Bonfiglioli EM-ENC-03 Expansion Module Configuration and System Bus Integration Guide

2. PDO channel (process data)

PDO is used for real-time exchange of dynamic data such as control words, status words, and frequency setpoint values. Each device supports 3 sets of TxPDO (transmit) and 3 sets of RxPDO (receive).

Identifier: By default, it follows the CANopen predefined connection set, for example, the identifier for TxPDO1 is 384+Node ID. Parameters 925, 927, etc. can be modified to resolve ID conflicts.

Transmission mode: Set through parameters 930-938. Supports time triggered (Cycle) and synchronous triggered (SYNC). In synchronous mode, all nodes simultaneously latch the input data and update the output data upon receiving the SYNC message sent by the master station, ensuring the synchronization of system control.

Timeout monitoring: Parameters 939, 941-945 are used to monitor the timeout of SYNC messages or RxPDO reception. Once the timeout occurs, the frequency converter will trigger a fault (such as F2200 system bus SYNC timeout) and safely shut down.

Virtual Links and Application Instances

This is one of the most powerful features of the EM-ENC-03 module. It allows users to map the internal functional blocks of the frequency converter (such as PID regulator output, frequency setpoint) to the input of another frequency converter through the system bus, without relying on PLC for relay.

1. Principle mechanism

The output data of each functional block is assigned a "Source Number". For example, the source number of the control word is 740, and the source number of the output frequency is 62. For the data received by RxPDO, the system will map it to a specific source number (such as RxPDO1 Byte 0 mapped to source number 700).

By setting the "input link" parameter of TxPDO (such as 950 TxPDO1 Word1) and entering the corresponding source number, the data of that source can be placed in a specific byte position in the PDO message. The receiver can complete the cross device 'virtual link' by configuring its functional block input parameters to point to the source number mapped by RxPDO.

2. Configuration Example

Assuming that the control word (source 740) of frequency converter 1 needs to be sent to frequency converter 2:

Inverter 1 (sender): Set parameter 950 (TxPDO1 Word1) to 740.

Inverter 2 (receiver): Set the control word parameter 99 (Control Word) to 704 (i.e. the source number of RxPDO1 Byte 0).

In this way, the control word of frequency converter 2 is synchronized with frequency converter 1, achieving master-slave control or synchronous start stop.

Speed sensor input and actual value monitoring

The second speed sensor input (speed sensor 2) provided by EM-ENC-03 enhances the redundancy and control accuracy of the system.

1. Configuration and selection

Operation Mode: Parameter 493. Support "Quadruple evaluation", which can identify the direction of rotation through A/B phase signals.

Division Marks: Parameter 494. It must be calculated based on the sensor model and motor speed to ensure that the input frequency does not exceed the limit value of 300kHz.

Level: Parameter 495. Optional "Push pull" or "Unipolar".

2. As an actual value source

Through parameter 766 (Actual Speed Source), users can choose speed sensor 1 (main body) or speed sensor 2 (expansion module) as the feedback source for speed closed-loop control. In addition, the signal from speed sensor 2 can also be used as a frequency reference source (reference frequency source 475 is set to 34 or 35) to achieve given control based on external speed measurement.

Fault diagnosis and system capacity planning

1. Common fault codes

The module will trigger specific fault codes to assist in diagnosis:

F2200: SYNC message timeout.

F2201-F2203: RxPDO1-3 data reception timeout.

F2210: CAN controller Bus Off. Triggered when the error counter overflows, the controller will automatically reinitialize afterwards.

2. Bus load planning

To ensure network stability, it is necessary to calculate the bus load rate. The manual provides calculation formulas and tables. In the worst case, a PDO message is about 140 bits. It is recommended to control the bus load rate below 80%, and if it exceeds 90%, it is considered a high-risk area.