ETEL DSB2P Series Servo Amplifier Connection and Configuration Guide

Complete Guide to On site Hardware Deployment and Wiring of ETEL DSB2P Series Digital Servo Amplifier

In precision motion control systems, the servo amplifier (driver) serves as the power interface connecting the controller and motor, and its hardware installation and wiring quality directly determine the stability and reliability of the system. The ETEL DSB2P series digital servo amplifier is designed for direct drive applications and supports single-phase, two-phase, and three-phase brushless/DC/stepper motors. It covers various physical forms such as rack mounted (6U 19 inch standard) and standalone with a chassis, with output currents ranging from 4.9A to 56A peak. However, from model selection and chassis heat dissipation planning to encoder wiring and EMC shielding grounding, negligence in hardware deployment details often leads to system malfunction or even equipment damage. This article is based on the core content of the DSB2P series hardware manual (version D), and systematically outlines the key points of on-site hardware installation and wiring to help engineers avoid common pitfalls.

Model selection and physical form

The DSB2P series offers four physical forms to adapt to different installation environments:

1.1 Rack Module (model suffix 1)

Width of 10F (approximately 50.8mm), height of 6U, suitable for standard 19 inch rack.

An external DC power supply (24-340VDC) is required, with a peak current of 11A or 21A (depending on the sub model X21/X31).

No built-in cooling fan, relying on forced air cooling from the cabinet.

1.2 Rack Module with Heat Sink (suffix 2)

Width of 14F (approximately 71.1mm), suitable for higher power requirements.

The peak current can reach 21A, 42 A, and even 56 A (sub models X32/X42/X52).

The heat sink area is larger, but it still requires coordination with the cabinet air duct.

1.3 Housed without PSU (suffix 3)

The independent box has a size of 65.2 × 168.7 × 318mm and can be wall mounted or installed inside a cabinet.

An external DC power supply (24-340VDC) is required, with a peak current of 11A or 21A.

1.4 Integrated power module with chassis (Housed with PSU, suffix 4)

The size of the independent box is 96 × 222 × 306mm, and it is directly connected to 85-240Vac AC mains power.

Built in power rectifier and fan, with peak current ranging from 11A to 56A.

Optional phase to phase short-circuit relay (suffix includes 2) and external regenerative resistor interface.

Selection points: If there is already a DC power supply on site and space allows, the rack module (suffix 1/2) has the highest cost-effectiveness; If you need to place or move it independently, it is more convenient to have a chassis module (suffix 3/4). High power applications (>21A) must choose suffix 2 or 4 and pay attention to the cooling air volume of the cabinet.

Mechanical installation and heat dissipation requirements

2.1 Key points for installing rack modules

The rack module is vertically inserted into a 19 inch sub rack through upper and lower rails, with a depth of 239.24mm.

Multiple drives can be centrally powered by the ETEL DSO-PWR power module, and one DSO-PWR can supply up to 7 DSB2P rack modules (depending on power allocation).

Be sure to use metal screws to secure the module to the rack rails during installation, ensuring good grounding.

2.2 Heat dissipation distance

It is recommended to maintain a tight fit of 0mm between modules (the manual recommends B=0mm), but at least 100mm (A=100mm) airflow channels should be left at the top and bottom of the cabinet.

The rack module itself does not have a fan and must rely on the axial flow fan installed inside the cabinet to provide forced air cooling. The air volume needs to be calculated based on the total power consumption - taking DSB2P-PX52 as an example, the power consumption at full load can reach several hundred watts. It is recommended that the air volume of the cabinet should not be less than 100CFM.

The integrated power module (suffix 4) has a built-in fan, but the air inlet and outlet must not be blocked, and a 100mm space needs to be reserved around it.

2.3 Environmental Protection

The drive must be installed in a closed cabinet to prevent liquid splashing, dust, and smoke from entering.

The ambient temperature should be controlled between 0-40 ℃, and the humidity should be less than 85% non condensing.

Detailed explanation of encoder interface wiring

The encoder signal is a critical feedback link for servo control, and the quality of wiring directly affects position accuracy and system stability.

3.1 TTL encoder (J10, 15 pin D-Sub female socket)

The TTL encoder outputs two orthogonal square wave signals (A+, A -, B+, B -) and one zero position pulse (Z+, Z -), which comply with the RS422 differential standard. Pin definition:

1: +5V output (protected by F7 500mA fuse)

2: UA2- (TTL signal 2 negative terminal, direction signal in pulse/direction mode)

3: UA1- (TTL signal 1 negative terminal, pulse signal in pulse/direction mode)

4: UA0- (TTL zero signal negative terminal)

9：GND

10：UA2+

11：UA1+

12：UA0+

Special note: If using a non differential TTL encoder (with only A, B, Z single ended signals), an external resistor needs to be added to the DSB2P input terminal. Section 3.1.1.2 of the manual provides the specific connection method - pulling down UA0-, UA1-, UA2- through resistors to GND to achieve single ended to differential conversion.

