Electrical Installation & Design
Source: is580-electrical.html (converted from relevant chapters of the IS580-S series servo drive comprehensive manual)
Scope
This page covers the installation and wiring essentials of the IS580-S 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 installation environment, clearances, main-circuit wiring, control-circuit wiring, grounding, and EMC handling.
The following content is extracted from text after the PDF was converted to HTML. For terminal numbers, parameter numbers, ratings, and safety requirements, always refer to the original manufacturer manual. Drawing-style content has been converted to text descriptions; add the original drawings later if you need the highest fidelity.
Installation environment
The IS580-S series is a cabinet-installed product. It must be installed in a final system that provides a fire-protective enclosure, an electrical-protective enclosure, and a mechanical-protective enclosure meeting local regulations and relevant IEC standards.
| Item | Requirement |
|---|---|
| Ambient temperature | Ambient temperature has a significant impact on drive life. Operating temperature must stay within -10℃ to 50℃. |
| Mounting surface | Install the servo drive on a flame-retardant surface. Leave enough space around it for heat dissipation, and mount it vertically with screws on the mounting bracket. |
| Vibration | Install in a low-vibration location. Vibration must not exceed 1G. Keep the drive away from presses and similar equipment. |
| Humidity and moisture | Avoid direct sunlight, damp locations, and places where water droplets may form. |
| Gas environment | Avoid corrosive, flammable, or explosive atmospheres. |
| Oil and dust | Avoid locations with oil mist or heavy dust. |
Installation clearance and orientation
Required mounting clearance and spacing vary with power rating. During actual installation, refer to the original dimensional drawings to confirm clearances for single, side-by-side, and stacked installations.
Installation principles: keep the drive mounted vertically; do not block the inlet or outlet airflow with cable ducts, terminal blocks, or cabinet structures; when several drives are mounted side by side, consider heat build-up and cabinet airflow; when the cabinet temperature approaches the upper limit, use a fan or air conditioner to keep the drive intake temperature within specification.
Standard wiring diagram
A typical system wiring includes the three-phase input power, drive main circuit, servo motor, braking resistor, controller signals, encoder feedback, analog/digital terminals, and communication terminals. Before wiring, confirm the drive model, input voltage level, motor model, encoder type, and injection-machine controller interface.
Main-circuit terminal functions
| 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 | Drive output | Connect to the three-phase motor |
| PE | Ground terminal | Protective earth |
Main-circuit cable selection and routing
Recommended cables for input and output main circuits are symmetrical shielded cables. Compared with four-core cables, symmetrical shielded cables reduce the electromagnetic emissions of the entire conducted system. Power cables with poor shielding, improperly arranged PE conductors, or shields that cannot be reliably bonded 360° are not recommended.
External power wiring must meet local regulations and applicable IEC standards. Power cables should be sized with copper conductors per external electrical component selection. When motor cables are long, distributed capacitance can cause electrical resonance, which may damage motor insulation or generate large leakage current that trips the drive’s overcurrent protection. If the motor cable is longer than 100 m, install an AC output reactor near the drive.
Use shielded cables for the motor output. The shield must be bonded 360° via the power-cable support bracket, and the shield pigtail must be crimped to the PE terminal. Keep the motor-cable shield pigtail as short as possible, with a width of at least 1/5 of its length.
Input power R, S, T
No phase sequence is required for the drive input. External power wiring specifications and installation must comply with local regulations and IEC standards. Install the filter close to the drive input; the cable between the filter and the drive should be shorter than 30 cm. Bond the filter ground terminal and the drive ground terminal together, and install them on the same conductive mounting plane connected to the cabinet’s main ground.
DC bus and braking circuit
Immediately after power-off, residual voltage remains on the DC bus (+) and (-) terminals. Wait until the CHARGE lamp is off and at least 10 minutes have passed after power-off before wiring. Otherwise there is a risk of electric shock.
The braking-unit wiring should not exceed 10 m. Use twisted-pair or closely paralleled double-wire routing. Do not connect the braking resistor directly to the DC bus; doing so can damage the drive or cause a fire.
The braking-resistor terminals are (+) and BR. Select the braking resistor per recommended values, and keep the wiring distance under 5 m; otherwise the drive may be damaged. Do not place combustible materials near the braking resistor to avoid ignition when the resistor heats up. For models under 75 kW with a built-in braking unit, after connecting the braking resistor, set F9-08 (braking-unit action start voltage) appropriately for the actual load.
Drive output U, V, W
Do not connect capacitors or surge absorbers on the drive output; doing so causes frequent protection or drive damage. When connecting the motor, check the U, V, W phase sequence, cable insulation, motor-to-ground insulation, and terminal tightness. Ground the motor-cable shield per the recommended method to avoid interference or leakage-current alarms.
Grounding terminal PE
| Requirement | Notes |
|---|---|
| Reliable grounding | The PE terminal must be reliably grounded with less than 10Ω ground resistance; otherwise the equipment may malfunction or be damaged. |
| No shared neutral | Do not combine the ground terminal with the neutral wire N. |
| Cable color | Use yellow-green cable for the protective earth conductor. |
| Grounding location | Ground the main-circuit shield as specified. |
| Mounting surface | Install the drive on a conductive metal mounting surface to ensure good bonding between the drive’s conductive base and the mounting surface. |
| Filter | Install the filter on the same mounting surface as the drive to preserve filtering effectiveness. |
Upstream protection
Install appropriate protective devices on the input distribution line to provide overcurrent, short-circuit, and isolation protection. When selecting the protective device, consider cable current capacity, system overload requirements, and short-circuit capability of the upstream distribution.
Control-circuit wiring
When working with the control circuit (jumper changes, terminal function switching, analog I/O, digital I/O, encoder interface, or communication interface), first confirm the control-board terminal definitions and parameter configuration. Route control cables separately from power cables. Use shielded cables for analog and encoder signals, and avoid running them in parallel with main-circuit cables over long distances.
Control-board terminals include digital inputs, digital outputs, analog inputs, and communication terminals. During field wiring, carefully verify terminal symbols, names, functions, signal levels, commons, and shield grounding to avoid abnormal pressure feedback, communication failures, or inadvertent operation caused by wrong commons, wrong wiring order, or improper shielding.
Pre-power-on checklist
| Item | Check |
|---|---|
| Power | Input voltage matches the nameplate; R/S/T firmly connected. |
| Motor | U/V/W to motor connected correctly; motor insulation sound; no ground short. |
| Braking | Braking resistor connected to (+) and BR; cable length matches power rating; no combustibles nearby. |
| Grounding | PE reliably grounded; ground resistance meets spec; shields bonded as required. |
| Control | DI/DO, AI/AO, encoder, and communication terminals wired correctly; commons not mixed. |
| EMC | Filter close to the input; power and signal cables separated; shield grounding proper. |
| Safety | Covers installed; no metal chips, oil, or water inside the cabinet; emergency-stop loop functional. |