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.

3.1 Voltage/Current Mode Switching (DIP Switch S3)

S3=OFF (right side): Voltage input mode (± 10V, input impedance 100k Ω)

S3=ON (left side): Current input mode (± 20mA, input impedance 250 Ω)

3.2 Programmable signal characteristic curve

The process of mapping an analog input signal to a reference value (frequency or percentage) is defined by two linear characteristic curves (Section 5.1.3), with four data points (X1/Y1 and X2/Y2) as parameters:

X-axis: Percentage of analog input signal (relative to ± 10V or ± 20mA full-scale)

Y-axis: Percentage of output reference value (relative to maximum frequency or maximum percentage)

3.3 Operation Mode 562

1- Bipolar: The complete ± 100% input range is mapped to the ± 100% output range (including directional control).

11- Monopolar: The negative input signal is mapped to 0 (no inversion).

21- Monopolar 2-10V/4-20mA: Suitable for standard industrial signals, cutting off the lower limit of input characteristics to 20%.

101- Bipolar Absolute Value: Bipolar input is mapped to unipolar output (in absolute value).

3.4 Tolerance Bands and Error Behavior

Tolerance Band 560: Set a zero dead zone to prevent frequent direction switching caused by signal noise (Chapter 5.1.6).

Error/Learning Behavior 563 (Chapter 5.1.7):

1 (Warning): A warning is issued when the signal is below 1V/2mA.

2 (Shutdown): When the signal is lost, follow the stop behavior 1 to slow down and stop the machine.

3 (Fault tripping): Immediately stop freely and report an error when the signal is lost.

3.5 Analog Input Calibration

Due to component tolerances, calibration can be performed through Adjustment 568 (Chapter 5.1.8):

Apply 0V (or 0mA) to the input and execute Adjustment=1.

Apply 10V (or 20mA) to the input and execute Adjustment=2.

Chapter 4: Analog Output Configuration and PTC Temperature Monitoring

4.1 Analog output (0-20mA)

EM-ENC-02 provides configurable 0-20mA analog output (Chapter 5.2):

Operation Mode 590: Select the actual value to be output (such as analog input value, speed, frequency, etc.).

Offset 585 and Amplification 586:

Offset: The zero offset of the output signal (% of 20mA).

Amplification: The slope of the output signal, adjustable from 5% to 1000%.

4.2 PTC Temperature Monitoring (Chapter 5.8)

EM-ENC-02 provides a dedicated PTC thermistor input (terminal X410B. 2) for motor winding temperature monitoring. The operation mode can be selected through Operation Mode Motor Temp. 570:

11: Warning only

12: Fault tripping (immediate)

13/14/15: Delayed fault tripping (1/5/10 minutes)

The PTC trigger threshold complies with DIN 44081 standard (response resistance value>2.6k Ω).

Chapter 5: CAN System Bus and Virtual Link

EM-ENC-02 integrates the same CAN system bus function as EM-SYS (Chapter 4), supports CANopen protocol stack (CiA DS301), and enables real-time data exchange between frequency converters.

5.1 Node Configuration

Node-ID 900: Set the node address (1-63). -1 is disabled, 0 is master mode.

Baud Rate 903: Supports baud rate settings from 50 kbps to 1000 kbps.

5.2 Terminal Resistance Configuration

The bus terminal is configured through DIP switches S1 and S2 (Chapter 4.1):

Passive terminal: S1=ON, S2=OFF

Active terminal: S1=ON, S2=ON (only allows activation at one location in the network)

5.3 Virtual Link and PDO Mapping

EM-ENC-02 supports transferring data between frequency converters through virtual links (Chapter 4.11.5):

TxPDO (Send): Package local data and send it over the system bus. Select data sources (such as control words, reference values, analog input values, etc.) through parameters 946-977.

RxPDO (receive): Receive data from the system bus and map it to locally available data sources (source numbers 700-729).

Extended reference value source (Chapter 5.5):

Both the analog input and encoder input of EM-ENC-02 can be used as reference value sources for the frequency converter, which can be selected through Reference Frequency Source 475 or Reference Percentage Source 476.

Chapter 6: Digital Ports and Fixed Frequency Expansion

The digital port EM-S1IOD (X410A. 7) of EM-ENC-02 can be configured as input or output through Operation Mode 558 (Chapter 5.7).

6.1 Digital Input Mode

When Operation Mode 558=0, the port is a digital input that can be used as a signal source (Operation Mode 320/520) for starting signals, fixed frequency selection, or fault reset.

6.2 Digital Output Mode

When Operation Mode 558=1, the port is a digital output, and the output function (such as operating status, arrival frequency, fault signal, etc.) can be selected through Operation Mode Output 559.

6.3 Eight segment fixed frequency

EM-ENC-02 expands the number of fixed frequencies by adding Fixed Frequency Change Over 3 131, allowing for up to 8 combinations of fixed frequencies to be selected (Chapter 5.7.1.1):

The three binary combinations (66, 67, 131) correspond to fixed frequencies 1-8 (parameters 480-488).

Chapter 7: Fault Diagnosis and Troubleshooting

EM-ENC-02 extends the fault diagnosis capability of the frequency converter, and common fault codes include (Chapter 7.1):

Analog input fault:

F1402: Analog input EM-S1INA signal fault (signal loss or overload), check the wiring and signal source.

Encoder malfunction:

F1430: Encoder signal fault (no signal), check the A+/A - or B+/B - wiring of X410A.

F1431A/B phase signal missing (single channel loss), check if the encoder cable is open circuit.

F1432: Rotation direction error (A/B phase sequence reversed), can be corrected by swapping A+and B+wiring.

System bus failure:

F2200-F2203: SYNC or RxPDO timeout, check if the bus load and SYNC message generation are normal.

F2210: CAN Bus Off status, check the terminal resistance configuration and whether the bus cable is short circuited/open circuited.

F21nn: The master station reports a slave station fault, where nn is the hexadecimal address of the faulty node.