Installation of Bonfiglioli Vectron EM-IO-02 Expansion Module and PTC Temperature Monitoring Configuration

The PTC input port of EM-IO-02 is equipped with an evaluation circuit that complies with DIN 44081 standard, with a rated response resistance of 2.85k Ω, and can be directly connected to standard motor PTC sensors.

3.2 Operation mode of PTC monitoring (parameter 570)

EM-IO-02 extends the operating modes of the "Motor Temperature" section of the frequency converter, providing the following 5 new modes (selected through parameter 570 (Operation Mode Motor Temp.)):

Operating Mode Function Description Application Scenarios

Only display a warning when the threshold is exceeded, without triggering a shutdown

When the fault shutdown exceeds the threshold, immediately report fault F0400 and stop freely

13 fault shutdown, delayed for 1 minute, exceeded the threshold for 1 minute before reporting fault shutdown

14 fault shutdown, delayed for 5 minutes, exceeded the threshold for 5 minutes before reporting fault shutdown

15 fault shutdown, delayed for 10 minutes, exceeding the threshold for 10 minutes before reporting fault shutdown

The application value of delay mode: In some process scenarios, it is normal for the motor to overheat for a short time (such as during the start-up phase). Using delay shutdown can avoid unnecessary production interruptions and ensure that protection is ultimately triggered when the overheating continues.

3.3 PTC fault handling and confirmation

Fault code: F0400

Display mode: Operation unit KP500 displays "FAULT F0400"

Confirmation method: Fault confirmation is performed through parameter 34 (Program) or a digital input signal linked to parameter 103 (Error Acknowledgment)

Independent of controller enable: PTC monitoring function is independent of the running/stopping state of the frequency converter, and temperature monitoring continues to work even when the frequency converter is in a stopped state.

3.4 Temperature measurement through analog input

In addition to PTC switch monitoring, EM-IO-02 also supports continuous temperature measurement through analog input EM-S1INA (mode 2, parameter 465):

Temperature range: 0 ° C~200 ° C

Signal mapping: 0 ° C corresponds to 0V/0mA, 200 ° C corresponds to 10V/20mA

Application scenario: Connect an external temperature transmitter (such as PT100 transmitter) to achieve full temperature monitoring throughout the process

CAN system bus configuration

The system bus function of EM-IO-02 is completely consistent with EM-IO-01, both based on the CANopen protocol framework (CiA DS 301). The following are the key configuration points.

4.1 Terminal resistor configuration (dip switch S1/S2)

Bus physical head and tail nodes must be set with terminal resistors:

Passive terminal (S1=ON, S2=OFF): Conventional terminal matching

Active terminal (S1=ON, S2=ON): Improve the shape of CAN signal edges

Factory default: S1 and S2 are both OFF

4.2 Node ID and Baud Rate

Parameter Description Range Factory Value

900 Node-ID-1~63-1 (disabled)

903 Baud-Rate 3~8（50~1000 kBaud） —

Node ID setting rules:

-1: System bus disabled

0: Defined as the main station (only one is allowed)

1~63: Slave station address

4.3 Network Management State Machine

CANopen standard state management:

Pre Operational: Only SDO communication is allowed

Operational: Both SDO and PDO are allowed

Stopped: All communication is prohibited

The master station switches the slave station to Operational state through the NMT command "Start Remote Node" (command code=1). After initialization is completed, the main station periodically sends startup commands with a delay time set by parameter 904 (Boot Up Delay).

4.4 Emergency Response of the Main Station (Parameter 989)

Mode function

0-Error: When receiving an emergency message from the slave station, the master station stops simultaneously and reports F21nn (nn is the hexadecimal base of the slave station Node ID)

1- No Error only displays warning Sysbus (0x2000), the main station continues to run

4.5 Virtual Links

EM-IO-02 supports horizontal data transmission between frequency converters through TxPDO/RXPDO. Each TxPDO can transmit 8 bytes of data and supports three data types: Boolean, Word (2 bytes), and Long (4 bytes):

TxPDO channel Boolean byte parameters Word byte parameters Long byte parameters

TxPDO1 946~949 950~953 954~955

TxPDO2 956~959 960~963 964~965

TxPDO3 966~969 972~975 976~977

Example of Source Number:

Boolean source: 740=control word, 161=running status

Word source: 9063=percentage reference value 1

Long source: 900=output frequency, 62=reference frequency value

Key points of analog/digital I/O configuration

5.1 Analog input characteristic curve

The analog input of EM-IO-02 supports flexible mapping through two-point linear characteristic curves (parameters 564~567):

Parameter Description Range Factory Value

564 characteristic point X1-1000.00%~100.00% -98.00%

565 characteristic point Y1-1000.00%~100.00% -1000.00%

566 characteristic point X2-1000.00%~100.00% 98.00%

567 characteristic point Y2-1000.00%~100.00% 100.00%

Operation mode (parameter 562):

1. Bipolar: Complete mapping according to characteristic points

11- Unipolar: Mapping negative X-axis value to reference value 0

21- Monopolar 2... 10V/4... 20mA: Input range limited to 20%~100%