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):

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 5.3.4):

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

2: Use the second encoder input of EM-ENC-05

Chapter 3: Bipolar Analog Input Configuration

The analog input of EM-ENC-05 provides a bipolar range of ± 10V/± 20mA, 12 bit resolution, and can be flexibly configured through hardware and software.

3.1 Voltage/Current Mode Switching (DIP Switch S3) (Chapter 5.1.2)

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 simulating input mapping to reference values is defined by two linear characteristic curves (Chapter 5.1.3):

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 5.1.4)

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 5.1.6, 5.1.7)

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 5.1.8)

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-05 provides ± 10V bipolar analog output, which can flexibly map different actual values (Chapter 5.2).

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 5.2.4)

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: CAN System Bus and Virtual Link

EM-ENC-05 integrates the complete CAN system bus function (Chapter 4), based on the CANopen protocol (CiA DS301), to achieve real-time data exchange and distributed control between frequency converters.

5.1 Node Address and Baud Rate Configuration

Node-ID 900 (Chapter 4.5): Set the node address (range -1~63). -1 is disabled (factory default), 0 is master mode. Only one main station is allowed in the network.

Baud Rate 903 (Chapter 4.4): Supports baud rate settings from 50 kbps to 1000 kbps.

5.2 Bus Terminal Resistance Configuration (DIP Switches S1 and S2) (Chapter 4.1)

Passive terminal: S1=ON, S2=OFF (standard 120 Ω terminal)

Active terminal: S1=ON, S2=ON (improves signal edge through bias circuit, suitable for long-distance bus)

Key rule: Active terminals are only allowed to be activated at one location in the network, and other terminal nodes must use passive terminals.

5.3 NMT State Machine and Network Startup Sequence

EM-ENC-05 follows the CANopen NMT state machine (Sections 4.7, 4.8.1):

Pre Operational: Power on default state, only SDO is available.

Operational: Activate PDO communication to achieve real-time data exchange.

Stopped: All communication is prohibited.

The master station switches all slave stations to the Operational state by sending the Start Remote Node command (command word 0x01, node ID 0x00 broadcast).

5.4 PDO Channel and Virtual Link

EM-ENC-05 supports three sets of PDO channels (Chapter 4.11.5) and achieves data mapping through the "source target" linking method:

TxPDO (send): Select the data source (control word, reference value, analog input value, etc.) through parameters 946-977.

RxPDO (receive): Map the received data to available source numbers (700-729).

Chapter 6: Reference Channel Expansion

Both the analog input and encoder input of EM-ENC-05 can be used as reference value sources for the frequency converter (Chapter 5.4). By selecting Reference Frequency Source 475:

2: Only EM-S1INA analog input

4: MFI1A+EM-S1INA overlay

34: Second encoder (speed sensor 2)

35: MFI1A+Second Encoder Overlay

Chapter 7: Fault Diagnosis and Troubleshooting

EM-ENC-05 extends the fault diagnosis capability of the frequency converter (Chapter 7.1):

Analog input fault:

F1402: Analog input EM-S1INA signal fault.

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 is missing.

F1432: Rotation direction error (A/B phase sequence reversed).

F1433: Encoder 2 division mark error (Z signal abnormality).

F1434: The division mark of encoder 2 is too low.

F1435: The division mark of encoder 2 is too high.

System bus failure:

F2200-F2203: SYNC or RxPDO timeout.

F2210: CAN Bus Off status.

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