Bonfiglioli Vectron EM-IO-03 Expansion Module Dual Analog Output and PTC Configuration

Bonfiglioli Vectron EM-IO-03 Expansion Module Dual Analog Output and PTC Configuration

In the engineering practice of industrial variable frequency drive systems, the number and type of analog output channels often determine the signal interaction capability between the control system and the controlled equipment. For application scenarios that need to drive both voltage type actuators and current type instruments at the same time, a single analog output channel often becomes the bottleneck of system integration. The Bonfiglioli Vectron ACTION and ACTION Cube series frequency converters integrate a dual-mode analog output channel of one voltage output and one current output on the basis of standard functions through the EM-IO-03 expansion module, while retaining PTC temperature monitoring and CAN system bus communication capabilities, providing a highly integrated hardware solution for complex control requirements.

This article is based on the EM-IO-03 extension module technical manual, providing a systematic technical operation guide for the core concerns of on-site engineers in installation, wiring, dual analog output configuration, and PTC temperature monitoring process.

Overview and Functional Positioning of EM-IO-03 Expansion Module

1.1 Module Core Functions

EM-IO-03 is an optional hardware expansion component designed by Bonfiglioli Vectron for the ACTION and ACTION Cube series frequency converters, supporting software versions 4.1.0 and higher for the ACTION series and all ACU series devices. This module achieves the following functional extensions by inserting it into the lower expansion slot of the frequency converter:

CAN system bus interface: compliant with ISO-DIS 11898 (CAN High Speed) standard, supporting a maximum communication rate of 1 MBaud

Bipolar analog input: 12 bit resolution, configurable for ± 10V voltage or ± 20mA current input

Dual mode analog output:

Output 1: ± 10V voltage output (overload and short circuit protection)

Output 2:0 (4)~20mA current output (overload and short circuit protection)

Two way digital input: PLC compatible, 24V level, supports up to 150kHz frequency signal, can be used as speed sensor input

One way relay output: normally open contact, 24V AC/DC, 1A (resistive load)

PTC thermistor input: compliant with DIN 44081 standard, rated response resistance value of 2.85k Ω

1.2 Function Comparison of EM-IO-01/02/03 Series

Function EM-IO-01 EM-IO-02 EM-IO-03

CAN system bus support

Analog input 1 channel 1 channel 1 channel 1 channel

Analog output 1 channel (voltage) 1 channel (voltage) 2 channels (voltage+current)

Digital input: 3 channels, 3 channels, 2 channels

Relay output 2 channels, 1 channel, 1 channel

PTC temperature input not supported, supported

Key difference: EM-IO-03 sacrifices one digital input in exchange for an independent current analog output, making it an ideal choice for devices that require simultaneous control of voltage (such as variable frequency drive speed settings) and current (such as valve positioners and recorders).

Key points of mechanical and electrical installation

2.1 Mechanical Installation

The installation steps are exactly the same as EM-IO-01/02:

Power off confirmation: The frequency converter is completely powered off and wait for the DC bus capacitor to discharge completely (several minutes).

Disassemble the lower cover plate: Remove the plastic cover plate on the lower part of the frequency converter.

Insertion module: Align the EM-IO-03 expansion module with the slot and apply even force to insert it, holding only the housing and avoiding contact with the PCB.

Reset cover plate: Reinstall the lower cover plate.

2.2 Electrical Connections - Detailed Explanation of Terminal Definitions

EM-IO-03 provides two sockets: X410A and X410B.

Socket X410A (terminals 1-7) - Analog current output is located in this socket:

Technical parameter description of terminal signal

1 20V output Imax=180mA to power external sensors

2 20V ground - corresponding to terminal 1 ground

3 analog current output (EM-S2OUTA) 0 (4)~20mA, Umax=10V overload and short circuit protection

4-digit input 2 (EM-S2IND) Umax=30V, 10mA@24V Can be used as a speed sensor Track A

5 digital inputs 3 (EM-S3IND) can be used as the speed sensor Track B as above

6-7 relay output (EM-S1OUTD) 24V AC/DC, 1A normally open contact

Socket X410B (terminals 1-7) - The PTC interface and voltage output are located in this socket:

Technical parameter description of terminal signal

1-2 PTC Input (EM-MPTC) Rated Response Resistance 2.85k Ω (DIN 44081) Motor Temperature Monitoring

3 analog inputs (EM-S1INA) ± 10V/± 20mA, 12 bit second channel analog input

4 Analog Voltage Output (EM-S1OUTA) ± 10V, Imax=2mA Overload and Short Circuit Protection

5 CAN_Low - System Bus CAN Low Line

6 CAN-High - System Bus CAN High Line

7 CAN_SND - System Bus Ground

Key Tip:

Terminal X410A. 3 is for analog current output and can be directly connected to instruments or actuators that require 4-20mA or 0-20mA signals.

Terminal X410B. 4 is an analog voltage output that can simultaneously output ± 10V signals.

Terminals X410B. 1-2 are PTC thermistor inputs and support sensors that comply with DIN 44081 standards.

2.3 Analog input voltage/current mode switching

The dip switch S3 on the module is configured with analog input signal type:

S3=OFF (right side): Voltage signal (± 10V)

S3=ON (left side): Current signal (± 20mA)

S1 and S2 switches are used for configuring the terminal resistance of the system bus.

Detailed explanation of dual-mode analog output configuration

3.1 Voltage output (EM-S1OUTA) configuration

The voltage output is located at terminal X410B. 4, with a range of ± 10V and low output impedance, suitable for connecting devices with high impedance inputs.

Operation mode (parameter 584):

Mode Function Application Scenarios

0-Off output off (0V) debugging or disabling

41 Absolute value EM-S1INA analog input signal absolute value, 0~10V monitoring input signal

100-10V fixed 10V output calibration

101~141 signed mode, -10V~10V bidirectional speed/position given

201~254 actual absolute value, 2~10V industrial instrument output

Zero adjustment (parameter 585) and amplification factor (parameter 586):

Offset: Set zero offset as a percentage of 10V full scale (-100%~+100%)

Magnification factor: Set the gain as a percentage of full scale (5%~1000%)

Calibration steps:

Set parameter 584=0 (Off), measure output voltage, input parameter 587

Set parameter 584 to 100 (10V), measure the output voltage, and input parameter 587 again

Return parameter 584=0, verify if the output is 0V (± 40mV accuracy)

3.2 Current Output (EM-S2OUTA) Configuration - Core Differentiation Function

The current output is located at terminal X410A. 3, with a range of 0 (4)~20mA, suitable for connecting industrial standard current loop equipment such as valve positioners, recorders, PLC analog input modules, etc. Its overload and short-circuit protection characteristics ensure the safety of on-site wiring.

Operation mode (parameter 525):

Mode Function Application Scenarios

0-Off output off (0mA) debugging or disabling

41 Absolute value EM-S1INA analog input signal absolute value, 0~20mA monitoring input signal

100-20mA fixed 20mA output calibration

201~254 actual absolute value, 4~20mA standard industrial instrument output

Key Tip: Modes 201~254 limit the output range to 4~20mA instead of 0~20mA, which is particularly important for industrial applications that require detecting wire breaks - when the output is below 4mA, the receiving device can recognize it as a line fault.

Zero adjustment (parameter 526) and amplification factor (parameter 527):

Offset: Set zero offset as a percentage of 20mA full scale (-100%~+100%)

Magnification factor: Set the gain as a percentage of full scale (5%~1000%)

Calibration steps (similar to voltage output, using parameter 528):

Set parameter 525=0 (Off), measure output current, input parameter 528

Set parameter 525=100 (20mA), measure the output current, and input parameter 528 again

Return parameter 525=0, verify if the output is 0mA (± 16 μ A accuracy)

3.3 Typical Applications of Dual Analog Output

The dual analog outputs of EM-IO-03 can work simultaneously, achieving the following typical application scenarios:

Application scenario Voltage output (± 10V) Current output (4-20mA)

Master slave speed synchronization, main frequency converter speed given, slave frequency converter speed feedback

Process control valve opening instruction flow/pressure transmitter signal

Remote monitoring speed indication, current/torque indication

Test platform bidirectional speed given unidirectional load simulation

PTC motor temperature monitoring

EM-IO-03 inherits the PTC temperature monitoring function of EM-IO-02 and connects a PTC sensor that complies with DIN 44081 through terminal X410B. 1-2.

