Electrical Installation

Cabling Lengths

Please observe the maximum allowed cable lengths:

Connection

 Maximum wire length

Power supply cable

30 m*

STO-SBC

30 m

Field bus

30 m
GPIO: Digital Inputs and Outputs 30 m
GPIO: External Encoder / Analog Inputs 3 m / 30 m**

* For large currents, consider the voltage drop along the cable.

** Wiring locally at the axis, max 3 m recommended. Up to 30 m possible with shielded cables and depending on signal quality.

With a daisy-chain topology, the cable lengths mentioned above apply to the length of the entire daisy-chain - from the power supply / battery / distribution box / network switch to the last motor of the chain.

Power Supply

Use a Protected Extra-Low Voltage (PELV) or Safety Extra Low Voltage (SELV) power supply to ensure that the DC supply voltage is isolated from the grid.

Synapticon recommends the use of a power supply optimized for motion applications, such as the Synapticon ACTILINK MPSU 1500-48-IB, with integrated braking chopper.

For battery powered applications, it is important that while charging the battery, the charger fulfills the requirements of a SELV/PELV power supply, or the drive is switched off from the battery during charging. To prevent damage to the battery in the event of a short circuit, it is crucial to implement short circuit protection mechanisms. These protections can include devices such as fuses and PPTC devices, among others.

Important:For the electrical safety concept of the drive, the mean DC voltage is not allowed to exceed 60V during operation, including regenerative conditions.

By satisfying these requirements, the equipment can be seen as fulfilling protective class Ill (3), hence no provision for basic protection is required.

DC Current Consumption

Note: Data is for 48 V supply. For performance at other voltages, refer to the Application Note 24 V - 60 V Operating ACTILINK-S Integro Outside Nominal Voltage.

Connection Guide

This section explains the connection pinouts and their associated functions.

Attention: For R1.5 users ("Early Samples", 2023), the pinout power connector has changed! Do not use your R1.5 / Early Samples power supply cable; instead, configure the cables as described in this document.

Connection Schemes

ACTILINK-S and its variants allow for different general connection schemes - daisy chain or star - depending on the variant and the required electrical load.

Both connection schemes are available in conjunction with the metric and hybrid connector variants.

Additionally, the option to select the connection scheme applies to the power cables, STO cables, field bus cables, or to the hybrid cable. It is possible to combine daisy and star topology for the different signal types.

Daisy Chain Wiring

In a daisy chain configuration, multiple servo drives are connected in a series, where the communication or power line runs from the controller (or power source) to the first drive, then from the first to the second, and so on. This setup reduces cabling complexity and is suitable for systems where devices are installed in a linear or sequential arrangement.

  • Advantages:

    • Requires less cabling and fewer connectors.

    • Simple and cost-effective installation.

  • Considerations:

    • Failure at one node or segment can disrupt communication or power to subsequent drives.

    • A voltage drop may occur over long chains or with high current demands.

This method is ideal for low- to medium-load systems with well-managed cable lengths.

Star Wiring

In a star wiring configuration, each servo drive connects individually back to a central node, such as a controller, power supply, or switch. Each drive has a dedicated path, forming a topology that resembles a star.

  • Advantages:

    • High reliability: failure in one branch does not affect others.

    • Easier troubleshooting and maintenance.

  • Considerations:

    • Requires more cabling and potentially larger enclosures or cable trays.

    • The central node (controller or power supply) must be capable of supporting multiple connections simultaneously.

This method is recommended for high-performance applications requiring higher current loads, or when redundancy and isolation between drives are critical.

Earthing

All live parts of the drive are isolated from the earth potential by basic isolation. The earth potential does not serve a protective purpose since the system is considered to be safe to touch. A proper functional earth (FE) connection could still be recommended to improve the EMC behavior of the system.

  • Earthing via motor chassis / flange is recommended

  • Earthing via the connector’s earth pin as an alternative

Note: It is not recommended to use both.

Conventions Used in this Document

The diagrams in this document use the following conventions, but are also explicitly labeled where feasible to avoid confusion:

  • Female pin slots are drawn as open (white) areas

  • Male pins are drawn as closed (black) areas

Note: All metric connectors conform to IEC 61076-2-101 (M12) and IEC 61076-2-104 (M8).

Metric (M8/M12) Variant

The power, fieldbus, and STO/SBC input connectors are shown below.

