Bonfiglioli EM-SYS System Bus Expansion Module

Bonfiglioli EM-SYS System Bus Expansion Module

ACT/ACU (ACTION/ACTIVE Cube) frequency converter; ACT requires firmware version ≥ V4.1.0. EM-SYS is a lower level slot option for the frequency converter, which implements the CAN HighSpeed (ISO 11898) system bus and is compatible with the CANopen basic framework; Can perform high-speed peer-to-peer data exchange (virtual link, master-slave synchronization) between multiple frequency converters.

Security and Document System

Safety Rules

The disassembly module must be completely powered off and wait for the DC bus capacitor to discharge for a few minutes; Sensitive to static electricity, do not touch the components on the back of the PCB, and operate with a certified electrician.

Storage conditions: The original packaging is dry and dust-proof, and it can be stored without electricity for up to 1 year.

Modules are optional and can be inserted into dedicated slots at the lower level; System bus failure may cause the motor to start unexpectedly, and external safety protection must be added.

Document positioning: This manual only describes the EM-SYS hardware and system bus protocol, and does not repeat the operation of the inverter body; The entire set of documents includes a quick start guide, a complete machine operation manual, and an application manual.

Core Competence

CAN High Speed physical layer, up to 1Mbit/s;

Support one frequency converter as the System Bus Master system bus master and the rest as slave stations;

Support SDO parameter read and write, PDO process data, NMT network management, SYNC synchronization message, Emergency message;

Virtual Links: Multiple frequency converters can directly exchange control words, given values, and actual values without the need for a higher-level PLC relay;

The master station can access all CAN slave station parameters on the bus through the local Profibus DP/RS232 485 transparent transmission.

Mechanical and Electrical Installation

Power off during mechanical installation, remove the lower cover plate of the frequency converter; EM-SYS is inserted into the dedicated slot at the lower level; Lock and restore the cover plate. Prohibit live plugging and unplugging; Do not touch the back of the circuit board.

Terminal X410B (pluggable Wieland terminal, torque 0.2-0.3Nm)

Terminal signal description

4 GND CAN‑GND

5 CAN‑Low CAN‑L

6 CAN‑High CAN‑H

7 PE shielding protection ground

Terminals 1-3 are empty and have no function.

Bus terminal dialing S1/S2 (module body)

S1=ON, S2=OFF: Passive terminal (conventional, recommended)

S1=ON, S2=ON: Active terminal, only one node on the entire bus can open the active terminal.

✅ Rule: The first and last nodes of the bus physics should have their terminals turned on, and all nodes in the middle should be turned off; Both S1 and S2 are turned off at the factory.

Cable requirements: CAN Bus dedicated twisted pair shielded cable; Large areas of PE are connected at both ends of the shielding layer; power cables and communication cables are physically separated and routed.

Basic configuration of system bus interface

Baud rate parameter 903 (the baud rate of all nodes on the bus must be exactly the same)

Maximum baud rate bus length

50kBaud 1000m

100kBaud 800m

125kBaud 500m

250kBaud 250m

500kBaud 100m

1000kBaud 25m

It is not recommended to use below 50k as the throughput is too low.

Node Address Node ID Parameter 900

-1: Disable system bus (factory default)

0: As the system bus MASTER master station, this machine only allows one master station per bus

1-63: Slave node; The bus can have a maximum of 63 slave stations and 1 master station.

Protocol foundation (based on CiA DS301 CANopen subset)

Message Addressing: Based on CAN identifiers, not node IDs; supports producer consumer mode, with multiple nodes receiving a single message.

After power on, all slave stations enter the Pre Operational state; Switching the NMT command of the main station to Operational operation is required for PDO process data exchange.

Support NMT network management, Boot Up power on reporting, and Emergency fault messages.

Network management NMT, master/slave station functions

4.7 Node Status

Pre Operational: SDO parameter read and write available; PDO process data is not working.

Operational operation: SDO+PDO are all available and data exchange is normal.

Stopped: SDO and PDO are all disabled.

4.8 Master station capability (frequency converter with Node-ID=0)

Boot Up Delay parameter 904:3500~50000ms; power on delay automatically sends NMT "Start Remote Node" to switch all slave stations to Operational.

Generate SYNC synchronization message (parameter 918 identifier, 919 SYNC cycle ms; 0=SYNC off); Used for multi node synchronous PDO sampling.

Receive and process all Emergency fault messages from slave stations; Parameter 989 Emergency Reaction

0-Error: Received fault message, the main station stopped directly and reported fault F21xx (xx is the ID of the faulty slave station)

1-No Error: Only the warning bit SysbusEmergency (source 730) is generated, and the main station does not shut down.

Transparent gateway function: The master station has a Profibus DP/CM-232-485 interface, which allows direct access to any slave station SDO parameters on the CAN bus without the need for a PLC to directly connect to CAN.

4.9 Slave Slave Slave Function (Node ID 1-63)

Automatically send Boot Up message when powered on; Waiting for the NMT command from the main station to enter Operational.

