Electrical Installation & Design
Source: 02.ES680N_电气安装与设计.html (the “Electrical Installation & Design” chapter of the ES680N comprehensive manual)
Scope
This page covers the installation and wiring essentials of the ES680N 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.
The following content is extracted from text after PDF-to-HTML conversion. For terminal numbers, parameter numbers, ratings, and safety requirements, always refer to the original manufacturer manual.
Pre-wiring checks
Do not wire the drive while power is applied. Keep all breakers OFF, otherwise there is a risk of electric shock.
- After disconnecting input and output power, wait 10 minutes until the power indicator is fully off before starting work.
- The operator is responsible for complying with local technical regulations when installing and connecting the motor, cabinet equipment, and other components. Pay particular attention to cable size, fuses, grounding, disconnection, isolation, and overcurrent protection.
- If a fuse on the current branch has tripped, fault current may have been interrupted. Inspect conductive parts and other components and replace any damaged parts.
Main-circuit terminal description
The ES680N is available in frame sizes T4–T8, so the main-circuit terminal layout differs slightly by rating.
| Terminal | Name | Function |
|---|---|---|
| R, S, T | Three-phase power input | AC three-phase input connection |
| (+), (-) | DC bus positive/negative | Common DC bus input |
| (+), BR | Braking-resistor terminals | Connect the braking resistor |
| U, V, W | Output | Connect the three-phase motor |
| PE | Ground (PE) | Protective earth |
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.
- Use shielded cable to meet EMC requirements. Shield braid density must exceed 90%.
Recommended main-circuit cable sizes (national standard)
| Drive model | Frame | RST/UVW cable (mm²) | RST/UVW lug | Ground cable (mm²) | Ground lug | Terminal width (mm) | Screw | Tightening torque (N·m) |
|---|---|---|---|---|---|---|---|---|
| ES680N-4T025S-C1 | T4 | 3 × 6 | TLK6-5 | 6 | TLK6-5 | 10 | M5 | 2.8 |
| ES680N-4T032S-C1 | T4 | 3 × 10 | TLK10-5 | 10 | TLK10-5 | 12 | M5 | 2.8 |
| ES680N-4T037S-C1 | T4 | 3 × 10 | TLK10-5 | 10 | TLK10-5 | 12 | M5 | 2.8 |
| ES680N-4T044S-C1 | T4 | 3 × 10 | TLK10-5 | 10 | TLK10-5 | 12 | M5 | 2.8 |
| ES680N-4T060S-C1 | T5 | 3 × 16 | TLK16-6 | 16 | TLK16-6 | 12 | M6 | 4.8 |
| ES680N-4T075S-C1 | T6 | 3 × 25 | TLK25-6 | 16 | TLK25-6 | 14 | M6 | 4.8 |
| ES680N-4T091S-C1 | T6 | 3 × 35 | TLK35-6 | 25 | TLK25-6 | 17 | M6 | 4.8 |
| ES680N-4T112S-C1 | T7 | 3 × 50 | TLK50-8 | 35 | TLK35-8 | 20 | M8 | 13.0 |
| ES680N-4T150S-C1 | T7 | 3 × 70 | TLK70-8 | 50 | TLK50-8 | 26 | M8 | 13.0 |
| ES680N-4T176S-C1 | T8 | 3 × 95 | TLK95-12 | 70 | TLK70-8 | 26 | M12 | 35.0 |
| ES680N-4T210S-C1 | T8 | 3 × 120 | TLK120-12 | 95 | TLK95-8 | 28 | M12 | 35.0 |
| ES680N-4T253S-C1 | T8 | 3 × 150 | SQNBS150-12 | 95 | TLK95-8 | 30 | M12 | 35.0 |
Cable temperature rating must be ≥70℃. Current-carrying capacity references GB5226 and GB50217. Recommended lugs are Suzhou Yuanli TNR, GTNR, and BC series.
