Bonfiglioli Vectron EM-ENC-02 Expansion Module Integration and Encoder Interface Guide

Bonfiglioli Vectron EM-ENC-02 Expansion Module Integration and High Speed Encoder Interface Guide

In modern industrial drive systems, high-performance closed-loop control often relies on precise feedback signals and flexible I/O expansion capabilities. The EM-ENC-02 expansion module provided by Bonfiglioli for the ACTION and ACTION Cube series inverters is a versatile solution designed for this requirement. It integrates high-speed encoder interface, bipolar analog input/output, PTC temperature monitoring, and CAN system bus function, providing a complete hardware platform for complex motion control tasks.

Chapter 1: EM-ENC-02 Hardware Architecture and Installation

EM-ENC-02, as a multifunctional expansion component of the frequency converter, is installed in the lower slot of the device. Its hardware architecture includes six functional modules: CAN system bus, high-speed encoder input, bipolar analog input, analog output, digital port (configurable as input or output), and PTC thermistor interface.

1.1 Key points for safe assembly

According to the guidelines in Chapter 3 of the manual, the assembly process must strictly follow the following safety steps:

Safe power-off: The module installation can only be carried out after the frequency converter has completely cut off the power and waited for the DC bus capacitor to discharge (at least 3 minutes).

Module insertion: EM-ENC-02 is pre installed in the housing, and touching the exposed PCB board on the back is prohibited to prevent damage from electrostatic discharge (ESD). Align the module with the lower slot and insert it smoothly until it is fully seated.

Cover plate reset: After installation, the lower cover plate needs to be reinstalled in place.

1.2 Definition of Wiring Terminals

EM-ENC-02 provides two connection sockets X410A and X410B (Chapter 3.3.2):

X410A (encoder and digital port):

Terminals 1-4: Encoder input A+, A -, B+, B - (RS-422A/RS-485 differential signal or HTL single ended signal)

Terminal 5: 5V power output (used to power the encoder, maximum 200mA)

Terminal 6: 5V ground (GND)

Terminal 7: Digital Port EM-S1IOD (configurable as input or output)

X410B (Analog I/O, PTC, and System Bus):

Terminal 3: Analog output EM-S1OUTA (0-20mA current output)

Terminal 4: Analog input EM-S1INA (± 10V or ± 20mA, 12 bit resolution)

Terminal 5-7: CAN system bus (CAN_L, CAN_S, CAN_SND)

Terminal 2: PTC thermistor input (for motor temperature monitoring)

Chapter 2: Configuration and Application of High speed Encoder Interface

One of the core functions of EM-ENC-02 is its high-speed encoder interface, which supports input frequencies up to 300 kHz and is suitable for high-resolution, high dynamic response closed-loop control applications.

2.1 Hardware signal compatibility

The encoder interface supports two signal types (Chapter 5.3.3), which can be selected through the parameter Level 495:

Level=0 (push-pull/differential): A 5V differential signal (A+/A -, B+/B -) that complies with the RS-422A/RS-485 standard, with strong anti-interference ability and suitable for long-distance transmission.

Level=2 (single ended): 10V~24V single ended HTL signal, using only A+and B+terminals.

2.2 Terminal Resistance Configuration

For 5V RS-422 differential signals, the built-in 150 Ω terminal resistor can be activated through DIP switch S4 (Chapter 5.3.1):

Both switches are placed in the ON position: activate the terminal resistor (only applicable to 5V push-pull signals).

Key warning: The two switches of S4 must be placed in the same position at the same time, otherwise it may cause damage to the components. For 24V single ended HTL signals, there is no need to activate terminal resistors.

2.3 Parameterization of Speed Sensor 2

The encoder interface of EM-ENC-02 is defined as "speed sensor 2", forming a redundant or dual channel feedback scheme with the basic equipment's "speed sensor 1".

Key parameters (Chapter 5.3):

Operation Mode Speed Sensor 2 493: It is recommended to set it to 4 (Quadruple Evaluation) to count the four edges of the A/B signal, which can achieve the highest resolution speed measurement.

Division Marks Speed Sensor 2 494: Set the number of lines in the encoder (number of pulses per revolution PPR), ranging from 1 to 8192. The maximum allowed number of lines is determined by the input frequency limit（Smax=three hundred thousand Hz×sixty/nmax S max=300000Hz×60/n max）.

Actual Speed Source 766: When using two encoders simultaneously, select which encoder to use as the actual value source for the speed controller based on this parameter:

1: Use speed sensor 1 for basic equipment (default)

2: Using EM-ENC-02 speed sensor 2

2.4 Encoder signal fault diagnosis

EM-ENC-02 extends the encoder fault detection capability of the frequency converter (Chapter 7.1):

F1430: Encoder signal fault (no signal)

F1431: Encoder single channel signal loss (A or B phase loss)

F1432: Encoder rotation direction error (A/B phase signal reversed)

Chapter 3: Bipolar Analog Input and Flexible Signal Characteristic Curve

EM-ENC-02 provides a 12 bit resolution bipolar analog input (± 10V or ± 20mA) that can be flexibly configured through hardware and software.