3.2 Simulated sine cosine encoder (J1, 9-pin D-Sub female socket)

The analog encoder outputs sine and cosine signals (with a phase difference of 90 °), which can provide higher resolution position information. DSB2P supports two types of signal amplitudes:

1Vptp (peak to peak value 1V): Model identification is DSB2P1xx xxxE

11 μ Aptp (peak to peak value of 11 μ A): Model identification is DSB2P2xx xxxE

The hardware circuits of the two models are different and cannot be interchanged. Pin definition:

1: SIN - (Negative Terminal of Sinusoidal Signal)

2：GND

3: COS - (cosine signal negative terminal)

4：GND

5: IDX - (Zero Position Signal Negative Terminal)

6: SIN+(sine signal positive terminal)

7: +5V (protected by F7 500mA)

8: COS+(cosine signal positive terminal)

9: IDX+(positive terminal of zero position signal)

Shielding requirement: The analog encoder signal has a small amplitude and is highly susceptible to electromagnetic interference, requiring the use of double shielded cables. The outer shielding layer is connected to the connector housing at both ends (360 ° ring connection), and the inner shielding layer is only connected to GND at the driver end to avoid ground loops.

3.3 Digital Hall Sensor and Temperature Protection (J9, 9-pin D-Sub Male Head)

J9 provides three digital Hall signal inputs (H1, H2, H3) and motor overheat protection input (PTC/temperature control switch). Pin definition:

1: +Text (external power input for Hall and PTC)

2: H1- (Hall sensor 1 input)

3: H2- (Hall sensor 2 input)

4: H3- (Hall sensor 3 input)

5：GND

6: TS - (PTC or temperature control switch input)

7: +5V (protected by F7)

8: +15V (protected by F3 250mA and shared with J2 auxiliary power supply)

9：GND

Hall signal wiring: Three Hall signals correspond to the position information required for three-phase motor commutation, and their timing relationship corresponds to the motor phase voltage. The manual provides a standard connection diagram. For ETEL motors, the PTC trigger temperature is usually 100 ℃ (ILx series) or 120 ℃ (LMx/TMx series). When this temperature is exceeded, the TS input is pulled low and the driver reports a "MOTOR OVERTEMP" error.

User I/O connection (J2, 15 pin D-Sub male)

J2 provides analog input, 6 digital inputs, 3 digital outputs, and auxiliary power supply.

4.1 Analog Input (AIN1)

Pin 2 (AIN1+) and Pin 9 (AIN1-)

Input range: ± 10V, 14 bit resolution (AD7863)

High input impedance, can be directly connected to the analog output of PLC or motion controller.

4.2 Digital inputs (DIN1-4, DIN9, DIN10)

Using optocoupler isolation, the input voltage range of+15~+28V corresponds to logic "1", and 0V corresponds to logic "0".

Function allocation (configured by software): DIN10 is usually used as a positive limit switch, DIN9 as a negative limit switch, and DIN2 as a home switch.

External power supply can be provided by an independent power supply (pin 11 is+Voxt, pin 3 is GNDext), or by a+15V auxiliary power supply provided by the driver (pin 10), but using an auxiliary power supply will lose the advantage of optocoupler isolation.

4.3 Digital outputs (DOUT1~3)

Optocoupler isolation, open collector output. External pull-up resistor or load power supply (+Text, pin 11) is required, with a maximum voltage of 28V.

Typical applications: outputting servo readiness signals, limit trigger signals, or fault alarm signals.

4.4 Auxiliary power output

Pin 10 provides+15V/250mA (protected by F3), which can be used to power external sensors or Hall encoders, but it should be noted that the total current does not exceed 250mA (shared with J9's+15V).

Communication interface wiring (J3~J6)

5.1 ETEL-Bus（J3/J4，RJ45）

J3 is the EB output (connected to J4 of the next level driver), and J4 is the EB input (from the previous level driver).

Default RS422 differential communication, speed 460000bps, supports up to 32 daisy chain drives.

If you need to use RS232 type EB (115200bps), you need to short-circuit pin 1 (EB_delect_422/232) of J6 to GND.

5.2 ETEL-Bus-Lite（J5，RJ45）

Used for debugging communication between PC and driver (ETEL Tools software).

Supports RS232 (pins 6/7) and RS422 (pins 2-5), default RS422. If RS232 is required, short pin 1 (EBL_select_422/232) to GND.

Serial port parameters: 9600~115200bps, 8 data bits, 1 stop bit, no checksum, no flow control.

5.3 Download key interface (J6, RJ45)

For firmware upgrade: Insert a dedicated download button (pin 4-8 short circuited, 5-2 short circuited), power on the drive and enter the "Wait for Program" mode to download new firmware through the RS232 serial port.

Motor and power wiring (J7/J7B/J11/J14/J15)

6.1 Motor Connection (J7/J7B)

J7 is a standard 5-pin high-power D-Sub that supports single-phase (using only PH1 and PH2), two-phase (PH1/PH2/PH3/PH4), and three-phase (PH1/PH2/PH3) motors.