Figure 1  -  Overview of the SOMANET Integro metric option connections - view from the cable side towards the device side

Note: GND refers to Ground (-).
VININ refers to Voltage In (+).

With the network connector, the pinout applies to all variants except the CAN variants.

Power Connector Pinouts

Figure 2  -  Power Connector from both SOMANET Integro and cable perspective
(This is an M12 4+1-pin L-coded connector.)

Pin # Color Function

1

Brown

VIN

2

White

GND

3

Blue

VIN

4

Black

GND

FE

Grey

PE

STO/SBC Input Connector Pinouts

Figure 3  -  STO/SBC input connector from both SOMANET Integro and cable perspectives
(This is an M8 3-pin A-coded connector.)

Pin # Color Function

1

Blue

STO-SBC B (+24 V)

3

Brown

STO-SBC A (+24 V)

4

Black

STO-SBC GND

Fieldbus Connector Pinouts

Figure 4  -  Fieldbus connector from both SOMANET Integro and cable perspectives
(This is an M8 4-pin A-coded connector.)

The devices with Ethernet/IP, EtherCAT, and PROFINET interface use the standard M8 4-pin Ethernet pinout. The CAN variant* uses the same connector for the respective CAN signals. All pinouts are the same for input and output.

Pin #

Color

Function for Ethernet, EtherCAT, Ethernet/IP and PROFINET

Function for CAN*

1

Yellow

TX+

CANL

2

White

RX+

CAN_0V

3

Orange

RX-

CANH

4

Blue

TX-

CAN_+V

ACTILINK SINGLE CABLE TECHNOLOGY Variant

The ACTILINK SINGLE CABLE TECHNOLOGY combines power, field bus and STO signal in one cable and one connector - the hybrid cable and hybrid connector.

The devices come either as:

  • I-Tech devices - with a male hybrid connector for input power and signals

  • Y-Tech devices - with a male hybrid connector for input power and signals and a female hybrid connector for output power and signals

Pinout

The pinout for a Y-Tec connector is as follows:

Pin

Dedication 

Cable Color 

1

GND

Black

2

VCC

Red

A

STO B

Yellow/Gray

B

STO GND

Black

C

STO A

Yellow/White

D

FE

Pink

E

TD+

Yellow

F

RD-

Blue

G

TD-

Orange

H

RD+

White

The pinout for the I-Tec connector is the same.

Both the I-Tec and the Y-Tec connector can be rotated freely by 320°. This rotation requires significant force and is intended to occur only during installation, not during operation. Refer to the image below for possible rotation positions.

Hybrid devices are available with GPIO functionality as well. The respective GPIO connector is separate from the hybrid connector and the pinout is the same as in I/O Connector Pinouts.

Cable Properties

ACTILINK HYBRID CABLE TECHNOLOGY cables use the following internal design:

Each cable consists of 10 wires:

Functionality Group

Functionality

Color

Cross Section

DC

VIN

red

2.5 mm2

GND

black

2.5 mm2

STO

STO A

yellow/white

0.25 mm2

STO B

yellow/grey

0.25 mm2

STO GND

black

0.25 mm2

Bus

TD+

yellow

0.25 mm2

RD-

blue

0.25 mm2

TD-

orange 

0.25 mm2

RD+

white

0.25 mm2

Earth

FE

pink

0.34 mm2

Variants with GPIO

I/O Connector Pinouts

In regard to I/O, both the M8/M12 connector configuration and the Hybrid variation use the following pinout on the M12 12-pin connector.

Figure 5  -  I/O Connector from both SOMANET Integro and cable perspectives
(This is an M12 12-pin A-coded connector.)

The I/O Connector pinout options depend on the variant. Refer to the table below for additional information.

Part Number Input Options

Ixxx-xxx-xxx-xxxx-xxG3-xxx-xx

Two AIN or BiSS/SSI/ABI encoder + One DI (up to 1Mhz) + Two DIOs + 24Vout

Ixxx-xxx-xxx-xxxx-xxD2-xxx-xx

Two DIs + 24Vout

Important:If a single-channel control source, e.g., an analog input or digital input, is used to control the motor, errors in the signal or hardware can cause unexpected motion. The user must ensure that the application is suitable and remains safe!

