4.2 Electrical connection
4.2.4 Connector pin assignment
4.2.4.2 Connector pin assignment at the supply side
Fig. 12: Connector overview on the supply side USB port (X1)
Tab. 22: Pin assignment at the USB port (X1)
Designation Value
Absolute encoder power supply 5 V
<100 mA Connection Chip Select 5 V
Connection data <5 V
5 kΩ
Connection clock 5 V
1 MHz
Designation Meaning
USB USB communication
USB • X1 COM • X2 I/O • X3 Up • X4
LA LA
Power IN OUT
RUN Status
ERR
Umot • X5
Installation
COM port (X2)
The pin assignment of the COM connection differs according to the type of communication.
The distinction is made between the following types of communication:
RS232
CANopen
Tab. 23: Pin assignment of the COM port (X2) for RS232
Tab. 24: Pin assignment of the COM port (X2) for CANopen
I/O connection (X3)
Tab. 25: Pin assignment of the I/O connection (X3)
Pin Designation Meaning
1 TxD RS232 interface transmit direction
2 RxD RS232 interface receive direction
3 GND Ground connection
Pin Designation Meaning
1 CAN-H CAN-High interface
2 CAN-L CAN-Low interface
3 GND Ground connection
Pin Designation Meaning
1 UDD Power supply for external consumer loads
2 GND Ground connection
3 DigOut 1 Digital output (open collector) 4 DigOut 2 Digital output (open collector)
Installation
Tab. 26: Electrical data for the I/O connection (X3)
Voltage supply of the controller (X4)
Tab. 27: Pin assignment for the power supply of the controller (X4)
Tab. 28: Electrical data for the voltage supply (X4)
Designation Value
Power supply for external consum-ers
5 V
<100 mA
DigOut low = GND
high = high resistance 47 kΩ
Max. 0.7 A
TTL level: low < 0.5 V, high > 3.5 V PLC level: low < 7 V, high > 11.5 V
DigIn <50 V
47 kΩ
<1 MHz
AnIn ±10 V
AGND
Pin Designation Meaning
1 GND Ground connection
2 UP Power supply for controllers
Designation Value
Power supply for controller 12–50 V
≤100 mA (without external consumer)
Installation
Power supply of the motor (X5)
Tab. 29: Pin assignment for the power supply of the motor (X5)
Tab. 30: Electrical data for the voltage supply (X5)
EtherCAT port (IN/OUT)
Tab. 31: Pin assignment EtherCAT (IN/OUT)
Pin Designation Meaning
1 GND Ground connection
2 Umot Power supply of the motor
Designation Value
Motor power supply ≤50 V
Designation Meaning
IN/OUT EtherCAT communication Pin 1: TxD+ Transmission Data + Pin 2: TxD– Transmission Data – Pin 3: RxD+ Receiver Data + Pin 6: RxD– Receiver Data –
Installation
4.2.5 Connection at the motor side
Fig. 13: BL/LM motor with Hall sensors
Fig. 14: DC-motor with incremental encoders 1
Sens A Hall Sensor A Motor B
Motor C
GND GND
Sens B Hall Sensor B Sens C Hall Sensor C
+5 V Power Supply UDD
Motor Phase A Motor Phase B Motor Phase C
1
Index Encoder Index Index Encoder Index Channel B Encoder Channel B Channel B Encoder Channel B Channel A Encoder Channel A Channel A Encoder Channel A Motor + Motor +
Motor – Motor –
Encoder UDD +5 V Encoder Supply
GND GND
Installation
Fig. 15: BL motor with absolute encoders 2
Motor Phase A
Motor C
UDD +5 V Power Supply
GND GND
1 Motor A
Motor Phase B Motor Phase C
Installation
Fig. 16: BL motor with Hall sensors and incremental encoders 1
Sens A Hall Sensor A Motor B
Motor C
GND GND
Sens B Hall Sensor B Sens C Hall Sensor C
+5 V Power Supply UDD
Motor Phase A Motor Phase B Motor Phase C
1
Index Encoder Index Index Encoder Index Channel B Encoder Channel B Channel B Encoder Channel B Channel A Encoder Channel A Channel A Encoder Channel A
Encoder UDD +5 V Encoder Supply
GND GND
Installation
Fig. 17: BL motor with Hall sensors and absolute encoders 1
Sens A Hall Sensor A Motor B
Motor C
GND GND
Sens B Hall Sensor B Sens C Hall Sensor C
+5 V Power Supply UDD
Motor Phase A Motor Phase B Motor Phase C
1
Installation
4.2.6 I/O circuit diagrams
Fig. 18: Analogue input circuit diagram (internal)
The analogue inputs are executed as differential inputs. Both inputs use the same reference input.
