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

Smax=three hundred thousand Hz×sixty s/min nmax

S max=300000Hz× n max 60s/min

Minimum line requirement: To ensure low-speed stability, the signal should be updated at least every 2ms

Smin=five hundred Hz×sixty s/min four × nmin

S min=500Hz× 4×n min 60s/min

2.4 Actual speed source switching

Select the feedback source for the speed controller through Actual Speed Source 766 (Chapter 4.4.4):

1: Use the encoder input of the basic device (default)

2: Use the second encoder input of EM-ENC-04

2.5 Zero pulse monitoring function

When selecting mode 1004 or 1104, the frequency converter will continuously monitor the integrity of the Z signal. If the Z signal is abnormal or does not match the A/B signal, it will trigger an encoder fault (Chapter 6.1):

F1433: Encoder 2 Division marks wrong

F1434: Encoder 2 division mark too low

F1435: Encoder 2 division mark too high

Chapter 3: Bipolar Analog Input Configuration

The analog input of EM-ENC-04 provides a bipolar range of ± 10V/± 20mA, a 12 bit resolution, and can be flexibly configured through hardware and software.

3.1 Voltage/Current Mode Switching (DIP Switch S1)

S1=OFF (right side): Voltage input mode (± 10V, input impedance 100k Ω)

S1=ON (left side): Current input mode (± 20mA, input impedance 250 Ω)

3.2 Programmable signal characteristic curve

The process of simulating input mapping to reference values is defined by two linear characteristic curves (Chapter 4.1.3):

Characteristic Point X1/Y1 564/565: Coordinates of the first point (input signal% → output reference%)

Characteristic Point X2/Y2 566/567: Second Point Coordinates

3.3 Operation Mode 562 (Chapter 4.1.4)

1- Bipolar: Mapping complete ± 100% input to ± 100% output.

11- Monopolar: The negative input signal is mapped to 0.

21- Monopolar 2-10V/4-20mA: Suitable for standard industrial signals, the lower limit of the input range is fixed at 20% (2V/4mA).

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

3.4 Tolerance Bands and Error Behavior (Sections 4.1.6, 4.1.7)

Tolerance Band 560: Set zero dead zone to prevent frequent direction switching caused by noise.

Error/Warning Behavior 563：

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

2 (Stop): When the signal is lost, perform the stop action 2 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 (Chapter 4.1.8)

Perform two-stage calibration through Adjustment 568:

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

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

Chapter 4: Bipolar Analog Output Configuration

EM-ENC-04 provides ± 10V bipolar analog output, which can flexibly map different actual values (Chapter 4.2).

4.1 Operation Mode 584

0-Off: Output off (0V, used for calibration)

41- EM-S1INA, absolute value: Output the absolute value of the analog input (0~10V)

100-10V: Fixed output of 10V (for calibration)

101-133: Signed output mode (-10V~+10V)

201-254: Absolute actual value output with a range of 2V~10V (including wire breakage monitoring)

4.2 Zero bias and amplification factor (Chapter 4.2.4)

Offset 585: Zero offset (percentage of ± 10V full-scale, ± 100%)

Amplification 586: Magnification factor (5%~1000%)

Calibration Example:

Select mode 0-Off, measure the output voltage, and fill in Adjustment 587.

Select mode 100-10V, measure the output voltage, and fill in Adjustment 587 again.

Repeat validation, and if the deviation is significant, recalibrate (with an optimal accuracy of approximately ± 40mV).

Chapter 5: Relay Digital Output Configuration

EM-ENC-04 provides independent relay outputs (normally open contacts) that can be used to drive external contactors, indicator lights, or as fault signal outputs (Chapter 4.3).

5.1 Operation Mode EM-S1OUTD 533

The optional operating modes are consistent with the digital output in the basic equipment of the frequency converter (see the "Digital Output" chapter of the frequency converter operation manual), including:

Running signal

fault signal

Frequency arrival

Current limit activation

Brake control, etc

Chapter 6: Reference Channel Expansion

Both the analog input and encoder input of EM-ENC-04 can be used as reference value sources for the frequency converter (Chapter 4.5), and can be selected through Reference Frequency Source 475 or Reference Percentage Source 476:

2: Only EM-S1INA analog input is used as a reference source

4: MFI1A+EM-S1INA overlay

12: EM-S1INA+fixed frequency superposition

34: Second encoder (speed sensor 2) as reference source

35: MFI1A+Second Encoder Overlay

102-135: Corresponding patterns with symbols

Chapter 7: Fault Diagnosis and Troubleshooting

EM-ENC-04 extends the fault diagnosis capability of the frequency converter and adds fault codes related to the encoder Z signal (Chapter 6.1):

Analog input fault:

F1402: Analog input EM-S1INA signal fault (signal loss or overload), check X410B. 4 wiring and signal source.

Encoder malfunction:

F1430: There is no signal from the encoder signal. Check the A+/A - and B+/B - wiring of X410A.

F1431: A or B phase signal missing (single channel loss), check if the cable is open circuit.