Bonfiglioli Vectron EM-IO-01 Expansion Module

Bonfiglioli Vectron EM-IO-01 Expansion Module

Bangfeili ACTION (ACT) and ACTION Cube (ACU) series frequency converters; ACT requires firmware version ≥ V4.1.0, and ACU natively supports this module. Document positioning: Special installation and operation manual for EM-IO-01 option hardware installation, CAN-System bus, IO signals, all parameters, and fault codes; Does not include basic operations of the inverter body.

Overview

EM-IO-01 is a pluggable option expansion board that can be directly inserted into the lower slot of the frequency converter. It can be assembled in a power-off state and activated when powered on. Provide hardware resources:

CAN high-speed system bus (ISO-DIS 11898, up to 1Mbaud)

1 bipolar analog input (± 10V/± 20mA, 12 bit resolution)

1 bipolar analog output (± 10V, maximum 2mA, short circuit protection)

3-channel digital input (can be used as an incremental encoder speed sensor interface, up to 150kHz)

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

Attention: If other CAN controller options are installed at the same time, the CAN bus function of EM-IO-01 will be disabled.

Safe, transportation and storage

High voltage equipment, all disassembly and wiring must be completely powered off, waiting for the DC bus capacitor to fully discharge before operation;

Only applicable to certified professional electricians and must comply with standards such as EN50178 and IEC60364;

Storage: Original packaging, dry and dust-proof, no power on storage for up to 1 year;

Static sensitive devices are prohibited from touching PCB circuit boards with bare hands;

The whole machine needs to meet mechanical instructions, low-voltage instructions UL508c/CSA C22.2‑No.14‑95； The responsibility for EMC compliance is borne by the equipment integrator.

Mechanical and Electrical Installation

3.1 Mechanical Installation

Disconnect the power supply of the frequency converter and wait for the capacitor to discharge;

Remove the lower cover plate of the frequency converter and insert the EM-IO-01 module into the lower slot as a whole; Restore the cover plate;

Do not touch the printed circuit board on the back of the module.

3.2 Terminals and dip switches

Two sets of wiring terminals for the module: X410A and X410B, using Wieland DST85/RM3,5 terminals, with a tightening torque of 0.2-0.3Nm.

Terminal group pin function

X410A 1+20V output, maximum 180mA

2 20V‑GND

3 digital inputs 1 EM-S1IND

4 digital inputs 2 EM-S2IND

5 digital inputs 3 EM S3IND

6-7 relay output 1 EM-S1OUTD (normally open contact)

X410B 1-2 relay output 2 EM-S2OUTD (normally open contact)

3 Analog inputs EM-S1INA

4 Analog outputs EM-S1OUTA

5 CAN‑Low

6 CAN‑High

7 CAN‑GND

Dial switch (module board S1/S2/S3)

S1, S2: CAN bus terminal resistance; Can use ordinary passive terminals (S1=ON, S2=OFF); Or active terminal (S1&S2 are both 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 ± 10V; ON=current ± 20mA.

CAN System Bus (Core)

Following the CANopen CiA DS301 specification, supporting master/slave mode, bus topology is linear, shielded twisted pair wiring, power cables and communication cables are physically isolated, and both ends of the shielding layer are extensively grounded with PE.

4.1 Basic configuration parameters

900 Node - ID Node Address: -1=Bus shutdown; 0=This machine serves as the bus master 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 Cable Length:

Maximum baud rate bus length

50kBaud 1000m

100kBaud 800m

125kBaud 500m

250kBaud 250m

500kBaud 100m

1000kBaud 25m

4.2 Bus Communication Model

SDO channel (parameter read-write): used for reading and writing frequency converter parameters; Each device has two SDOs.

SDO1: Used for PLC/upper master station to access parameters, supporting Profibus DP, RS232/485 transparent transmission to access all nodes on the bus;

SDO2: reserved for visual debugging tools; SDO2 can be parameterized to avoid compatibility conflicts.

The protocol uses Expedited SDO and only supports uint/int/long types, not string parameters.

PDO channel (real-time process data): Each device has 3 sets of RxPDO (receive) and 3 sets of TxPDO (send);

Working mode: Time cycle triggered/SYNC synchronization message triggered;

Virtual links: do not use CANopen standard object mapping; Map the internal signal into an 8-byte message of PDO using the source number Source Number; Realize direct data exchange between multiple frequency converters;

Support 1-to-many broadcast transmission; Set PDO timeout detection to report faults F2201~F2203 when exceeded.

NMT network management: Control node status: Pre Operational, Operational, 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: Automatically reported when the slave station fails, the master station can be configured to stop the machine or only sound an alarm upon receiving the emergency message.

4.3 Bus Planning Tool

The manual provides supporting planning documents:

Kbl.doc: Communication Relationship Definition Table

Vvk.doc: Virtual Link Configuration Table

Load_Systembus.xls: Bus load rate calculation table; Suggested total bus load ≤ 80%; 90% unavailable.

4.4 Bus status monitoring parameters

978 Node State node status;

979 CAN‑State：OKAY / WARNING / BUS‑OFF； When BUS-OFF reports F2210 fault, the module automatically reinitializes the bus.

Detailed explanation of IO signal function

5.1 Analog Input EM-S1INA (12 bits)

Switch voltage ± 10V/current ± 20mA through S3 dialing.

Can be used as a frequency/percentage given source, limit source; Supports 4 input feature modes:

1- Bipolar polarity;

11 Unipolar unipolar;

21-Unipolar 2-10V/4-20mA industrial sensor mode;

101- Bipolar Abs. Value Absolute Value Mode.

Can set 2-point coordinates X1/Y1, X2/Y2 to customize input-output mapping; Configure tolerance bands, hysteresis, and low-pass filtering time constants.

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

5.2 Analog output EM-S1OUTA

Output ± 10V; can output analog input absolute value, actual speed, etc; Set offset, amplify amplification, and calibrate hardware zero gain.

5.3 Digital inputs EM-S1IND/S2IND/S3IND

Universal digital input; Expand 8 fixed frequency selections (FF5-FF8).

Incremental encoder interface function (speed sensor 2):

S2IND=Phase A, S3IND=Phase B, S1IND=Reference Label;

The maximum input frequency is 150kHz; Support quadruple frequency evaluation; Can be used as an actual speed feedback source for speed closed-loop (parameter 766 switches speed sources);

Set the number of encoder lines; Provide fault alarms for encoder disconnection and phase sequence errors.

5.4 Relay Digital Output EM-S1OUTD, EM-S2OUTD

The relay has normally open contacts, and the software maps the internal status of the frequency converter (running, faulty, reaching a given value, etc.).

Parameter Summary Table

Divided into VAL actual value menu and PARA parameter menu

VAL actual value (monitoring): encoder 2 frequency/speed, analog input%, analog output V, digital input/output status, CAN bus node status, CAN physical layer status.

PARA setting parameters

Analog inputs: characteristic points, modes, filtering, tolerance bands, fault behavior, calibration;

Analog output: mode, offset, amplification, calibration;

Encoder: working mode, number of encoder lines;

Fixed frequency FF5-FF8; Selection of digital output function;

Complete set of CAN bus: Node ID, baud rate, startup delay, SYNC, SDO/PDO identifiers, PDO mode, timeout, virtual link source mapping, emergency message response.

Advanced bus parameters are not visible on the KP500 panel; VPlus software needs to load XPI configuration files for configuration.

Fault code (EM-IO-01 related)

Local IO failure

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

System Bus bus malfunction

F21-nn: Report fault from station nn;

F22-00: SYNC message timeout;

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

F22-10: Bus BUS OFF.