Bonfiglioli Vectron EM-ENC-05 Full Function Expansion Module Integration Guide

Bonfiglioli Vectron EM-ENC-05 Full Function Expansion Module Integration and Encoder Interface Guide

In the field of high-end industrial automation, frequency converters often need to simultaneously process high-speed encoder feedback, analog signals, and distributed network communication. The EM-ENC-05 expansion module provided by Bonfiglioli for the ACTION and ACTION Cube series inverters is a versatile solution designed for this requirement. It integrates three major functions: high-speed encoder interface with zero pulse detection, bipolar analog input/output, and CAN system bus, providing a complete hardware expansion platform for complex drive systems.

Chapter 1: EM-ENC-05 Hardware Architecture and Installation

EM-ENC-05 is the flagship model in the Bangfeili ACT/ACU inverter expansion module series, installed in the lower slot of the device. Its hardware architecture includes three major functional modules: high-speed encoder input (including A/B/Z channels), bipolar analog input (± 10V/± 20mA, 12 bit resolution), bipolar analog output (± 10V), and CAN system bus interface.

1.1 Overview of Hardware Function Modules

According to Chapter 2 of the manual, EM-ENC-05 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 S3, with 12 bit resolution.

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

CAN system bus: compliant with ISO-DIS 11898 (CAN High Speed) standard, supporting a maximum transmission rate of 1 MBaud.

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-05 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-05 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 System Bus):

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

Chapter 2: Encoder Interface Configuration with Zero Pulse

The core differentiation function of EM-ENC-05 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 working mode through the parameter Operation Mode Speed Sensor 2 493 (Chapter 5.3):

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 Reference 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 types of signals, which can be selected through the parameter Level 495 (Chapter 5.3.3):

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): 12V~24V single ended HTL signal, only using A+, B+, Z+terminals.

Terminal resistor configuration (DIP switch S4) (Chapter 5.3.1):

For 5V RS-422 differential signals, the built-in 150 Ω terminal resistor can be activated through S4:

All three switches of S4 are turned on: activate the terminal resistor (only applicable to 5V push-pull signal)

All three switches of S4 are turned off: the terminal resistor is not activated

Key warning: The three switches of S4 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 5.3.2):