The analogue inputs can be used flexibly:
Specification of set-points for current, speed or position
Connection of actual value encoders for speed or position
Use as a free measurement input (queried via the interface)
Fig. 19: Digital input circuit diagram (internal)
The digital inputs are switchable from the input level (PLC/TTL). The digital inputs can be configured for the following purposes (see the Drive Functions):
Digital input for reference and limit switches
Connection of an external encoder
PWM (Pulse Width Modulation) set-point specification for current, speed and position So that the voltage drop on the supply side does not affect the speed specification value, connect the analogue input ground (AGND) to the power supply ground (GND).
AnIn
AGND –
+
A D
In Dig-In
Installation
Fig. 20: Digital output circuit diagram (internal) The digital output has the following properties:
Open collector switch to ground
Monitored output current (switch opens in the event of an error)
A digital output can be assigned to an error output. It can be freely programmed.
4.2.7 External circuit diagrams
Bipolar analogue set-point specification via potentiometer DigOut
33k UP
DigOut
– + 20 V
10k
4,7k
1k
Motion Controller
AnIn AGND
Interface
Ref
UP
UP
10 V
Installation
Analogue set-point specification via potentiometer with internally set offset and scaling
Fig. 22: Analogue set-point specification via potentiometer with internally set offset and scaling
Connection of reference and limit switches
Fig. 23: Connection of reference and limit switches
Depending on the type of switch it may be necessary to use additional pull-up resistors.
No internal pull-up resistors are incorporated in the Motion Controller.
–
Installation
Connection of an external incremental encoder
Fig. 24: Connection of an external incremental encoder
Wiring between PC/controller and a drive
Depending on the type of encoder it may be necessary to use additional pull-up resis-tors. No internal pull-up resistors are incorporated in the Motion Controller.
2,7k
Interface
Quadrature Counter A
A B
Index B
Index
DigIn2
DigIn3 Encoder
UDD
GND UP
DigIn1
PC or High Level Control
Node 1
TxD
RxD RxDTxD GNDGND(D-Sub9 Pin 2) (D-Sub9 Pin 3) (D-Sub9 Pin 5)
Installation
Wiring with several Motion Control Systems in RS232 network operation
Fig. 26: Wiring with several Motion Control Systems in RS232 network operation
Connection to the CANopen network
Fig. 27: Connection to the CANopen network
Depending on the number of networked Motion Control Systems, a smaller value may be necessary for the pull-down resistor.
If the CAN wiring is not laid in a straight line it may be necessary to individually opti-mise the amount and location of the terminating resistors. For instance in a star net-work a central 60 Ohm terminating resistor may be more suitable. When the optimum arrangement of terminating resistors is fitted, no accumulation of error frames should be evident.
PC or High Level Control
4,7k
Node 1 Node n
TxD
TxD
RxD RxDRxDTxD GNDGNDGND(D-Sub9 Pin 2) (D-Sub9 Pin 3) (D-Sub9 Pin 5)
Node 1
CAN Bus Line
Node n
GND CAN_H
CAN_L
120 120
Installation
4.3 Electromagnetic compatibility (EMC)
Follow the instructions in the following chapters to perform an EMC-compliant installa-tion.
NOTICE!
Drive electronics with qualified limit values in accordance with EN-61800-3: Category C2 can cause radio interference in residential areas.
For these drive electronics, take additional measures to limit the spread of radio inter-ference.
4.3.1 Considered systems
The following considerations assume installations that can be described with the following circuit diagrams.
Fig. 28: Circuit diagrams of the considered systems
M 3~
L N PE
V+
GND
M 3~
Low voltage
distribution grid AC power
supply Controller
DC power supply Controller
Installation
AC-mains system
Fig. 29: Interference sources in an AC-mains system
Parasitic current usually arises from the following components:
Semiconductors
Capacitive portion of the motor supply line
Parasitic elements in the motor
Operating the motors with PWM is the cause here.
The DC-DC converter in the device and the used switching power supply also produce inter-ference that could affect the mains. The created interinter-ference of the DC-DC converter in the device is, however, normally of little relevance due to the switched power (<5 W).
In contrast to this are the switching power supply, which supplies the controller with motor voltage or electronics voltage, and the PWM drive. Depending on the design, quality and effectiveness of the integrated filters (where present), the power supply can also cause interference.
DC-mains system
Prerequisite for connecting to the DC mains is that the switching interference of the power supply be negligible. A linear power supply can be used to reduce this interference.
ZN Mains impedance of mains transformer – power supply connection ZE1 Common-mode impedance of electronics on DC side
ZE2 Common-mode impedance of electronics on AC side – power supply connection ZM1 Impedance of motor housing – controller
IS Parasitic current
CP Parasitic capacitance/filter capacitance
The qualitative assessment of a power supply can be performed with an interference voltage test and a resistive load (e.g., fanless heater / hot plate).
DC filter Power adapter
AC DC
Filter Control Filter
Motor
Installation
Problem solutions
The interference may vary depending on load and installation.
The mentioned variants are effective only if the following chapters are followed correctly.
4.3.2 Functional earthing
DANGER!Danger to life through ground leakage currents ≥3.5 mA
Check the earthing of the devices for proper installation.