Pin Color Ixxx-xxx-xxx-xxxx-xxG3-xxx-xx Ixxx-xxx-xxx-xxxx-xxD2-xxx-xx

1

 White

AI_2_n/Clock-/B-

NC

2

 Brown

I-

DI_4*

3

 Green

DI_1/DO_1*

NC

4

 Yellow

DI_2/DO_2*

NC

5

 Gray

DI_3** (Fast DI)

DI_3* (Fast DI)

6

 Pink

DI_COM

GND

7

 Blue

AI_1_p/Data1+/A+

NC

8

 Red

AI_1_n/Data1-/A-

NC

9

 Black

AI_2_p/Clock+/B+

NC

10

 Violet

GND

GND

11

 Gray/Pink

I+

NC

12

 Red/Blue

+24V_out*

+24V_out*

* Referenced to GND.

** Referenced to DICOM. This is functionally isolated from GND.

Detailed Specification of Inputs and Outputs

Analog Inputs (AI)

SOMANET servo drives use differential and single-ended analog inputs to measure various sensors. These inputs support analog sensors for temperature, pressure, torque measurements, etc.

The analog inputs of SOMANET Integro can also be used for sensors that output resistance as a measured value. The measured analog values can be converted into a corresponding temperature, pressure, etc, by the drive itself.

For information on installing analog sensors to SOMANET Integro, refer to Analog In.

SOMANET servo drives have different ports for measuring analog voltage. They are connected to an integrated ADC (Analog-to Digital converter) with 16-bit resolution (0-65,520 ticks).

ADCs scale the measured voltage of a sensor to digital ticks.

The analog input specification for differential and single-ended inputs is listed below.

Differential Mode

Differential inputs measure the voltage between two distinct input signals.

A differential input resists electromagnetic noise better than a single-ended input. Most of the noise induced in one line is also induced in the other. The differential input measures only the difference between the two lines, and the noise common to both is ignored. The advantages of a differential input are: its wider input range, the possibility to measure negative voltage, and the robustness against common mode noise.

Symbol

Min.

Typical

Max.

Description

Impact

Vdiff

-10.2V

-

+10.2V

The input voltage between the positive and negative input pins

Any voltage out of this range causes saturation to the min/max ADC value.

Vdiff, max

-12V

-

+14V

The tolerable input voltage 

Any voltage out of this range damages the analog input’s circuitry.

Vcm

-1

+5V

+6V

The common mode voltage applied to the inputs

Any voltage out of this range causes excessive DC bias to the input pins.

Vcm, max

-10V

-

+12V

Absolute maximum common mode voltage

Any voltages out of this range may cause permanent damage to the input circuit.

Rin, diff

19.9K

20.3K

20.7K

Internal input impedance

-

fc

-

9.5KHz

-

Cut-off frequency of the input circuit low pass filter

-

Error

-1%

  -

+1%

  -

 -

ADC Ticks Calculation in Differential Mode

The conversion between deferential voltage and ADC ticks is given by :

To calculate the differential input voltage, use the following formula:

Single-ended Mode

The accuracy of the single-ended measurement will be affected by the source impedance. To keep the accuracy in the acceptable range, use an analog source with output impedance below 200R.

Symbol

Min.

Typical

Max

Description

Impact

Vin

-10.2V

  -

+10.2V

The input voltage between the input and GND

Any voltage out of this range causes saturation to min/max of the input circuitry.

Vin, max

-12V

-

+14V

The tolerable input voltage between the Vp input and GND

Any voltage out of this range damages the analog input’s circuitry.

Rin, single

11K

12.5K

14K

Internal input resistance

-

fc

-

9.5KHz

-

Cut-off frequency of the input circuit low pass filter

-

Error

-1%

  -

+1%

 -

-

ADC Ticks Calculation in Single-ended Mode

The conversion between measured voltage in volts to digital ticks for single-ended mode is given by:

To calculate the single-ended input voltage, use the following formula:

Digital Inputs (DI)

  • Digital inputs can be used to read digital signals “into” the ACTILINK device. For example:

    • Home switches or limit switches can be connected to digital inputs so that the status (open/closed) of the end switch becomes available in the drive’s object dictionary.

    • The 24V supply line can be used to supply such switches.

  • Compliant thresholds according to IEC 61131-2:2017 Type 1

  • Input voltage/Current curve displaying ON/OFF thresholds:

  • Input logic: Current Sinking (NPN)

  • Max input current: 2.5 mA

  • Protections:

    • ESD

    • Overvoltage up to 60V

    • Reverse polarity connection

  • Signal propagation time:

    • Standard mode: <1 communication cycle (<250 µs)

    • Touch probe mode: contact Support for details.