Recommended main-circuit cable sizes (UL)
| Drive model | Frame | RST/UVW cable (AWG/Kcmil) | RST/UVW lug | Ground cable (AWG/mil) | Ground lug | Terminal width (mm) | Screw | Tightening torque (N·m) |
|---|---|---|---|---|---|---|---|---|
| ES680N-4T025S-C1 | T4 | 8 | TLK10-5 | 8 | TLK10-5 | 12 | M5 | 2.8 |
| ES680N-4T032S-C1 | T4 | 8 | TLK10-5 | 8 | TLK10-5 | 12 | M5 | 2.8 |
| ES680N-4T037S-C1 | T4 | 6 | TLK16-5 | 6 | TLK16-5 | 12 | M5 | 2.8 |
| ES680N-4T044S-C1 | T4 | 6 | TLK16-5 | 6 | TLK16-5 | 12 | M5 | 2.8 |
| ES680N-4T060S-C1 | T5 | 3 | TLK25-6 | 3 | TLK25-6 | 14 | M6 | 4.8 |
| ES680N-4T075S-C1 | T6 | 3 | TLK25-6 | 3 | TLK25-6 | 14 | M6 | 4.8 |
| ES680N-4T091S-C1 | T6 | 2 | TLK35-6 | 3 | TLK25-6 | 17 | M6 | 4.8 |
| ES680N-4T112S-C1 | T7 | 1/0 | TLK50-8 | 2 | TLK35-8 | 20 | M8 | 13.0 |
| ES680N-4T150S-C1 | T7 | 3/0 | TLK95-8 | 1/0 | TLK50-8 | 26 | M8 | 13.0 |
| ES680N-4T176S-C1 | T8 | 4/0 | TLK120-12 | 2/0 | TLK70-8 | 28 | M12 | 35.0 |
| ES680N-4T210S-C1 | T8 | 250 kcmil | SQNBS150-12 | 3/0 | TLK95-8 | 22 | M12 | 35.0 |
| ES680N-4T253S-C1 | T8 | 300 kcmil | SQNBS150-12 | 3/0 | TLK95-8 | 22 | M12 | 35.0 |
Recommended lugs are KST’s TLK and SQNBS series. AWG notes: “5” means 5 AWG, “1/0” means 0 AWG, “2/0” means 00 AWG, “3/0” means 000 AWG, “4/0” means 0000 AWG, “2 × 250 Kcmil” means two 250 Kcmil cables.
Main-circuit wiring requirements
- External main-circuit wiring specifications and installation must comply with local regulations and applicable IEC standards.
- No phase-sequence requirement on the drive input R, S, T.
- To protect the main circuit, isolate it from any surfaces it may touch.
- The control circuit is a safety extra-low-voltage circuit. Keep it reinforced-insulated from other circuits.
- Do not solder stranded conductors.
- Terminal tightening torques may differ; tighten each screw to the specified torque.
- Terminals BR, (-), and (+) are for optional equipment. Do not connect them to AC power.
DC bus wiring
Right after power-off, residual voltage remains on the DC-bus (+), (-) terminals. Wait until the power indicator is off and at least 10 minutes have passed before wiring. Otherwise there is a risk of electric shock.
- 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.
- Select the braking resistor per recommended values, and keep the wiring distance under 5 m.
- Do not allow combustibles near the braking resistor.
- After connecting the braking resistor, set
H01.41(DC-bus release point) appropriately for 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, communication, and encoder cables.
Cable ducts must be well connected and well grounded. Aluminum ducts maintain equipotential. The filter, drive, and motor should all be well bonded to the system.
Protection requirements
Main-circuit cable protection
At the lug and cable-core transitions, 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 injury may occur.
- When a residual-current device is in use and trips on power-up, removing the EMC selectable ground screw may allow power-up.
Motor connection
Motor cable shield
Use shielded cable for the motor output. Use the power-cable shield ground bracket to bond the shield 360° and 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
Fast switching of the power devices produces a large dU/dt on the output. Long motor cables create large voltage stress on the motor windings and may cause insulation breakdown. Motors compliant with IEC 60034-25 IVIC B are strongly recommended.
| Frame | Drive model | Rated voltage (V) | Minimum cable length needing an output reactor (m) |
|---|---|---|---|
| T4 | ES680N-4T025S-C1 | 200–500 | 110 |
| T4 | ES680N-4T032S-C1 | 200–500 | 125 |
| T4 | ES680N-4T037S-C1 | 200–500 | 135 |
| T4 | ES680N-4T044S-C1 | 200–500 | 150 |
| T5–T8 | ES680N-4T060S-C1 – ES680N-4T253S-C1 | 280–690 | 150 |
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.