4.1 Operating Mode (Parameter 570)

Mode Function Engineering Description

Only display warning when overheating, without triggering shutdown

12. Immediately report fault F0400 and stop the machine freely

13 fault shutdown, delay for 1 minute, short-term overheating tolerable, continuous overheating before shutdown

14 fault shutdown, delayed for 5 minutes, suitable for processes with overheating during the start-up phase

15 fault shutdown, with a maximum tolerance delay of 10 minutes

Fault confirmation: F0400 can be confirmed through parameter 34 (Program) or a digital input signal linked to parameter 103.

4.2 Continuous temperature measurement through analog input

In addition to PTC switch monitoring, EM-IO-03 also supports continuous temperature measurement through analog input EM-S1INA (parameter 465, mode 2):

Temperature range: 0~200 ° C mapped to 0~10V or 0~20mA

Application scenario: Connecting PT100 transmitter to achieve full temperature monitoring throughout the process

CAN system bus configuration

The system bus function of EM-IO-03 is consistent with EM-IO-01/02, based on the CANopen protocol framework (CiA DS 301).

5.1 Terminal resistor configuration (dip switch S1/S2)

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

5.2 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） —

Set rules:

Node ID=-1: System bus disabled

Node ID=0: defined as the main station (only one is allowed)

Node ID=1~63: Slave address

5.3 NMT State Machine and Startup

CANopen standard tri state management:

Pre Operational: SDO communication only

Operational: Both SDO and PDO are allowed

Stopped: All communication is prohibited

The master station switches the slave station to Operational through the NMT command "Start Remote Node" (command code=1). Parameter 904 (Boot Up Delay, 3500~50000ms) sets the interval for sending periodic startup commands.

5.4 Virtual Links

EM-IO-03 supports horizontal data transmission between frequency converters through TxPDO/RXPDO. Each TxPDO supports Boolean, Word, and Long data type mapping:

TxPDO channel Boolean parameter Word parameter Long parameter

TxPDO1 946~949 950~953 954~955

TxPDO2 956~959 960~963 964~965

TxPDO3 966~969 972~975 976~977

Common source number:

Boolean source: 740=control word, 161=running status, 163=target value reached

Word source: 9063=percentage reference value 1133=output percentage

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

Simulation input characteristic curve configuration

The analog input of EM-IO-03 supports two-point linear characteristic curve mapping (parameters 564~567), which is suitable for linearization of nonlinear sensor signals.

Operation mode (parameter 562):

Typical Applications of Mode Functions

1. Bipolar complete mapping according to characteristic points ± 10V bidirectional control

11- Unipolar negative X-axis value mapping to 0 unidirectional speed control

21- Unipolar 2~10V/4~20mA input range limited to 20%~100% active zero position signal

101- Bipolar absolute value negative Y-axis value mapping to positive absolute value control

Tolerance band (parameter 560): 0%~25%, factory 2%, used to expand the zero crossing range and avoid direction switching oscillation.

Quick Reference Table for Fault Codes

Fault code description and troubleshooting suggestions

F0400 motor PTC temperature over limit inspection motor load, cooling, and PTC wiring

F1402 Analog Input EM-S1INA Signal Fault Check Signal Source and Wiring

F30 speed sensor 2 signal fault check sensor wiring and power supply

F31 speed sensor 2 phase loss signal check A/B phase signal

F32 Speed Sensor 2 Direction Error Check A/B Reverse Connection

F21nn system bus slave fault check corresponding node (nn hexadecimal)

F2200 SYNC message timeout check for main station SYNC generation

F2201~03 RxPDO1-3 timeout check corresponding to TxPDO configuration

F2210 CAN bus BUS-OFF check for physical connections, terminal resistance, and baud rate

Bus load planning reference

PDO message transmission time at different baud rates:

Baud rate (kBaud) message transmission time (μ s)

1000 140

500 280

250 560

125 1120

100 1400

50 2800

Load assessment: A total load rate of ≤ 80% for all TxPDOs is normal, 80%~90% is critical, and>90% is unacceptable.