Bonfiglioli EM-IO-04 Expansion Module Configuration Guide

Timeout monitoring: Timeout times (939, 941, 942, 945, in milliseconds) can be set for SYNC and each RxPDO separately. If timeout occurs, faults F2200~F2203 will be reported.

Virtual Links and Data Mapping

EM-IO-04 maps internal variables (such as control words, status words, and actual frequencies) to 8 bytes of PDO through a "virtual link" mechanism. Each byte of TxPDO can be configured as a boolean, word, or long integer.

1. Selection of TxPDO data source

The input parameters corresponding to each byte are 946-977 (for example, Byte1-4 of TxPDO1 corresponds to Boolean1-4, Byte5-8 corresponds to Word1-4, or Long1-2).

Enter the 'source number' during setup. Common sources: control word 740, status word 741, output frequency reference value 62, output percentage 138, digital input status 250.

Unused bytes are set to source 9 (zero value) or 7 (False).

2. RxPDO data target

The received data is mapped to source numbers 700~729 (such as 704 for Boolean1709 for Word1, etc.), and then these sources can be referenced internally through parameters in the frequency converter (for example, setting control word input parameter 99 as source 704).

Engineering example: Two frequency converters need to start and stop synchronously. The host places the control word (740) into Byte1 of TxPDO1; After receiving RxPDO1, link Byte1's source 704 to its own control word input parameter 99. In this way, the slave can follow the start stop instructions of the host.

Digital input/output configuration

1. Digital port EM-S1IOD

Select input (0) or output (1) through 558 (Operation Mode).

When in input mode, the signal source can be selected in 558 (320=direct input, 520=inverse), and the signal can be mapped to logic such as fixed frequency switching (parameter 131 defines the third bit fixed frequency switching).

When in output mode, select the output function (such as operating status, faults, etc.) through 559. Please refer to the frequency converter operation manual for specific functions.

2. Digital inputs EM-S2IND and EM-S3IND

High trigger (PNP) or low trigger (NPN) can be selected through the operation mode, corresponding to parameter values of 0 or 1 (see section 5.2.1).

When referencing these inputs in the parameters, use operation mode 321 (S2IND) or 322 (S3IND), or take the reverse version 521/522.

3. Fixed frequency switching extension

EM-IO-04 has expanded the third fixed frequency switching (131), which, when combined with the original two bit switching (66, 67), can achieve 8 fixed frequencies (480~488).

4. Status monitoring

All digital signal statuses can be viewed through parameters 250 (Digital inputs) and 254 (Digital outputs). Binary bits 7, 8, and 9 correspond to EM-S1IND, EM-S2IND, and EM-S3IND, respectively; Bit 3 corresponds to the state when EM-S1IOD is used as the output.

Motor temperature protection configuration

EM-IO-04 supports two types of temperature sensors: PTC thermistor (or bimetallic switch) and KTY84-130 temperature sensor, which can be switched by dialing S3.

1. PTC/bimetallic mode (S3 to the right)

Connect PTC (response threshold>2.4 k Ω) or normally closed bimetallic switch.

570 (Operation Mode Motor Temp.) can be selected from:

11: Warning only;

12: Fault shutdown (immediate);

13-15: Fault shutdown delay of 1/5/10 minutes.

Fault F0400 reported during overheating.

2. KTY temperature measurement mode (S3 to the left)

Connect the KTY84-130 sensor (resistance range 424 Ω~1722 Ω corresponding to -20 ℃~200 ℃).

Parameter 465 needs to be set to 22 (temperature measurement).

The maximum allowable winding temperature can be set to 617 (max. Temp. Windings), and in case of overheating, a warning or fault shutdown (F0400) will be generated according to the setting of 570.

The actual temperature can be read in real-time through parameter 226 (Winding Temperature).

The KTY mode also allows the frequency converter to automatically adjust control parameters (such as magnetic field orientation control) based on actual temperature, optimizing motor performance.

Note: Regardless of the type of sensor used, temperature evaluation is independent of digital input enable signals and will continue to monitor even in a shutdown state.

System bus fault diagnosis and troubleshooting

The fault codes caused by EM-IO-04 are as follows:

Fault code description, troubleshooting suggestions

F0400 motor temperature is too high or the sensor connection is faulty. Check X410B. 1-2 wiring, confirm that the sensor type matches the S3 dip code, and check whether the PTC resistance or KTY is short circuited/open circuited

F1450 KTY temperature measurement fault check if S3 is on the left position, check if the sensor resistance is within the effective range, and check the wiring terminals

F21nn system bus slave fault (nn=node ID) Check if the corresponding slave loses power or if the bus is short circuited, and check the terminal resistance configuration

F2200 SYNC timeout: Confirm whether the master station sends SYNC, check 919 settings, and check bus load

F2201~F2203 RxPDO1-3 timeout check whether the corresponding TxPDO is sent normally and whether the identifier matches