Immediately send an Emergency message (8 bytes, compatible with CANopen fault codes and Bangfeili custom fault codes) for local faults; Send an all zero Emergency message after fault reset.

SDO parameter channel

SDO: Used for reading and writing frequency converter parameters; Client Server model; Each device has two SDOs: SDO1 (fieldbus/PLC) and SDO2 (visualization tool).

SDO Expedited fast transfer mode, supporting int/int (16 bit) and long (32 bit); The string parameter cannot be accessed.

Index=parameter number; Sub Index=Dataset Number.

Write SDO Download; Read SDO Upload; Exception returns Abort termination code.

Identifier: 0=using pre-defined CANopen connection set; Customizable RxSDO1/TxSDO1 identifiers (parameters 921, 922). SDO2 can be turned on/off through parameter 923.

Key points of gateway transparent transmission

Profibus DP (PKW channel): Fill in Byte3 of the PKW into the target CAN slave node ID; 0 accesses the main site local machine.

VABus (CM-232/485): Fill in the target CAN slave Node ID in the header byte of the message.

As a gateway, the master station only needs to communicate with the master station to read and write all the parameters of the slave stations on the entire CAN system bus.

SDO abort error codes: illegal parameter number, parameter read-only, dataset error, EEPROM read-write error, running status prohibits parameter writing, etc.

PDO process data channel

Each frequency converter provides 3 sets of PDOs (TxPDO1-3 for transmission and RxPDO1-3 for reception), with a fixed 8-byte payload for each set of PDOs.

Do not use CANopen standard PDO mapping objects; Bangfeili uses Source code+Virtual Links to configure PDO content.

6.1 PDO Basic Configuration

Identifier: Parameters 924-929; If set to 0, use CANopen predefined identifier.

PDO trigger mode (independently configured for each group)

Time Controlled: TxPDO automatically sends according to the set cycle triggered by time; RxPDO takes effect immediately upon receiving the data. TxPDO time parameter 931/933/935 (in ms).

SYNC synchronization trigger: After receiving the SYNC message from the main station, sample and send/receive it uniformly; Multi axis synchronous application.

Timeout monitoring: SYNC Timeout (939), RxPDO1-3 Timeout (941-945); 0=Close monitoring; Overdue fault: F2200 (SYNC timeout), F2201-03 (PxPDO timeout).

6.2 Virtual Links [The biggest feature of this module]

TxPDO (local transmission): Fill in the source number Source Number as the configuration parameter, and map the internal signals of the local machine (control word, status word, frequency, current, DI/DO, etc.) to the 8-byte payload of TxPDO (supporting 4 Bool/4 Word/2 Long mixed). Parameters 946-977 correspond to the byte positions of TxPDO1-3.

RxPDO (local reception): Receive PDO message on the bus and generate a new RxPDO source number (700-729); The internal function input of the frequency converter directly references these source numbers, without the need for PLC relay, and data is exchanged directly between frequency converters.

Example: The # 1 frequency converter sends the control word and frequency reference to TxPDO1; #The control word input and slope setting of the 2/# 3 frequency converter are directly bound to the source number corresponding to RxPDO1 to achieve multi axis following.

Data types: Bool (2 bytes), Word/Int16 (2 bytes), Long/Int32 (4 bytes); 8-byte total length limit.

A large number of built-in source numbers: digital input/output, control word STW, status word ZSW, output frequency, percentage setting, fault warning bit, etc.

6.3 Bus load calculation

The manual provides calculation tables; The recommended total bus load is ≤ 80%; 90% of the system is unreliable; You can use the accompanying Excel tool Load_Systembus.xls for evaluation.

Key parameter list

Basic bus parameters

Parameter meaning factory

900 Node‑ID， Disable 1, 0 master station, 1-63 slave stations -1

903 Baud Rate Baud Rate

904 Boot Up Delay Main station startup delay 3500ms

918 SYNC Identifier SYNC Message ID 0 (pre-defined)

919 SYNC Time SYNC cycle 0 off

989 Emergency Reaction fault handling mode 0

PDO related

TxPDO Function (930/932/934): trigger mode; TxPDO Time (931/933/935) transmission cycle

RxPDO Function (936-938) receiving mode; Timeout timeout parameter 939941-945

946-977: TxPDO1-3 Boolean/Word/Long mapping parameters

Actual Value Monitoring VAL Menu

Parameter meaning

978 Node State: 1 Pre operation/2 Run/3 Stop

979 CAN State: 1 Normal/2 Warning/3 BUS OFF

Note: The PDO mapping parameters cannot be seen on the KP500 operation panel and must be loaded into the corresponding VPlus software XPI configuration files are required to access all system bus parameters.

Fault code

F21 nn: The master station receives a fault message from the slave station nn (nn=hexadecimal ID of the slave station)

F22-00: SYNC message timeout

F22-01: RXPDO1 timeout; F22-02: RXPDO2 timeout; F22-03: RXPDO3 timeout

F22-10: CAN hardware BUS OFF; The module automatically restarts the CAN controller and resends the Boot Up message.