  • Minimum pulse duration: 13 µs

  • Object 0x2210 determines specific functionalities assigned to the input.

Configuring Digital Inputs/Outputs (DIO)

Via object 0x2210, the DIOs can be configured to serve as either input or output.

Configured as Inputs

See Digital Inputs (DI).

Configured as Outputs

  • Digital outputs can be used to “switch” external devices connected to ACTILINK-S. For example, a valve, a relay, or an external status LED can be connected to a digital output and be controlled through the motor’s object dictionary; thus, by signals coming from the PLC or an internal control logic.

  • Voltage and current: The digital outputs are internally supplied from the 24V Out. Refer to V Out for specifics. The claimed current capacity is shared between the 24V output and all digital outputs in use.

  • Output logic: Sourcing (PNP)

  • Max. switching frequency: 2.5 kHz

  • Isolation: Functional isolated

  • Load capabilities: Resistive, inductor,

    • Capacitive load < 100 nF

    • Resistive load > 100 Ω

  • Protected against:

    • ESD

    • Reverse polarity

    • Short-circuit and overload

For additional information, refer to Digital IO.

Digital IO Hardware Specification

Digital IO Timing Characteristics (Propagation Delay)

The following propagation delays were measured on SOMANET Integro / ACTILINK-S Integro Digital IO lines.

DIOs

Mode

Low → Hight Delay 

Hight → Low Delay 

DIO1 

Input

15 µs

18 µs

Output

21 µs

22 µs

DIO2 

Input

15 µs

21 µs

Output

21 µs

22 µs

DIO3

Input

850 ns

1100 ns
Default Input State (nothing connected)

With the pin configured as Input and no external connection:

DIO1, DIO2, DIO3: LOW

External Encoder Interface (ExtEnc)

Incremental

  • Digital incremental encoders with differential lines for A/A̅ and B/B̅

  • Index pulses (I/I̅) optional

  • Signal level: RS-422 with maximum 3.3V voltage level

  • Max frequency: on request

  • Receiver input impedance: 1 kΩ. Proper termination is imperative to minimize reflections. In point-to-point networks, the main cable should be terminated in its characteristic impedance (typically 120Ω) at the end that is farthest from the driver.

  • Cable length: <= 3 m recommended, longer possible

BiSS / SSI

  • Interface type: BiSS-C or SSI

  • Signal level: RS-422 compliant differential signals

  • Supported Encoder types: Absolute, Single-turn, Multi-turn

  • Cable length: <= 3 m recommended, longer possible

  • Max clock frequency: On request

  • Data word: Configurable, 32 bit

EnDat

This is available on request.

V Out

  • Voltage

    • 24V +/-1V if the device’s DC supply voltage is >= 26V

    • [DC supply voltage] +0/-2V if the DC supply voltage is < 26V

    • If using the 24V output, it is recommended to use a continuous DC supply voltage of 30V or more to ensure that the above condition is fulfilled even in transient conditions.

  • Current:

    • Max. 250 mA for the sum of all digital outputs and the 24V out

  • Protections

    • Protected against short-circuit/over-current.

Isolation and Grounding on the I/O Connector (Digital Inputs)

The inputs and outputs are designed according to IEC 61131-2.

Some connections on the I/O connector are not galvanically isolated. When external sensors/PLCs are connected, ensure that return currents do not flow back to the power supply via unintended paths through the I/O connector.

Reference domains on the I/O connector are as follows:

  • DI1 / DI2 are referenced to GND.

  • DI3 is referenced to DI_COM. DI_COM is functionally isolated from GND.

  • 24V_out is referenced to GND.

Important:If DI_COM is connected (directly or indirectly) to GND, the DI3 / DI_COM circuit is no longer isolated from the drive GND.

Wiring Scenarios

For wiring scenarios, refer to the figures that follow.

  • Figure 6
    Sensor supplied by ACTILINK-S Integro. There is no return path to an external power supply.

Figure 6  -  Illustration

  • Figure 7
    If galvanic isolation1 is required, it must be provided either by the I/O interface (often inside the PLC I/O module), or by isolating the sensor/PLC supply from the drive supply, e.g., using an isolated DC/DC converter.

