General points on the documentation The present supplement of the documentation is valid for the frequency inverter se- ries ACT and ACU. The information necessary for the assembly and application of the EM-IO-03 expansion module is documented in this guidance. For better clarity, the user documentation is structured according to the customer- specific demands made of the frequency inverter.
TABLE OF CONTENTS General points on the documentation .................. 1 General safety and application information ..............5 General information....................5 Proper use........................ 5 Transport and storage ..................... 6 Handling and positioning..................6 Electrical connection....................6 Operation information ..................... 6 Maintenance and service ..................6 Introduction ........................
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TABLE OF CONTENTS 4.10 Communication channels, SDO1/SDO2.............. 28 4.10.1 SDO telegrams (SDO1/SDO2) ................. 28 4.10.2 Communication via field bus connection (SDO1) ............30 4.10.2.1 Profibus-DP ....................30 4.10.2.2 RS232/RS485 with VECTRON bus protocol ............30 4.11 Process data channels, PDO ................32 4.11.1 Identifier assignment process data channel..............
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TABLE OF CONTENTS Digital inputs EMS2IND and EMS3IND..............63 5.5.1 Fixed reference values and fixed value switch-over........... 63 Digital inputs for speed sensor 2................64 5.6.1 Division marks speed sensor 2 ................64 5.6.2 Actual speed source ....................65 5.6.3 Actual value comparison..................
General information Warning! BONFIGLIOLI VECTRON frequency inverters have high voltage levels dur- ing operating, depending on their protection class, drive moving parts and have hot surfaces.
Transport and storage Transport and storage are to be done appropriate in the original packing. Store the units only in dry rooms, which are protected against dust and moisture and are sub- jected to little temperature deviations only. Observe the climatic conditions according to standard EN 50178 and to the information on the label of the original packing.
Introduction This document describes the possibilities and the properties of the EM-IO-03 expan- sion module for the frequency inverters of the ACT and ACU series of devices. Note: This document exclusively describes the EM-IO-03 expansion module. It does not provide basic information on the operation of the ACT and ACU series frequency inverters.
3 Installation of the EM-IO-03 expansion module General The mechanical and electrical installation of the EM-IO-03 expansion module is to be carried out by qualified personnel according to the general and regional safety and installation directives. Safe operation of the frequency inverter presupposes that the documentation and the device specification are complied with in installation and start of operation.
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The EM-IO-03 expansion module is supplied in a housing for assembly on the lower slot of the frequency inverter. • Remove the lower cover (1) of the frequency inverter. The slot for the EM-IO-03 expansion module becomes accessible. Caution! The EM-IO-03 expansion module (2) is pre-fitted in a housing. Do NOT touch the PCB visible on the back, as modules may be damaged.
Electrical installation Danger! If the following instructions are not complied with, there is direct danger with the possible consequences of death or severe injury by electrical current. Further, failure to comply can lead to destruction of the fre- quency inverter and/or of the expansion module. •...
3.3.2 Control terminals The control and software functionality can be freely configured for economical opera- tion with a safe function. Expansion module EM-IO-03 Wieland DST85 / RM3,5 0.14 … 1.5 mm AWG 30 … 16 0.14 … 1.5 mm AWG 30 … 16 0.25 …...
Either set S1 to ON and S2 to OFF for a regular passive termination. • or set S1 and S2 to ON for an active termination. This results in an improved edge shape of the CAN signals, which causes an improvement of the signal shapes, in particular in extended systems.
Cables For the bus line, use twisted a cable with harness shield (no foil shield). Attention! The control and communication lines are to be laid physically separate from the power lines. The harness screen of the data lines is to be con- nected to ground (PE) on both sides on a large area and with good con- ductivity.
Baud rate setting/line length The setting of the baud rate must be identical in all nodes on the system bus. The maximum possible baud rate is based on the necessary overall line length of the sys- Baud-Rate tem bus. The baud rate is set via the parameter 903 and thus defines the possible line length.
Functional overview The system bus produces the physical connection between the frequency inverters. Logical communication channels are produced via this physical medium. These chan- nels are defined via the identifiers. As CAN does not possess a node-oriented, but a message-oriented addressing via the identifiers, the logical channels can be displayed via it.