If you build your own encoder cable, use twisted-pair shielded cable with conductors no smaller than 26 AWG. 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 (≥10 m), grounding effectiveness degrades due to cable inductance. In that case, leave the encoder shield ungrounded.
A3 series high-performance encoder cable signal and color coding
| Drive end (DB9 male) | 1 | 2 | 3 | 4 | 5 | 9 | 7 | 8 | 6 | Shell |
|---|---|---|---|---|---|---|---|---|---|---|
| Motor end (17-pin aviation connector) | 10 | 7 | 5 | 6 | 4 | 14 | 16 | 17 | 9 | 8 / 15 |
| Signal | PS+ | PS- | / | / | PT1000+ | PT1000– | +5V | GND | / | / / shield |
| Wire color | Yellow | Yellow/black | Grey | Orange | White | Green | Red | Black | Blue | Purple / shield |
| Note | Twisted | Twisted | Twisted |
Control-circuit wiring
Control-circuit terminals
| Type | Symbol | Name | Function |
|---|---|---|---|
| Power input (CN4) | +24V-0V | External 24V power input | Control-board control supply; 24V ±10%, max 1 A |
| Power output (CN5) | 24VA-GND | 24VA analog-signal supply | 24V ±10%, max 30 mA; typically feeds the pressure sensor |
| Analog input (CN5) | AI1-GND | Analog input 1 | DC -10V–+10V, 52 kΩ, 12-bit, calibrated accuracy 0.5% |
| Analog input (CN5) | AI2-GND | Analog input 2 | Same as AI1 |
| Analog input (CN5) | AI3-GND | Analog input 3 | 0–10 Vdc / 0–20 mA, selected by function code; 52 kΩ (voltage) / 500 Ω (current) |
| Digital input (CN6) | DI1–DI5-COM | Digital inputs 1–5 | Opto-isolated, frequency <100 Hz; S1 selects external/internal supply; input impedance 1.98 kΩ; valid level 9–30 V |
| Digital input (CN6) | OP | External 24V supply | DIP switch selects external 24V supply for the DI circuit |
| Digital output (CN4) | DO1, DO2-COM | Digital outputs 1, 2 | Opto-isolated, bipolar open-collector; 0–24 V, 0–50 mA |
| CAN (CN7) | CANH, CANL, CGND | CAN +/-, signal ground | One standard isolated CAN channel, up to 1 Mbps, up to 64 nodes |
| STO (CN8) | 24VD, STO1, STO2, COM | STO safety function | SIL3; when STO is not used, short STO1, STO2, and 24VD; remove the jumper to use STO |
| Aux | CN1, CN2 | EtherCAT network ports | Supports 100Mbps EtherCAT with COE and EOE application layers; CN1 in, CN2 out |
| Aux | CN3 | 23-bit motor encoder interface | Standard with PT1000, KTY-compatible |
| Aux | CN9 | Remote keypad interface | Remote keypad |
| DIP | S1 | DI signal drive source | Internal or external drive of DI signals; default internal 24V |
| DIP | S2, S3 | CAN termination | Terminating resistor selectable; default terminated |
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) for 360° shield grounding.
- 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. Use shielded cable and keep the run 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.
DI1–DI5 wiring
Sink configuration:
- The most common configuration uses the drive’s internal 24V. Flip S1 to the left (internal 24V wiring) and tie COM to the external controller’s 0V.
- When using an external 24V, flip S1 to the right, feed the external +24V to OP, and route the external 0V through controller contacts to the DI terminals.
In sink configuration, do not parallel DI terminals across different drives; doing so may cause DI misoperation. If DI terminals must be paralleled across drives, add a series diode at each DI terminal (anode to DI) with IF>40 mA and VR>40 V.