Figure 7  -  Illustration

  • Figure 8
    When using DI3, additional measures are not required for functional isolation2. DI3 and DI_COM are functionally isolated from the drive GND inside ACTILINK-S Integro. To benefit from this isolation, keep DI_COM separated from GND in the external wiring.

Figure 8  -  Illustration

1 Galvanic isolation: There is no conductive (DC) path between two circuits. It breaks ground loops and can provide safety separation (if rated).

2 Functional isolation: Circuits are separated for function/noise reasons; however, it is not a safety barrier by itself. In Integro, DI3/DI_COM are functionally isolated from GND.

Connecting Sensor / PLC Outputs to Digital Inputs

This section provides wiring examples for connecting common industrial outputs, e.g., home switch, limit switch, PLC output, to the digital inputs of ACTILINK-S Integro. It focuses on PNP (sourcing) and NPN (sinking) transistor outputs.

Definitions

Output Active / Output Inactive

  • Output Active indicates that the sensor output transistor is ON.

  • Output Inactive indicates that the sensor output transistor is OFF (high‑impedance / open)

    • PNP sensor output (sourcing): When the sensor output is activated, OUT pulls high.

    • When the sensor output is deactivated, the output is high‑impedance (open).

NPN sensor output (sinking)

  • When the sensor output is activated, OUT pulls low.

  • When the sensor output is deactivated, the output is high‑impedance (open).

Note: Real output levels: Sensor outputs are transistor switches and are not ideal. In the Active state, the output voltage is typically close to +24 V (PNP) or close to 0 V (NPN), but not exactly equal due to internal voltage drops.

Connecting a PNP Output to Integro Input

Connecting a PNP Output Sensor to DI1 and DI2

DI1 and DI2 are referenced to GND. A PNP sensor can be connected directly. Depending on how the sensor is powered, refer to the corresponding wiring diagram.

Note: If the sensor is supplied by INTEGRO 24V_out, GND must also be connected.

Figure 9 - Sensor powered from the Integro drive

Note: DI1/DI2 are referenced to GND. If the sensor is powered from the Integro drive, the sensor 0V/GND must be connected to the drive GND to provide the return path.

Figure 10 - Sensor powered from an external power supply

Expected behavior:

  • Not Active → input reads LOW

  • Active → input reads HIGH

Connecting a PNP Sensor Output to DI3

DI3 is referenced to DI_COM (not to GND). DI_COM is the return path for the DI3 input current. Use one of the following options depending on whether DI3/DI_COM must be functionally isolated from drive GND.

  • Functional isolation not required

Figure 11 - Sensor powered from the Integro drive

Use this option when functional isolation is not required. The sensor may be powered from the drive supply.

Note: This wiring references the DI3 loop to the drive supply and does not maintain DI3/DI_COM functional isolation from drive GND.

  • Keep DI3/DI_COM functionally isolated from drive GND

Figure 12 - Sensor powered from an external power supply

Use this option when DI3/DI_COM must remain functionally isolated from drive GND. In this case, power the sensor from an external (preferably isolated) 24 V supply and connect the supply 0V/GND to DI_COM only (do not connect DI_COM to drive GND).

Expected behavior:

  • Not Active→ DI3 reads LOW

  • Active → DI3 reads HIGH

Connecting an NPN Output to Integro Input

An NPN sensor output does not directly produce a “high” level. For Integro, the recommended and validated method is to use DI3 together with DI_COM.

Note: DI3 is referenced to DI_COM (not to GND).

  • Functional isolation not required

Figure 13 - Sensor powered from the Integro drive

Use this option when functional isolation is not required. The sensor may be powered from the drive supply.

Note: This wiring references the DI3 loop to the drive supply and does not maintain DI3/DI_COM functional isolation from drive GND.

  • Keep DI3/DI_COM functionally isolated from drive GND

Figure 14 - Sensor powered from an external power supply

Use this option when DI3/DI_COM must remain functionally isolated from drive GND. Power the sensor from an external (preferably isolated) 24 V supply and connect the supply 0V/GND only to DI_COM.

Expected behavior:

  • Not Active → DI3 reads LOW

  • Active → DI3 reads HIGH

Notes / Limitations:

  • This method is supported for DI3 only.

  • Ensure the sensor output can sink the required input current.

Compatible Cables

For information on cabling, see Accessories / Cabling / Compatible Cables.