4.7.1 SDO channels (parameter data) Each frequency inverter possesses two SDO channels for the exchange of parameter data. In a slave device, these are two server SDO's, in a device defined as a master a client SDO and a server SDO. Attention must be paid to the fact that only one master for each SDO channel may exist in a system.
4.7.2 PDO channels (process data) Each frequency inverter possesses three PDO channels (Rx/Tx) for the exchange of process data. The identifier assignment for the PDO channel (Rx/Tx) is done by default according to the Predefined Connection Set. This assignment corresponds to an alignment to a central master control.
Master functionality An external control or an frequency inverter defined as a master (node ID = 0) can be used as a master. The fundamental tasks of the master are controlling the start of the network (boot-up sequence), generating the SYNC telegram and evaluating the emer- gency messages of the slaves.
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Einschalten Initialisation aus beliebigem Zustand Pre-Operational Stopped Operational After Power On and the initialization, the slaves are in the Pre-Operational state. The transition (2) is automatic. The system bus master (frequency inverter or PLC/PC) triggers the transition (3) to Operational state. The transitions are controlled via NMT telegrams.
4.8.2 SYNC telegram, generation If synchronous PDO’s have been created on the system bus, the master must send the SYNC telegram cyclically. If an frequency inverter has been defined as a system bus master, the latter must generate the SYNC telegram. The interval for the SYNC tele- gram of an frequency inverter defined as the system bus master is adjustable.
4.8.3 Emergency message, reaction If a slave on the system bus suffers a fault, it transmits the emergency telegram. The emergency telegram marks the node ID for the identification of the failed node via its identifier and the existing fault message via its data contents (8 bytes). After a fault has been acknowledged on the slave, the latter again transmits an emer- gency telegram with the data content zero.
4.8.4 Client SDO (system bus master) Each node on the system bus can be addressed via the SDO channels. In this way, each node can be addressed and parameterized by one master via its client SDO1. All the parameters of the data types uint/int/long are accessible. String parameters can not be processed.
Slave functionality 4.9.1 Implement boot-up sequence, network management 4.9.1.1 Boot-up message After the initialization, each slave on the system bus transmits its boot-up message (heartbeat message). Note: The boot-up telegram has the identifier 1792 + node ID and a data byte with contents = 0x00.
4.9.2 Process SYNC telegram If synchronous PDO’s have been created in an frequency inverter, their processing is synchronized with the SYNC telegram. The SYNC telegram is generated by the system bus master and is a telegram without data. The identifier is 128 according to the Predefined Connection Set. If a PC or PLC is used as a master, the identifier of the SYNC telegrams can be adapted by parameterization on the frequency inverter.
4.9.3 Emergency message, fault switch-off As soon as a fault switch-off occurs in a slave frequency inverter, the emergency tele- gram is transmitted. The emergency telegram marks the node ID for the identification of the failed node via its identifier and the existing fault message via its data contents (8 bytes).
4.9.4 Server SDO1/SDO2 The communication channel for the exchange of parameter data is the SDO channel. Communication works according to the client/server model. The server is the node holding the data (here the frequency inverter), the client the node requesting or want- ing to alter the data (PLC, PC or frequency inverter as system bus master).
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Max. Fact. sett. 922 TxSDO1-Identifier 2047 The setting "0” results in identifier assignment according to the Predefined Connection Set. SDO2 Set Active The second SDO channel can be deactivated via the 923. Operation mode Function 0 -SDO2 deactivated Communication channel deactivated...
4.10 Communication channels, SDO1/SDO2 4.10.1 SDO telegrams (SDO1/SDO2) The service used for the exchange of parameter data is SDO Segment Protocol Expedited. The data (type uint, int, long) are exchanged in a telegram. Access to the parameters in the frequency inverters with a statement of parameter number and data set is displayed via the addressing defined for object access pursuant to the specifications of CANopen via Index/Sub-Index.