The earthing system is essential for discharging parasitic current and for a potential distri-bution in the system that is as uniform as possible. The most efficient systems have a star or mesh shape. A star-shaped connection is easier to implement.
Ensure an adequate cross section and a very good electrical earth connection so that the contact resistances are low not only for the low-frequency currents.
The earth connection can be improved, e.g., by removing the oxide layers from the ends of conductors with fine sandpaper.
For electrical safety:
Earth in accordance with current standards and guidelines.
Solution Mode of action Benefits Disadvantages
3-phase common-mode choke / ferrite ring around all motor phases
Removes common-mode interference of the motor
Removes RF common-mode interference
Fast testing possible
Does not remove all inter-ference
Fabrication necessary PWM motor filter
(e.g., EFM 5003 6501.0035 7)
Removes switching noise on the motor cable through DC averaging
Interference limited to input side
Does not remove all RF inter-ference
Motor filters and ferrites (e.g., EFC 5008 6501.00351 )
Removes RF interference on the motor cable
Optimum for radio emis-sions
Does not remove all low-fre-quency interference
Input filter upstream of the controller
(e.g., EFS 5004 6501.00350 )
Removes interference of the switching regulator and part of the motor interference on DC net-works
Pass an interference volt-age measurement with correct wiring
Does not remove interference on the motor side
Mains filter upstream of the switching power supply
Removes common-mode interference of the power supply
Very cost-effective solu-tion
Often only effective for power supply
Does not remove all inter-ference
Installation
4.3.3 Cable routing
The cable routing depends on various factors, such as:
Is the cable shielded, twisted?
Were interference-reducing measures taken?
What material and what cable routing are used in the cable duct?
Over what surface is the cable routed?
Observe the following when laying the cables:
Use a full-surface, u-shaped and, if possible, metal cable duct.
Lay the cables near the corners of the cable duct.
Separate the cables by function where possible.
Maintain distances when laying the cables.
The distances may vary depending on the zone in the switching cabinet.
If possible, all cables should be twisted pairs or twisted and shielded in function groups (e.g., motor phases together, Hall sensors and supply together).
Fig. 30: Laying in the cable duct
Fig. 31: Grouping and shielding of the cables 1 High-current cable
2 Digital cable
3 Sensor cable
1 Shielding 2 Motor phase
3 Hall sensor
1
Installation
4.3.4 Shielding
Shield cables in all cases.
Shield cables that are longer than 3 m with tightly meshed copper braiding.
Shield all supply lines according to current guidelines/standards (e.g., IPC-A-620B) and connect using (round) shield clamp.
In special cases (e.g., with pigtail) or after qualification, the shield can be omitted for the following cables:
Cables with length <50 cm
Cables with low power supplies (e.g., <20 V)
Sensor cables
Connect shield clamps to a low-impedance (<0.3 Ω) earthing bar or earth plate.
A connection to the controller housing should only be made if no earthing bar is availa-ble.
Establish a star-point earth connection (see chap. 4.3.2, p. 43).
Lay the motor phases in a shield, separate from the sensor or encoder signals, and con-nect on at least the motor side (see 1 or 2 in Fig. 32).
Fig. 32: Various possibilities for the shield connection
The sensor signals can optionally be laid with the motor phases in a shared cable/insula-tion hose using another outer braided shield. This outer braided shield must be con-nected at both ends (e.g., 4 in Fig. 32). A solution such as 2 in Fig. 32 is not functional in 1 Suppressing electrical fields
2 Alternating magnetic field
3 Interruption of the earthing loop for direct currents or low-frequency currents 4 Discharging parasitic currents to the reference potential
1
2
3
4
Installation
4.3.4.1 Establishing the shield connection
The best results when establishing a shield connection on the cable are achieved in the fol-lowing way:
Fig. 33: Motor cable shield connection
1. Remove approx. 50-100 mm from the outer cable shield (1). Make certain that none of the fibres of the braided shield (2) are destroyed.
2. Either push back the shield or roll it up and fasten with heat-shrink tubing (4).
3. Optionally fit crimp-sleeves on the cable ends (5) and attach to the plug connectors.
4. Fasten the shield and the fixed end of the heat-shrink tubing with a cable tie (3).
1 Outer cable shield 2 Braided shield 3 Shield clamp
4 Heat-shrink tubing 5 Crimp-sleeve
1 2 4
5 3
Installation
4.3.4.2 Establishing shield connection with cable lug
A shield connection with cable lug should be avoided whenever possible. If it is necessary, however, the connection should be established as follows.
Fig. 34: Shield connection with cable lug
1. Scrape the surface around the hole to remove as much of the oxide layer as possible.
2. Guide screw with washers through the cable lug.
3. Place lock washer on the screw.
Depending on the screw length, also position the lock washer against the roughened surface.
4. Fix screw with nut on the bottom side or screw into the thread.
1 Screw 2 Nut
3 Spring washer 4 Washer
5 Lock washer 6 Wall
7 Wire eyelet
8 Protective conductor 3
2 1
4
6 5 4
7 8
1 2