged when powered off; The CAN bus adopts braided shielded twisted pair cables; Physical isolation between power cables and communication cables; Both ends of the shielding layer are extensively grounded with PE.

CAN System Bus (completely consistent with EM-IO-01/02 architecture)

Following the CANopen CiA DS301 specification, with a linear topology, supporting master/slave modes.

1. Core configuration parameters

900 Node – ID Node Address: -1=Bus shutdown; 0=This machine serves as the main station; From station 1 to 63; A single network can have a maximum of 63 slave stations and 1 master station.

903 Baud Rate Baud Rate

Maximum baud rate bus length

50 kBaud 1000 m

100 kBaud 800 m

125 kBaud 500 m

250 kBaud 250 m

500 kBaud 100 m

1000 kBaud 25 m

2. Communication channel model

SDO channel (parameter read-write, Client Server)

SDO1: The upper/master frequency converter accesses all slave parameters; Supports Profibus DP and RS232/485 transparent transmission to access bus nodes.

SDO2: Reserved for visual debugging tools, can be parameter disabled to avoid compatibility conflicts.

Only supports the uint/int/long data type, string parameters are unreadable and non writable, using the Expedited SDO protocol.

PDO channel (real-time process data): 3 sets of TxPDO (transmit) and 3 sets of RxPDO (receive) for each frequency converter

Trigger mode: time triggered/SYNC synchronization message triggered;

Virtual links: Bangfeili custom source number Source Number mechanism; Real time process data can be directly exchanged between frequency converters without the need for a PLC; Support one-to-one and one to many broadcasting; Equipped with PDO and SYNC timeout monitoring, reporting faults when exceeded.

NMT network management: There are three states for nodes: Pre Operational, Operational, and Stopped; Only the Operational status PDO is effective.

SYNC synchronization message: The master station periodically sends out synchronization messages to all slave stations PDO.

Emergency message: Automatic reporting of slave station faults; Parameter 989: Configure the main station to “stop” or “only alert” after receiving an emergency message.

3. Bus planning tool

Supporting document: kbl.doc communication relationship definition; VVK.doc virtual link configuration; Load_Systembus.xls bus load calculation table; The recommended total bus load is ≤ 80%; 90% unavailable.

The KP500 panel can only view the bus status; CAN advanced configuration can only be completed by loading XPI configuration files using VPlus software.

IO Function Detailed Explanation 

4.1 Analog Input EM-S1INA (12 bit)

Dial code S3 to switch voltage/current; Can be used as a frequency setting, percentage setting, and limit source.

4 input characteristic modes: 1- Bipolar; 11- Monopolar; 21- Industrial sensor mode (2-10V/4-20mA); 101- Absolute bipolar.

Two point custom calibration X1/Y1, X2/Y2; Support tolerance bands, hysteresis, and low-pass filtering time constants.

Fault monitoring: If the signal is below 1V/2mA, warning, deceleration shutdown, and free shutdown can be configured; Support hardware zero point and full-scale calibration.

4.2 Analog voltage output EM-S1OUTA

Output ± 10   V; map speed, analog input absolute value and other signals; Support offset, amplification, and hardware zero gain calibration.

4.3 Analog current output EM-S2OUTA (newly added in EM-IO-03)

Output 0 (4) -20 mA, overload and short circuit protection; Support offset, amplification, hardware zero/full-scale calibration; It can output actual speed, given value, analog input absolute value, etc.

4.4 Digital Input EM-S2IND/S3IND

Universal DI: Extended fixed frequency FF5-FF8 selection.

Second incremental encoder (speed sensor 2): S2IND=phase A, S3IND=phase B; Up to 150 kHz; Four fold frequency evaluation; Can be used as an actual speed feedback source for speed closed-loop; Detect encoder disconnection and phase sequence errors, and output corresponding faults.

4.5 Relay output EM-S1OUTD

Single channel normally open relay, software mapping of the internal status of the frequency converter (running, faulty, reaching given, etc.).

4.6 EM-MPTC Motor PTC Temperature Input

Supports DIN44081 standard PTC thermistor (action 2.85   k Ω), compatible with bimetallic normally closed thermal protection contacts. Parameter 570 provides multiple protection strategies: alarm only; Immediately shut down F0400 due to malfunction; Delay 1/5/10 minutes for fault shutdown; The fault can be reset through panel or digital input.

Parameter Overview

Divided into VAL (Actual Value Monitoring Menu) and PARA (Parameter Setting Menu)

VAL actual monitoring: second encoder frequency/speed, analog input%, two analog outputs (voltage V, current mA), DI/DO status, CAN node status, CAN physical layer status.

PARA setting parameters

AI: feature points, patterns, filtering, tolerance bands, fault behavior, hardware calibration;

AO (voltage+current two-way): mode, offset, amplification, hardware calibration;

DI、 Second encoder: number of encoder lines, working mode;

PTC temperature protection: protection mode selection;

CAN bus complete set of parameters: node ID, baud rate, startup delay, SYNC, SDO/PDO identifier, PDO mode, timeout, all virtual link mapping parameters.

Most of the CAN advanced parameters KP500 panel are not visible and can only be enabled through VPlus software and XPI configuration files.

Fault Code 

IO local fault

F14-02: Analog input signal fault

F14-30: Speed sensor 2 malfunction

F14-31: Encoder is missing one phase

F14-32: Encoder phase sequence error

F14-33~35: Encoder line configuration error

F0400: EM-MPTC motor overheating fault

CAN system bus fault

F21-nn: Report fault from station nn;

F22-00: SYNC message timeout;

F22-01~03: RXPDO1-3 received timeout;

F22-10: Bus BUS OFF; After BUS OFF, the module automatically reinitializes the CAN bus.