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Reading parameters: Client Server SDO Upload (expedited) Ctrl. byte Parameter number Data set Data 0x40 0xnn Server Client Upload Response Reading process free of errors Ctrl. byte Parameter number Data set Data 0x42 0xnn uint/int 0x00 0x00 long Server Client Abort SDO Transfer Reading process faulty Ctrl.
4.10.2 Communication via field bus connection (SDO1) If an frequency inverter has been defined as the system bus master and equipped with a field bus interface, access to the parameterization of all the nodes in existence on the system bus is possible by means of this field bus interface via the first SDO channel (SDO1).
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Display of node ID system bus in the VECTRON bus protocol: System bus Node-ID System bus (ASCII-) HEX value System bus (ASCII-) HEX value address character address character 06/05 06/05...
4.11 Process data channels, PDO 4.11.1 Identifier assignment process data channel The process channel for the exchange of process data under CANopen is the PDO channel. Up to three PDO channels with differing properties can be used in one de- vice.
TxPDO2 Function TxPDO3 Function 930, 932 und Operation mode Function 0 - Not Active No data are sent. 1 - Controlled by time In the cycle of the adjusted time interval the data are sent. 2 - Controlled by SYNC To arrival of a SYNC telegram the data are sent.
4.11.3 Timeout monitoring process data channel Each frequency inverter monitors its received data for whether they are updated within a defined time window. The monitoring is done onto the SYNC telegram and the RxPDO channels. Monitoring SYNC / RxPDO‘s Parameter Setting Description Min.
4.11.4 Communication relationships of the process data channel Regardless of the process data to be transmitted, the communication relationships of the process data channels must be defined. The connection of PDO channels is done via the assignment of the identifiers. The identifiers of Rx-/Tx-PDO must match in each case.
4.11.5 Virtual links A PDO telegram contains 0 ... 8 data bytes according to CANopen. A mapping for any kind of objects can be done in these data bytes. For the system bus, the PDO telegrams are firmly defined with 8 data bytes. The map- ping is not done via mapping parameters as with CANopen, but via the method of sources and links.
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For the system bus, the input data of the TxPDO’s are also displayed as input parame- ters and the output data of the RxPDO’s as sources. Example 2: Function A TxPDO Inverter 1 Inverter 1 Parameter 977 Source-No. 27 system bus Function B Inverter 1 Parameter 972...
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The virtual links with the possible sources are related to the Rx/TxPDO channels. For this purpose, the eight bytes of the Rx-/TxPDO’s are defined structured as inputs and sources. This exists for each of the three PDO channels. Each transmit PDO and receive PDO can be occupied as follows: 4 Boolean variables 4 uint/int variables 2 long variables...
4.11.5.1 Input parameters of the TxPDO’s for data to be transmitted The listed parameters can be used to stipulate the data that are to be transported there for each position in the TxPDO telegrams. The setting is done in such a way that a source number is entered for the required data in the parameters.
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With this method, there are up to three possibilities for a meaning of the contents of the individual bytes. Each byte may only be used for one possibility. To ensure this, the processing of the input links is derived from the setting. If an input link has been set to the fixed value of zero, it is not processed.
4.11.5.2 Source numbers of the RxPDO’s for received data Equivalent to the input links of the TxPDO’s, the received data of the RxPDO’s are displayed via sources or source numbers. The sources existing in this way can be used in the frequency inverter via the local input links for the data targets. RxPDO1 Source No.
4.11.5.3 Examples of virtual links Example 1: Frequency inverter 1 Frequency inverter 2 Source Input link TxPDO1 RxPDO1 Source Target - No. Byte Byte - No. Control word Control input, Control word Output ref- Ramp input, erence fre- Line set value quency channel 62 Parameter 950 = Source-No.
4.12 Control parameters For the monitoring of the system bus and the display of the internal states, two con- trol parameters are provided. There is a report of the system bus state and a report of the CAN state via two actual value parameters. Node-State The parameter 978 gives information about the Pre-Operational, Opera-...
KP232. Experienced users have complete access to all the existing sources and possible input links with the XPI file of the active functions. The selection depends on the selected configuration and control procedure. The display of the parameters when using the XPI file is according to the following...
