Bonfiglioli EM-IO-04 Expansion Module

Bonfiglioli EM-IO-04 Expansion Module

EM-IO-04 is a pluggable option board for Bangfeili's ACTION (ACT) and ACTION Cube (ACU) frequency converters; The ACT frequency converter requires firmware version ≥ 4.2.1 and supports all ACU versions. The module provides electrical isolation CAN HighSpeed system bus, multi-channel digital IO, and motor temperature detection interface (PTC/KTY). The module can be directly inserted into the bottom slot of the frequency converter without the need for tools; Cannot be used simultaneously with CM-CAN. If CM-CAN is installed, the CAN interface of EM-IO-04 will be automatically disabled. The document includes safety specifications, mechanical and electrical installation, CAN system bus protocol, IO functions, parameters, and fault codes.

Safety instructions

The operators must be professionals with qualifications for frequency converters and comply with standards such as EN 50178 and IEC 60364.

The disassembly and assembly module must be completely powered off, and after the power is turned off, wait for the DC bus capacitor to fully discharge to prevent residual high voltage electric shock.

Transportation and storage: Use original packaging, dry and dustproof, store for up to 1 year without power supply; Static protection: It is prohibited to touch the PCB circuit board with bare hands.

The module belongs to the internal components of the whole machine, and the whole machine must meet the EU Machinery Directive, Low Voltage, and EMC Directive before it can be put into operation.

2、 Hardware Overview

1. Mechanical installation

Disconnect the power supply of the frequency converter and remove the lower cover plate of the frequency converter;

Align the EM-IO-04 module with the bottom slot and insert it;

Restore the cover plate; The power on module is ready.

2. Terminal and onboard dip switch

Connectors: X410A (digital input, 20V power supply), X410B (temperature, configurable digital port, CAN bus)

EM-S2IND, EM-S3IND: 2-channel independent digital input; Parameter selection: PNP (high effectiveness)/PNP (low effectiveness); The maximum voltage is 30V, with a response of approximately 16ms.

EM-S1IOD: 1-channel configurable digital port, software options for input or output; Output mode is 24V/maximum 40mA.

EM-MPTC/EM-KTY: Motor temperature detection, choose one of dialing S3

PTC thermistor/bimetallic normally closed contact (DIN44081, trigger resistance>2.4-k Ω);

KTY84-130 semiconductor temperature sensor, temperature measurement -20~200 ℃.

CAN system bus: Optically isolated CAN High Speed (ISO DIS 11898), X410B terminals: CAN Low, CAN High, CAN GND.

Dial switches S1 and S2: CAN terminal resistors

S1=ON, S2=OFF: Passive terminal (commonly used at both ends of the bus)

S1+S2 simultaneous ON: active terminal, only one active terminal can be enabled in the entire CAN network

S3: Select PTC/KTY as the temperature sensor type.

3. Hardware requirements for CAN bus

Cable: Braided shielded twisted pair; Both ends of the shielding layer are extensively connected to the PE protective ground; Power cables and communication cables are physically routed separately.

Baud rate and maximum cable length

Maximum cable length for baud rate

50 kBaud 1000 m

100 kBaud 800 m

125 kBaud 500 m

250 kBaud 250 m

500 kBaud 100 m

1000 kBaud 10 m

Less than 50 kBaud throughput is too low and not recommended for use.

Parameter 900 Node ID Node Address

-1: CAN bus turned off (factory default)

0: This machine is a CAN system bus master station, and the entire bus can only have one master station

1-63: Slave station; The bus supports a maximum of 1 master and 63 slaves.

CANopen compatible system bus with complete functionality

The bus follows the CiA DS301 specification, supports NMT network management, Boot up power on messages, Emergency fault messages, SDO parameter read and write, PDO process data, and supports Bangfeili's unique virtual link Virtual Links to achieve high-speed data exchange between multiple frequency converters (multi axis synchronization, electronic gears).

1. NMT Network Management

Node has three states: Pre Operational (SDO parameter read-write, PDO invalid), Operational (SDO+PDO all available), and Stopped (all communication disabled).

The main station issues the NMT command to complete the node state switch; Support Boot Up Delay (parameter 904) delay and adapt to differences in slave initialization time.

2. SYNC synchronization message

The main station periodically sends SYNC messages to synchronize the PDO sampling time of the entire network, achieving strict multi axis synchronization.

Parameter 918 SYNC Identifier sets SYNC message ID, 0=standard predefined ID=128; Set the sending cycle for parameter 919 SYNC Time; 0 represents not sending SYNC.

