Bonfiglioli EM-IO-04 Expansion Module

Overview of Hardware Resources

A plug-in option board for power-off plugging, inserted into the lower slot of the frequency converter, and automatically recognized when powered on. Hardware List:

CAN HighSpeed system bus (ISO-DIS 11898, up to 1 Mbaud), optocoupler electrical isolation (EM-IO-01-03 no isolation)

EM-S1IOD: Configurable bidirectional digital port (software parameter switching DI input/DO output)

DI mode: maximum frequency of 150 kHz;

DO mode: 24V output, maximum 40mA;

2-channel universal digital input EM-S2IND/S3IND; The software can switch PNP (high effective)/PNP (low effective) logic, with a maximum input frequency of 1kHz;

Multi functional motor temperature interface EM-MPTC/EM-KTY (dialing S3 switching mode)

S3 right position: PTC thermistor (DIN44081, action>2.4k Ω)/bimetallic normally closed hot contact; Implement over temperature threshold protection;

S3 left: KTY84-130 linear temperature sensor; Continuous temperature measurement from 20 ℃ to 200 ℃, capable of participating in motor parameter temperature adaptation.

Hardware conflict reminder: If other CAN controller options (CM-CAN) are installed at the same time, the CAN bus of EM-IO-04 will be automatically disabled.

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

X410A

Pin function

1+20V output, maximum 180 mA

2 20V‑GND

3 DI2 EM‑S2IND

4+20V output

5 20V‑GND

6 DI3 EM‑S3IND

7+20V output

X410B

Pin function

1-2 EM-MPTC/EM-KTY motor temperature detection (dial S3 to select sensor type)

3 EM-S1IOD configurable bidirectional IO (DI/DO)

4 20V‑GND

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 in the entire network is allowed to enable active terminals; All products are turned off at the factory.

S3: Temperature input mode switching; Right=PTC/bimetallic contact; Left=KTY84-130 linear temperature sensor.

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; Static sensitive devices are prohibited from touching PCB circuit boards with bare hands; Only licensed professional electricians are allowed to operate.

Storage: Original factory packaging, dry and dust-proof, non powered storage for up to 1 year, in accordance with EN50178 standard.

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

Electrical wiring: Control wires 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

Following CANopen CiA DS301, linear bus topology, supporting master/slave mode.

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 10 m

2. Communication channel model

SDO channel (parameter read-write, Client Server model)

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

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

Only supports uint/int/long data types; String parameters are not supported; Expedited SDO protocol.

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

Trigger mode: time triggered/SYNC synchronization message triggered;

Virtual links (a feature of Bangfeili): Source Number mechanism, allowing real-time data exchange between multiple frequency converters without the need for PLC; Support one-to-one and one to many broadcasting; Equipped with PDO and SYNC message timeout monitoring, triggering faults upon timeout.

NMT network management: nodes in three states: Pre Operational, Operational, and Stopped; Only the Operational PDO process data is valid.

SYNC synchronization message: The master station periodically sends and synchronizes all slave station PDOs.

Emergency message: The slave station automatically reports an alarm due to a fault; Parameter 989: Configure the main station to “stop” or “only alert” after receiving an emergency message.

3. Bus planning tool

Supporting documents: kbl.doc communication relationship definition; VVK.doc virtual link configuration; Load_Systembus.xls bus load rate calculation; The total bus load is recommended to be ≤ 80%, and cannot be put into use if it exceeds 90%.

The KP500 panel can only view the bus status; CAN advanced configuration requires VPlus software to load XPI configuration files.

Detailed explanation of IO and temperature detection functions

4.1 EM-S1IOD Bidirectional Configurable Port (Parameter 558 Select Mode)

Mode 0=Digital Input DI: up to 150 kHz, capable of receiving high-speed pulse signals; The signal source can take the original signal or the reverse signal.

Mode 1=Digital output DO: 24V, maximum output 40   mA; maps the internal operation, faults, and reaching given states of the frequency converter.

4.2 EM-S2IND/S3IND Two channel Universal Digital Input

Parameters can switch between PNP (high level effective)/NPN (low level effective) logic; The maximum input frequency is 1kHz.

Used for fixed frequency FF5-FF8 selection, supporting original logic/anti logic reading.

All digital input states can be read through parameter 250 (decimal) and converted into binary to parse each IO state.

4.3 Multi functional temperature input for motor EM-MPTC/EM-KTY

Dial S3 hardware to switch sensor types, set parameter 570 for fault behavior.

PTC thermistor/bimetallic normally closed contact (S3 right)

Action threshold>2.4   k Ω; protection mode: only alarm, immediate fault shutdown F0400; Delay by 1 minute/5 minutes/10 minutes for fault shutdown.

KTY84-130 linear temperature sensor (S3 left)

Measurement range -20 ℃~+200 ℃; Parameter 226 can directly read the actual temperature of the winding;

Parameter 617 sets the maximum allowable temperature for the winding; Support only alarm, immediate shutdown, and delayed shutdown;

The measured temperature can be used for temperature adaptation of internal control parameters of the frequency converter, optimizing the performance of magnetic field orientation control.

Parameter Overview

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

VAL actual monitoring

226 winding temperature (effective in KTY mode);

250 digital input status, 254 digital output status;

978 Node State node status; 979 CAN State bus physical status.

PARA setting parameters

Bidirectional IO: 558 port mode, 559 output mapping;

Digital input logic; Expand fixed frequency FF5-FF8 parameters;

Temperature: 570 temperature protection behavior; 617 motor winding maximum temperature;

Complete set of CAN bus: node ID, baud rate, startup delay SYNC、SDO、 All PDO identifiers, PDO modes, timeouts, and virtual link source number mapping parameters.

The KP500 operation panel can only read the basic status; The vast majority of CAN advanced configurations can only be accessed by loading XPI configuration files into VPlus software.

Fault code

IO&temperature related faults

F04-00: Motor overtemperature fault (triggered by PTC/KTY)

F14-50: EM-KTY temperature measurement hardware failure; Prompt to verify the position and wiring of dialing code S3.

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; The module detects BUS OFF and will automatically reinitialize the CAN bus.