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TxPDO-Function 930TxPDO1 Function 931TxPDO1 Time 932TxPDO2 Function 933TxPDO2 Tome 934TxPDO3 Function 935TxPDO3 Time RxPDO-Function 936RxPDO1 Function 937RxPDO2 Function 938RxPDO3 Function Timeout 939SYNC Timeout 941RxPDO1 Timeout 942RxPDO2 Timeout 945RxPDO3 Timeout TxPDO1 Objects 946TxPDO1 Boolean1 947TxPDO1 Boolean2 948TxPDO1 Boolean3 949TxPDO1 Boolean4 950TxPDO1 Word1 951TxPDO1 Word2 952TxPDO1 Word3 953TxPDO1 Word4...
4.14 Utilities For the planning of the system bus according to the drive tasks in question, there are utilities in the form of tables. The planning of the system bus is done in three steps: 1. Definition of the communication relationships 2.
4.14.1 Definition of the communication relationships The communication relationships are planned and documented with the help of the table. The table is available as a Microsoft Word document "kbl.doc" on the BONFIGLIOLI VECTRON product CD or upon request. 06/05 06/05...
4.14.2 Production of the virtual links The virtual links are planned and documented with the help of the table. The table is available as a Microsoft Word document "vvk.doc" on the BONFIGLIOLI VECTRON product CD or upon request. 06/05 06/05...
4.14.3 Capacity planning of the system bus Each PDO telegram possesses a constant useful data content of 8 Bytes. According to worst case, this results in a maximum telegram length of 140 bits. The maximum tele- gram run time of the PDO’s is thus stipulated via the set baud rate. Capacity planning Baud rate / Telegram run time / μs...
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The capacity planning are planned and documented with the help of the table. The work sheet is available as a Microsoft Excel document "Load_Systembus.xls" on the VECTRON product CD or by request. Load system bus Baud rate [kBaud]: 1000 50, 100, 125, 250, 500, 1000 Frequency TxPDO Workload...
5 Control inputs and outputs Analog input EM-S1INA 5.1.1 General The analog input of the EM-IO-03 expansion module can optionally be configured as a voltage or a current input. Parameterization of the input signal is done by the defini- tion of a linear characteristic and assignment as a −...
5.1.3 Characteristic The mapping of the analog input signals onto a frequency or percentage reference value is possible for various demands. The parameterization is to be done via two points of the linear characteristic of the reference channel. The characteristic point 1, with the coordinates X1 and Y1, and the characteristic point 2, with the coordinates X2 and Y2, are to be set in the four data sets.
5.1.4.1 Examples The analog input signal is mapped onto a reference value as a function of the charac- teristic. The following examples show the operation modes for an analog voltage sig- Minimum Frequency nal. The parameter 418 is set to the value 0.00 Hz. The charac- Maximum Frequency teristic point 100% for the Y axis corresponds to the parameter 419 of 50.00 Hz in the examples...
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Characteristic point 1: X1 = 30,00% · 10 V = 3.00 V (X2=80% / Y2=85%) Y1 = -50.00% · 50.00 Hz = -25.00 Hz 42.50Hz Characteristic point 2: X2 = 80.00% · 10 V = 8.00 V Y2 = 85.00% · 50.00 Hz = 42.50 Hz 3.00V Tolerance band: 8.00V...
Operation mode "101 – bipolar abs. value" The operation mode "101 – bipolar abs. value“ maps the bipolar analog signal onto a unipolar input characteristic. The formation of the absolute value takes the character- istic into account comparable to the "bipolar" operation mode, but the characteristic points are reflected on the X axis with a negative value for the Y axis.
5.1.6 Tolerance band and hysteresis The analog input characteristic with change of sign of the reference value can be Tolerance band adapted by the parameter 560 of the application. The tolerance band to be defined extends the zero crossing of the speed relative to the analog control signal.
< 1 V / 2 mA drive mechanism stops freely. The monitoring of the analog input signal is active independent of the release of the frequency inverter according to the operation mode selected. In operation mode 2, the drive mechanism is decelerated independent of the stopping...