3. Emergency fault message

Automatically send an Emergency message when a fault occurs at the slave station, ID=128+Node‑ID。 Parameter 989 Emergency Reaction configuration main station behavior:

0-Error: Upon receiving a fault message, the master station directly shuts down due to a fault, reporting fault code F21xx, where xx is the node number of the faulty slave station;

1-No Error: Only an alarm, the main station continues to operate, and the SysbusEmergency Boolean flag is set.

4. SDO service (Client Server, parameter read-write channel)

SDO1: Used for PLC/main station frequency converter to access all slave station parameters; Support accessing nodes on the CAN bus through Profibus DP and RS232/485 transparent transmission.

SDO2: Specially reserved for VPlus visual debugging software, SDO2 can be parameterized to improve standard CANopen compatibility.

Only supports int/uunt/long values, not string parameters; Use Expedited to accelerate SDO; The document fully defines the SDO read-write message format and abort error code.

5. PDO process data (real-time control channel)

Each device can have up to 3 sets of TxPDO (transmit) and 3 sets of RxPDO (receive), with a maximum of 8 bytes of valid data per PDO.

Two triggering modes

Time triggered: automatically sent according to the set cycle;

SYNC trigger: Send and receive SYNC messages only after receiving them, used for multi axis synchronization.

Timeout monitoring: parameter RxPDOx Timeout, non-zero enables timeout detection; Report fault F2200 (SYNC timeout) and corresponding RxPDO1-3 timeout for F2201-F2203.

Virtual Links (a feature of Bangfeili) does not use standard CANopen object dictionary mapping, but uses Source Number to achieve cross device data binding:

TxPDO: Assign the internal signal (control word, frequency setting, IO status) source number to the byte of TxPDO and send it out via the CAN bus;

RxPDO: The data received on the bus is mapped to the local source number and directly assigned to the internal control parameters of the frequency converter;

Supports Boolean, 16 bit Word, 32-bit Long; Implement a frequency converter to issue speed commands and control words to multiple slave machines, completing electronic gear synchronization.

Provide planning assistance documents: kbl.doc communication relationship table, vvk.doc virtual link configuration table, Load_Systembus.xls bus load calculation table.

Bus load design rules: OK for total load ≤ 80%; critical for 80-90%; >90% is not allowed.

6. BUS OFF bus disconnection protection

Serious errors in the physical layer trigger BUS OFF fault F2210, causing the module to automatically reinitialize the CAN controller and the node to resend Boot up messages.

IO and temperature detection function

1. Digital inputs EM-S2IND, EM-S3IND

Configurable PNP high effective/NPN low effective logic;

Expand 8 sets of fixed frequency sources (fixed frequencies 5-8) to achieve multi-stage speed switching with terminals;

The input state can be read as decimal state value through parameter 250 (Digital inputs), and each bit can be parsed to obtain the voltage level of each terminal.

2. Configurable digital port EM-S1IOD

Software parameter selection input mode or output mode; The output mode can be bound to logical events such as internal alarms and operating status of the frequency converter.

3. Motor temperature acquisition EM-MPTC/EM-KTY (switch by dialing S3)

PTC/bimetallic contact mode: Overtemperature directly triggers fault F0400 motor overheating shutdown.

KTY84-130 mode: real-time reading of winding temperature (parameter 226 Winding Temperature, unit ℃); Provide multiple action modes: alarm only, immediate fault shutdown, and fault shutdown after a delay of 1/5/10 minutes.

Fault code F0400: Motor overheating; F1450: KTY sensor wiring fault.

4. Actual value monitoring menu VAL

It can be directly read on the frequency converter panel KP500 or VPlus software: digital input, digital output, motor winding temperature, Node State node status, CAN State physical bus status.

Summary of key parameters and faults

Core parameters of system bus: Node‑ID (900)、Baud‑Rate (903)、Boot‑Up Delay (904)、SYNC‑Identifier (918)、SYNC‑Time (919)、 Each SDO, PDO identifier, PDO cycle, timeout parameter.

IO parameters: fixed frequency, digital port mode, motor temperature action mode 570.

Main fault codes

Meaning of fault code

F0400 motor overheating (PTC/KTY)

F1450 KTY sensor wiring/hardware failure

F21nn slave node nn has malfunctioned

F2200 SYNC message timeout

F2201-F2203 RxPDO1-3 reception timeout

F2210 CAN bus BUS OFF

Attention: Comparison of EM-IO-04 and EM-ENC-02 functions analyzed earlier

EM-ENC-02: CAN bus+incremental encoder interface+analog input/output+PTC;

EM-IO-04: CAN bus+3-channel digital IO+PTC/KTY temperature acquisition, no encoder, no analog IO.