Bonfiglioli Vectron EM-ENC-04 Multi functional Expansion Module Complete Configuration Guide

Bonfiglioli Vectron EM-ENC-04 Multi functional Expansion Module Complete Configuration Guide

In high-end industrial automation applications, frequency converters often need to expand more analog signal processing and high-speed feedback interfaces to meet the needs of complex motion control. The EM-ENC-04 expansion module provided by Bonfiglioli for the ACTION and ACTION Cube series frequency converters is a versatile solution tailored to this demand. It integrates a second high-speed encoder interface with zero pulse detection, bipolar analog input, bipolar analog output, and relay digital output, providing a one-stop hardware expansion platform for complex drive systems.

Chapter 1: EM-ENC-04 Hardware Architecture and Installation

EM-ENC-04 is a high-end model in the Bangfeili ACT/ACU inverter expansion module series, installed in the lower slot of the device. Its hardware architecture includes four major functional modules: high-speed encoder input (including zero pulse detection), bipolar analog input (± 10V/± 20mA, 12 bit resolution), bipolar analog output (± 10V), and relay output (normally open contacts).

1.1 Overview of Hardware Function Modules

According to Chapter 2 of the manual, EM-ENC-04 provides the following functions:

Speed sensor input (second encoder): Incremental encoder interface, supports A/B/Z three channel differential signals, maximum input frequency of 300 kHz, supports quadruple frequency evaluation and zero pulse monitoring.

Analog input EM-S1INA: Bipolar analog input, switchable to ± 10V voltage input or ± 20mA current input through DIP switch S1, with 12 bit resolution.

Analog output EM-S1OUTA: Bipolar ± 10V voltage output, can output different actual values through parameter configuration.

Digital output EM-S1OUTD: Relay output (normally open contact), maximum 24V AC/DC, 1A resistive load.

1.2 Mechanical Installation and Safe Operation

The installation process must strictly follow the following safety steps (Chapter 3.2):

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-04 is pre installed in the housing, and touching the exposed PCB board on the back is prohibited to prevent electrostatic discharge (ESD) from damaging components.

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

1.3 Definition of Wiring Terminals

EM-ENC-04 provides two connection sockets X410A and X410B (Chapter 3.3.2):

X410A (encoder input and power supply):

Terminal 1-2: Encoder A+/A - signal

Terminal 3-4: Encoder B+/B - signal

Terminal 5-6: Encoder Z+/Z - (zero pulse reference signal)

Terminal 7: 5V power output (used to power the encoder, maximum 200mA)

X410B (Analog I/O and Relay Output):

Terminal 1:20V power output (maximum 180mA)

Terminal 2: Ground (GND)

Terminal 3: Analog output EM-S1OUTA (± 10V)

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

Terminal 5-6: Relay output EM-S1OUTD (normally open contact)

Chapter 2: Encoder Interface Configuration with Zero Pulse

The core differentiation function of EM-ENC-04 is its support for A/B/Z three channel incremental encoder interfaces, where the Z channel (zero pulse) can be used for encoder monitoring and position reference.

2.1 Encoder working mode selection

Select the operating mode through the parameter Operation Mode Speed Sensor 2 493 (Chapter 4.4):

0 (Off): Speed measurement disabled

4 (Quadruple Evaluation): Quadruple Evaluation - Counting the four edges of A/B signals to achieve the highest resolution speed measurement.

104: Same as Mode 4, but the speed value is reversed.

1004 (Quadruple Evaluation with Pulse): Quadruple frequency evaluation+zero pulse monitoring - Z signal is used for encoder reliability monitoring.

1104: Same mode as 1004, but the speed value is reversed.

2.2 Hardware signal compatibility and terminal resistance

The interface supports two signal types, which can be selected through the parameter Level 495 (Chapter 4.4.3):

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

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

Terminal resistor configuration (DIP switch S2) (Chapter 4.4.1):

For 5V RS-422 differential signals, the built-in 150 Ω terminal resistor can be activated through S2:

Both switches of S2 are turned on to activate the terminal resistor (only applicable to 5V push-pull signals)

Both switches of S2 are turned off: the terminal resistor is not activated

Key warning: The two switches of S2 must be placed in the same position at the same time, otherwise it may damage the components. For 24V single ended signals, there is no need to activate terminal resistors.

2.3 Encoder line count calculation and parameterization

The number of encoder lines is set through Division Marks Speed Sensor 2 494 (range 1~8192, default 1024).

The maximum allowable number of lines is determined by the upper limit of the input frequency (300 kHz) and the maximum speed (Chapter 4.4.2):