5.1.8 Adjustment As a result of component tolerances, it can be necessary to adjust the analog input. Adjustment Parameter 568 is used for this purpose. Operation mode Function 0 - no adjustment Normal operation Adjustment of the measurement with an analog 1 - Adjustment 0 V / 0 mA signal of 0 V or 0 mA.
Analog output EM- S1OUTA (voltage output) 5.2.1 General The analog output 1 of the EM-IO-03 expansion module is a voltage output with a range of +/-10 V. Parameterization of the output signals is done by the definition of the operation mode and a linear characteristic, stating the offset and the amplification. 5.2.2 Operation modes Operation...
5.2.4 Zero adjustment and amplification After the adjustment has been carried out, the voltage of the output signal at 0% and Offset 100% of the reference signals can be set with the parameters 585 (zero ad- Amplification justment) and 586. Offset The zero adjustment with the parameter 585 is done specific to the application...
Analog output EM- S2OUTA (current output) 5.3.1 General The analog output 2 of the EM-IO-03 expansion module is a current output with a range of 0(4)...20 mA. Parameterization of the output signals is done by the definition of the operation mode and a linear characteristic, stating the offset and the amplifica- tion.
5.3.4 Zero adjustment and amplification After the adjustment has been carried out, the current of the output signal at 0% and Offset 100% of the reference signals can be set with the parameters 526 (zero ad- Amplification justment) and 527. Offset The zero adjustment with the parameter 526 is done specific to the application...
Digital output EM-S1OUTD 5.4.1 General The digital output of the EM-IO-03 expansion module is designed as a relay make contact. Parameterization of this digital output permits a linking to a variety of func- tions. The selection of functions depends on the parameterized configuration. 5.4.2 Operation modes The operation mode of the digital output (Terminals X410A.6 and 7) is selected via...
With the help of parameter 493, the following opera- tion modes are available: Operation mode Function Speed measurement not active The digital inputs are 0 -Off available for further functions. Two-channel speed sensor with recognition of direction 4 -Quadruple evaluation of rotation via track signals A and B;...
5.6.2 Actual speed source If speed sensor 2 of the expansion module is to deliver the actual value signal for the speed controller, speed sensor 2 must be selected as the source. Switch-over is ef- Actual Speed Source fected via parameter 766.
Frequency and percentage reference channel The varied functions for the specification of the reference values are connected in the Refer- various configurations by the frequency or percentage reference channel. The ence frequency source Reference percentage source 475, and the 476 determine the additive connection of the available reference sources as a function of the installed hardware.
Status of the digital signals Digi- The status of the digital signals can be read in decimal coding via the parameters tal inputs Digital outputs 250 and 254. The display of the digital input signals enables checking the various control signals and their connections with the software functions in question, in particular in commissioning.
5.10 Motor temperature Temperature monitoring forms part of the configurable fault and alarm behavior. The connected load can be monitored by connecting a measuring resistor (motor PTC) with temperature characteristics according to DIN 44081 or by means of a bimetal tempera- ture sensor (break contact).
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The motor temperature for a temperature adjustment, as described in chapter "Tem- perature Adjustment", can be effected via analog input EM-S1INA. The selection is Operation Mode effected via parameter 465. Operation mode Function Temperature synchronization ° Temp. meas. at (0 ... 200 C =>...
6 Parameter list The parameter list is structured according to the menu branches of the control unit. For better clarity, the parameters are marked with pictograms: The parameter is available in the four data sets. The parameter value is set by the SETUP routine. This parameter cannot be written in the operation of the frequency inverter.
Annex Error messages The various control functions and methods and the hardware of the frequency inverter contain functions which continuously monitor the application. As a supplement to the messages documented in these operating instructions, the following failure keys are activated by the EM-IO-03 expansion module. Control connections 02 Reference value signal on analog input EM-S1INA faulty, check signal.
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Bonfiglioli has been designing and developing innovative and reliable power transmission and control solutions for industry, mobile machinery and renewable energy applications since 1956. www.bonfiglioli.com Bonfiglioli Riduttori S.p.A. VEC 219 R1 tel: +39 051 647 3111 fax: +39 051 647 3126 Via Giovanni XXIII, 7/A bonfiglioli@bonfiglioli.com 40012 Lippo di Calderara di Reno...
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