Electrical Installation & Design

Source: 02.ES610_电气安装与设计.html (the “Electrical Installation & Design” chapter of the ES610 comprehensive manual)

Scope

This page covers the installation and wiring essentials of the ES610 drive in injection-molding machine electro-hydraulic servo systems, targeting electrical designers, cabinet assemblers, field commissioners, and after-sales maintenance personnel. The focus is on main-circuit wiring, motor connection, encoder connection, control-circuit wiring, communication connection, and grounding.

Pre-wiring checks

• After disconnecting input and output power, wait 10 minutes until the power indicator is fully off before starting work.
• The operator is responsible for installing and connecting the motor, cabinet equipment, and other components in accordance with the technical regulations recognized in the country and other applicable regional rules. Pay particular attention to cable size, fusing, grounding, disconnection, isolation, and overcurrent protection.
• If a fuse on the current branch has tripped, fault current may have been interrupted. To reduce the risk of fire and electric shock, inspect conductive parts and other components of the equipment and replace damaged parts.

Main-circuit terminal description

The ES610 is available in multiple frame sizes T3–T8 depending on power rating, so the main-circuit terminal layout differs slightly.

Main-circuit cable selection

Power-cable requirements

• Comply with EN 60204-1 and IEC 60364-5-52.
• PVC copper cable.
• 40℃ ambient, 70℃ cable surface temperature. (If ambient exceeds 40℃, contact the manufacturer.)
• Symmetrical cable with a copper-braid shield.
• To meet EMC requirements, a shielded cable must be used. Shield braid density must exceed 90%.

Recommended main-circuit cable sizes (national standard)

Recommended main-circuit cable sizes (UL)

Main-circuit wiring requirements

• External main-circuit wiring specifications and installation must comply with local regulations and applicable IEC standards.
• There is no phase-sequence requirement on the drive input R, S, T.
• To protect the main circuit, isolate it from any surfaces it could touch.
• The control circuit is a safety extra-low-voltage circuit. Keep it reinforced-insulated from other circuits.
• Terminal tightening torques may differ; tighten each screw per the specified torque using a torque screwdriver, torque ratchet, or torque wrench.
• Terminals BR, (-), and (+) are for optional equipment. Do not connect them to AC power.

DC bus (+), (-) wiring

• Keep braking-unit wiring under 10 m. Use twisted-pair or closely paralleled double wires.
• Do not connect the braking resistor directly to the DC bus; doing so may damage the drive or cause a fire.

Braking-resistor terminals (+), BR

• The braking-resistor terminals are active only on models of 132 kW or less that include a built-in braking unit.
• Select the braking resistor per recommended values, and keep the wiring distance under 5 m. Otherwise the drive may be damaged.
• Do not allow combustibles near the braking resistor to avoid ignition due to overheating.
• On models of 132 kW or less with a built-in braking unit, after the resistor is connected, set F6-15 (braking duty) and F9-08 (braking transistor turn-on voltage) based on the actual load.

Main-circuit routing

Drive power input and motor cables produce strong electromagnetic interference. Keep main-circuit cables at least 30 cm away from signal cables. Common main-circuit cables are input RST, output UVW, DC bus, and braking cables; signal cables are I/O signal, communication, and encoder cables.

Cable ducts must be well connected and well grounded. Filter, drive, and motor must all be well bonded to the system (machine or equipment).

Wiring on IT or corner-grounded supply

On IT or corner-grounded supplies, disconnect the EMC selectable ground screw; otherwise equipment damage or personal injury may occur.

For non-IT and non-corner-grounded supplies, EMC and VDR selectable ground screws are fixed. During dielectric-withstand testing, disconnect the selectable ground screw first; otherwise the test may fail.

Protection requirements

Main-circuit cable protection

At the lug and cable-core transitions of main-circuit cables, add heat-shrink tubing that completely covers the conductor portion.

Requirements for upstream protection

• Install suitable protection on the input distribution line to provide overcurrent, short-circuit, and isolation protection.
• When selecting protection, consider main-circuit cable capacity, system overload requirements, and short-circuit capability of the upstream distribution.

IT-supply considerations

• The product suits supplies with a grounded neutral. On IT supplies (ungrounded neutral), remove the EMC selectable ground screw and do not install a filter; otherwise equipment damage or personal injury may occur.
• When a residual-current device is in use and trips during power-up, EMI may not meet IEC 61800-3 Class C3 once the EMC selectable ground screw is removed.

Motor connection

Motor cable shield

Use shielded cable for the motor, and use a power-cable shield-ground bracket to bond the shield 360° structurally. Crimp the shield pigtail to the PE terminal. Keep the pigtail as short as possible with a width of at least 1/5 of its length.

Motor cable length

Do not use unnecessarily long cables between drive and motor. Long cables have high distributed capacitance and tend to generate higher-harmonic currents. When the output-cable length reaches or exceeds the values below, install an output reactor near the drive.