Source configuration:
Source configuration requires an external 24V, S1 to the right, 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.
STO terminal wiring
| Signal | Input state | Notes |
|---|---|---|
| STO1 | ”1” or “H” | Input normal |
| STO1 | ”0” or “L” | STO activated |
| STO2 | ”1” or “H” | Input normal |
| STO2 | ”0” or “L” | STO activated |
Electrical characteristics of the safety inputs:
| Item | Specification |
|---|---|
| Voltage range | 24 VDC (±15%) |
| Input current | 3 mA (typ.), per channel |
| Logic-level standard | ”0” <5 V, “1” >15 V |
| Digital input impedance | 7.88 kΩ |
Communication connection
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-side control-board CN5 (A) | PLC side (B) | ||
|---|---|---|---|
| Type | Signal | Type | Signal |
| CAN | CANH | CAN | CAN-H |
| CAN | CANL | CAN-L | |
| CAN | CGND | CGND | |
| - | +24V | ||
| - | Shield | Shield |
In cross-cabinet installations, tie all CAN shields to CGND. Considering potential interference on PE in the field, do not tie the CAN shield to PE.
Topology:
- CAN requires a daisy-chain topology.
- Use twisted-pair shielded cable; CANH and CANL are twisted.
- 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.
Baud rate and distance:
| Baud (kbps) | Conductor size | Distance (m) | Nodes |
|---|---|---|---|
| 1024 | 0.205 mm² | 25 | 64 |
| 500 | 0.34 mm² | 95 | 64 |
| 100 | 0.5 mm² | 560 | 64 |
| 50 | 0.75 mm² | 1100 | 64 |
Termination:
| Terminal | Name | Function |
|---|---|---|
| S2, S3 | CAN termination DIP switches | Termination on/off; S2 and S3 must match |
EtherCAT wiring
EtherCAT supports bus, star, tree, and other topologies through suitable switches.
Grounding
Main-circuit grounding
Ground the drive reliably. The product leakage current exceeds 3.5 mA, so per IEC/EN 61800-5-1 use a protective earth conductor of at least 10 mm² copper.
- 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 for good bonding.
- Tighten ground screws to the recommended torque.
- Install the filter on the same mounting surface as the drive.
Single-drive grounding
| Item | Notes |
|---|---|
| ① | Do not ground the DC-bus or braking-resistor terminals. |
| ② | Tie input-power PE to the drive input PE. |
| ③ | Connect drive output PE to the motor-cable shield. |
| ④ | Input protection (fuse; the filter is downstream of the fuse). |
| ⑤ | Input power. |
| ⑥ | Three-phase motor. |
| ⑦ | Ground the motor casing. |
Multi-drive grounding
| Item | Notes |
|---|---|
| ① | Tie the product’s main-circuit input PE to the cabinet ground bus via a protective earth conductor. |
| ② | Tie the input-power PE to the cabinet ground bus. |
| ③ | Tie the cabinet ground bus to the metal enclosure of the cabinet via a protective earth conductor. |
| ④ | Tie the motor-output cable shield to the product’s output PE. |
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.
Post-wiring checks
| Item | Check |
|---|---|
| 1 | Drive matches the ordered model. |
| 2 | Peripheral equipment (braking resistor, braking unit, AC reactor, filter, breaker, etc.) matches the design. |
| 3 | Installation method and location meet requirements. |
| 4 | Drive input voltage is within 323–528 V. |
| 5 | Motor rated voltage matches the drive output rating. |
| 6 | Input power is connected to R, S, T. |
| 7 | Motor is connected to U, V, W. |
| 8 | Main-circuit cable size meets requirements. |
| 9 | Motor output-cable length does not exceed 50 m; if it does, lower carrier frequency F0-15. |
| 10 | Grounding is correct. |
| 11 | Drive output and control signal terminals are firmly fastened. |
| 12 | If a braking resistor and unit are used, wiring is correct and the resistance is suitable. |
| 13 | Control-circuit signal cables are shielded twisted pair. |
| 14 | Control-circuit cables are routed separately from main-circuit power cables. |
| 15 | Encoder wiring is firmly fastened. |