J7B is a motor interface with a short-circuit relay option (only versions with suffix 4 and sub models including 2). During normal operation, the relay contacts are open, and during faults or emergency stops, the contacts are closed. The motor is short circuited in three phases to achieve dynamic braking.

6.2 DC power input (J11, rack module)

15 pin DIN41612 connector, key signal:

Z20/d22:+VPWR (main power supply 24-340VDC)

Z16/d18/d26: GNDpwr (power ground)

Z12:+V/AUX (auxiliary power supply, 24-55VDC or 96-340VDC, depending on the sub model)

Z24: GNDaux (auxiliary ground)

D14: INRISH (surge signal from power supply, 0V=OK,+15V=charging in progress)

Z28/d30: PE (protective grounding, must be connected first! ）

Important: If using a non ETEL power supply, d14 (INRISH) and d18 (GNDpwr) must be short circuited, otherwise the drive cannot enter normal operation mode.

6.3 AC power input (J14/J13, integrated power module)

J14 (3-pin) is the main power input, connected to 85-240Vac single-phase or three-phase AC power.

J13 (2-pin) is an auxiliary power input, also 85-240Vac.

Attention: It is recommended to install an external isolation transformer at the power input end to meet CE/EMC requirements, and configure a circuit breaker to urgently cut off the motor power without losing encoder position data (maintaining auxiliary power).

6.4 External regeneration resistor (J12, 2-pin)

Only suffix 4 modules are supported, with pins R+and R - connected to external regenerative resistors.

The minimum resistance of the resistor is 39 Ω, and the power is not less than 3.8kW (@ 380Vdc) to protect the internal regeneration transistor.

EMC cable shielding and grounding

DSB2P, as a PWM chopper amplifier, generates strong electromagnetic interference during operation. Section 3.7 of the manual provides strict EMC wiring requirements that must be followed during on-site wiring.

7.1 Lines that must use shielded cables

Motor cable (J7/J7B): high di/dt circuit, strong radiation source.

Encoder cable (J1/J9/J10): weak signal, highly susceptible to interference. The analog encoder (11 μ Aptp) requires double shielded cables.

7.2 Shielding Layer Connection Specification

Single shielded cable: The shielding layer is connected to the connector housing at both ends (360 ° ring connection).

Double shielded cable: The outer shielding layer is connected to the outer shell at both ends, and the inner shielding layer is only connected to GND at one end (driver end).

It is prohibited to use "pig tail" (short lead) to connect the shielding layer - this connection method is completely ineffective at high frequencies and must use cable clamps with 360 ° ring contact.

7.3 Cable Routing Principles

Power cables and signal cables should be routed separately to avoid parallel long-distance laying.

All cables should be as short as possible and fixed to the metal bottom plate of the cabinet using cable clamps.

If there is an intermediate connector along the shielded cable, its casing must be insulated and not in contact with each other to prevent the formation of a ground loop.

Short circuit relay configuration and application (DSB2Pxx4-2xx)

Short circuit relay is an optional safety function of the integrated power module, used to quickly brake the motor in case of emergency stop or driver failure.

Working principle: The normally closed contacts of the relay are connected in series in the three-phase circuit of the motor. During normal operation, the driver applies a+24V power supply through pins 3-4 to energize the relay coil, causing the contacts to open and the motor to run normally; In case of emergency stop or malfunction, cut off the coil power supply, close the contacts, cause a three-phase short circuit in the motor, and generate braking torque.

Recommended Control Circuit:

Connect the normally closed contacts of the emergency stop button in series with the relay coil power supply circuit.

Simultaneously configure DIN1 as a safety enabled input (K33=0), and the driver will automatically shut down the power bridge when DIN1=0V.

Program DOUT1 as a fault output (K37=1), with DOUT1=0V in case of a fault, which can be used to disconnect relay coils or notify the upper computer simultaneously.

External power supply requirements: The relay coil must have an independent+24V external power supply and must not be grounded with the internal power supply of the driver to ensure that braking can still be performed even when the driver is completely powered off.

Quick troubleshooting table for on-site hardware failures

Possible causes of malfunction, inspection methods, and solutions

Power on, no display. Auxiliary power supply not connected or fuse F3/F7 blown. Measure J11/J15 auxiliary voltage. Check auxiliary power supply and fuse

The motor does not rotate and there is no current. The INRISH signal is not connected correctly. Measure d14 and short-circuit d14 to ground voltage (non ETEL power supply)

Encoder reading jumps, shielding layer not grounded 360 ° or cable too long. Check shielding connection and reprocess cable shielding

Frequent overcurrent alarm of the driver, poor shielding of the motor cable or incorrect phase sequence of the motor. Check K56 and cable, execute AUT command or exchange phase lines

Zero return repeatability difference Hall signal or encoder zero position signal interference oscilloscope inspection signal quality enhancement shielding, check J9 wiring

Emergency Stop Invalid Short Circuit Relay Control Circuit Wiring Error Check J16 Wiring and Power Supply Reconfigure Relay Circuit According to Manual

Communication connection cannot be established, serial port type selection error check J5 pin 1 level floating=RS422, connected to GND=RS232