Motor wiring

Connect the drive U, V, W phases to the motor U, V, W phases one-to-one.

Encoder connection

• During field installation, route signal cables (e.g. encoder cables) in separate ducts from power cables. Do not bundle encoder cables with power cables; doing so is a frequent cause of encoder interference.
• The motor casing must be connected to the drive PE terminal, and the motor-side ground must be well bonded; otherwise grounding is ineffective.
• If you build your own encoder cable, use twisted-pair shielded cable with conductors no smaller than 26AWG. Ground the shield at both ends—to the drive PE and the motor casing.
• On some large equipment where the drive is far from the motor and the motor cable is very long (≥10 m), grounding effectiveness degrades due to cable inductance. In that case, leave the encoder shield ungrounded by disconnecting the control-board ground from the small ground bus.

A3 series high-performance encoder cable signal and color coding

Control-circuit wiring

Control-circuit terminals

DIP-switch settings

Control-circuit wiring requirements

• Use shielded cables for the control circuit. Different analog signals must use separate shielded cables; digital signals use shielded twisted pair.
• Recommend pairing shielded cables with the cable-shield ground bracket (optional) so the shield can be grounded 360°.
• Keep shield pigtails short and secure them to the drive’s small ground bus with a screw.
• Keep control-circuit cables away from main-circuit cables; use separate ducts.
• If control-circuit and drive cables must cross, cross them at 90°.
• Use insulated ferrules; exposed conductor length for single or stranded wires must not exceed 6 mm.

Analog-input wiring

Weak analog voltage signals are very sensitive to external interference, so shielded cables are normally required, and the cable should be kept short (under 20 m). For severe interference, install a filter capacitor or ferrite core at the signal source. Ground the shield pigtail of the analog terminals to PE on the drive side.

DI wiring

Sink configuration:

• The most common configuration uses the drive’s internal 24V. Flip S1 down and tie COM to the external controller’s 0V.
• When using an external 24V, flip S1 up, feed the external +24V to OP, and route the external 0V through controller contacts to the DI terminals.

Source configuration:

Source configuration requires an external 24V, S1 flipped up, and the external 0V tied to OP.

DO wiring

• When a DO drives a relay, install a flyback diode across the relay coil, otherwise the DC 24V supply can be damaged. Drive capability is ≤50 mA.
• Install the flyback diode with correct polarity; otherwise the DC 24V supply is destroyed as soon as the DO turns on.
• DO requires an external 24V supply. If DO1 is driven externally, confirm whether the external 24V ground can be tied to the drive control-board ground.

Communication connection

RS485 wiring

To use RS485, install the RS-485 expansion card (MD38IO3).

Use three-core shielded cable for the 485 bus. Connect 485+, 485-, and CGND in that order. 485+ and 485- are twisted; the third conductor is the 485 reference ground CGND. Bond the shield to equipment ground. Install a 120 Ω termination resistor at each end of the bus to prevent reflections.

PLC-to-drive wiring

Topology

• For many nodes, prefer a daisy-chain topology.
• Add 120 Ω termination only at both ends.
• Tie all node 485 reference grounds together, up to 128 nodes, with each node stub <3 m.

Transmission distance

CAN wiring

Use three-core shielded cable for the CAN bus. Connect CANH, CANL, and CGND. CANH/CANL are twisted; the third conductor is the CAN reference ground CGND. Bond the shield to equipment ground. Install a 120 Ω termination resistor at each end.

Drive-to-PLC wiring

CAN topology

• CAN requires a daisy-chain topology.
• Add 120 Ω termination only at both ends.
• Tie all node CAN reference grounds together, up to 64 nodes, with each node stub <0.3 m.

CAN distance

Profinet wiring

After the MD500-PN1 card communicates with the drive, wire it correctly to the Profinet master. Supported topologies include bus, star, and tree. Maximum bus length is 100 m.

Profibus-DP wiring

Add a termination resistor at each end of the Profibus bus. The system PE must be reliably grounded.

Grounding

Main-circuit grounding

• Use yellow-green copper cable for the protective earth conductor. Do not insert a breaker or similar switching device in series.
• The ground terminal must be reliably grounded; otherwise equipment may malfunction or be damaged.
• Do not combine the ground terminal with the neutral wire N.
• Install on a conductive metal mounting surface to bond the entire conductive base to the mounting surface.
• Tighten ground screws to the recommended torque to avoid loose or overstressed connections.
• Install the filter on the same mounting surface as the drive to preserve filtering effectiveness.

Single-drive grounding

Multi-drive grounding

Control-circuit grounding

The control board is not grounded at the factory. If you need to ground it, fasten an M3×8 cross-recess combo screw into the control-board ground hole to make the connection.

Post-wiring checks