Bonfiglioli Vectron EM-IO-01 Expansion Module Installation and System Bus Configuration Guide

TxPDO byte mapping parameters:

Channel data type parameter number (bytes 1-4/5-8)

TxPDO1 Boolean 946, 947, 948, 949

TxPDO1 Word 950, 951, 952, 953

TxPDO1 Long 954, 955

TxPDO2 Boolean 956, 957, 958, 959

TxPDO2 Word 960, 961, 962, 963

TxPDO2 Long 964, 965

TxPDO3 Boolean 966, 967, 968, 969

TxPDO3 Word 972, 973, 974, 975

TxPDO3 Long 976, 977

Example of Source Number:

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

Word source: 9063=percentage reference value 11133=output percentage

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

RxPDO receiving source number: The data received by RxPDO is presented through source numbers 700~729 (RxPDO1), 710~719 (RxPDO2), and 720~729 (RxPDO3), which can be used locally through parameter links.

Detailed configuration of analog input/output

6.1 Analog input characteristic curve

The analog input signal is mapped to a frequency or percentage reference value through a two-point linear characteristic curve. Two characteristic points are set through 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%

Calculation formula for characteristic curve:

Y=Y two−Y one X two−X one⋅(X−Xone)+Y one

Y= X2−X1 Y2−Y1⋅(X−X1)+Y1

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: Limit the input range to 20%~100%

101- Bipolar absolute value: negative Y-axis value mapped to positive reference value

6.2 Tolerance bands and hysteresis

For applications that require switching the direction of rotation, the tolerance band (parameter 560) is used to expand the range of the reference value crossing zero, avoiding frequent direction switching near zero and causing system oscillation. The parameter range is 0.00%~25.00%, and the factory value is 2.00%.

6.3 Fault/Warning Behavior (Parameter 563)

Mode function

0-OFF does not monitor input signals

When the warning signal is less than 1V/2mA, a warning will be issued

When the shutdown signal is less than 1V/2mA, slow down and stop the machine according to the shutdown mode

When the fault shutdown signal is less than 1V/2mA, the machine can stop freely and report a fault

6.4 Analog Output Configuration

Simulate output by selecting the output signal source through parameter 584 (operating mode), and adjusting the application level through parameters 585 (offset) and 586 (amplification factor). Set the zero offset as a percentage of the simulated output full range (10V); The amplification factor is set to the signal gain as a percentage of the full scale, ranging from 5% to 1000%.

Digital input as speed sensor (EM-ENC)

The three digital inputs of EM-IO-01 can be configured as an incremental speed sensor interface through parameter 493 (Operation mode speed sensor 2):

Mode Function Description

Four fold frequency evaluation of dual channel speed sensor, identifying direction through A/B phase signals, evaluating 4 edges per turn

On the basis of the fourth harmonic inversion, the velocity value is inverted (equivalent to exchanging A/B signals)

1004- Four fold increase in reference pulse with reference pulse for sensor monitoring

1104- with reference pulse reverse fourth harmonic as above, the velocity value is taken in reverse

Index mark (parameter 494): Set according to the number of pulses per revolution of the speed sensor, ranging from 1 to 8192, with a factory value of 1024.

Maximum division mark calculation:

Smax=one hundred and fifty thousand Hz×sixty n max

S max=150000Hz× n max sixty 

Among which

n max For the maximum speed (RPM) of the motor, 150kHz is the maximum frequency limit for digital input.

Actual speed source selection (parameter 766): 1=speed sensor 1 (body), 2=speed sensor 2 (EM-IO-01).

Bus load planning

The capacity planning of the system bus is crucial for reliable communication. Each PDO message contains 8 bytes of user data, and in the worst case scenario, the total message length is 140 bits.

Single 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

Bus load calculation formula:

Load=TelegramRunTime

TransmissionInterval×one hundred%

Load= TransmissionInterval

TelegramRunTime×100%

Load assessment criteria:

≤ 80%: Normal

80%~90%: critical

90%: unacceptable

Note: The sum of the total loads of all TxPDOs determines the overall load rate of the system bus. A margin must be reserved for message retransmission during design.

Common fault codes and troubleshooting

Fault code description and troubleshooting suggestions

F1402 Analog Input EM-S1INA Signal Fault Check Signal Source and Wiring, Confirm Signal is within Effective Range

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

F31 speed sensor 2 phase loss signal check whether the A or B phase signal is lost