Wiring Guidelines

For a reliable and robust power interface and communication between the modules, some rules should be followed. A high power, low voltage DC drive needs high current to deliver the maximum power to the motor. Power losses and regenerated energy should also be considered when sizing the DC link cable.

There are a lot of EMI issues around the motor, Drive and power cables. Wires act as antennas, which enables them to pick up radiated signals from nearby sources. The longer the wire, the more pronounced the effect.

Proper grounding, cable shielding, proper connectors and connection are the most critical parts that should be considered for minimum electromagnetic interference (EMI).

DC bus

There are a lot of online sizing tools for selecting the right cable according to a specific application. Some ground rules apply:

  • Low resistance cable can increase efficiency.

  • Cable flexibility depends on the application.

  • Using shielded cable can improve EMC and it will decrease noise.

  • Cable length must be as short as possible to avoid noise and copper losses.

EtherCAT cable

It is recommended to use communication cables with a length of no more than 20 meters to minimize the effect of Electromagnetic interference (EMI). Under exceptional circumstances, cable length of up to 100 m can be used.

Preventing connection loss because of connectors or noise, consider high-quality standard cables.

The cables between the drive modules and to the master controller should be as short as possible.

Encoder wiring

Encoder cables should be run in conduits, preferably separate from other wires. If this is not possible, they should be run only with other low-power DC cables.

  • Follow the encoder wiring scheme or pinout designated on the encoder datasheet.

  • Run cabling in conduits, separated from power cables.

  • Shield cables and or individual wires to protect from EMI.

  • Avoid ground loops. Ground cables on one side only.

  • Consider the shortest cable between drive and encoder.