Kollmorgen SERVOSTAR-CD servo drive hardware installation and system configuration

Method 2: Use specialized connectors from Phoenix Contact and other brands (such as SK series) to connect the cable shielding layer to the grounding busbar.

If the power supply is introduced into the cabinet through a metal conduit, the power input line may not be shielded, but the metal conduit itself needs to be properly grounded. Otherwise, the power input line also needs to be shielded and properly overlapped.

4. EMC filtering technology

To meet the CE emission requirements in industrial environments, it is necessary to correctly apply input power filtering and add motor lines and I/O filtering as needed.

4.1 Input power filtering

Each driver (or a group of parallel drivers) needs to be equipped with an EMI line filter on the incoming power supply side. The filter should:

Install on the same backplane as the drive and as close as possible to the power inlet of the cabinet.

Install on unpainted metal surfaces to ensure good contact.

Reliable grounding (the internal capacitor of the filter may still have dangerous voltage after power failure).

Select the model with "line to line" and "line to ground" capacitors at the output end.

The document recommends Filter Concepts and Schaffner filter models for different driver models.

4.2 Motor line filtering

Although not necessarily necessary for CE compliance, motor line filtering can improve system reliability.

Differential mode noise: Long motor cables can exacerbate inter line capacitive coupling. A ferrite magnetic ring (such as Fair Rite P/N 2643665702) can be wound around each motor wire near the driver end for several turns to attenuate. Do not pass the ground wire through the magnetic ring.

Common mode noise: generated by PWM switching frequency. Common mode chokes (such as Schaffner RD series) can be used on motor lines to increase common mode impedance, protect encoders and I/O signals.

4.3 I/O filtering

Depending on the system environment, it may be necessary to use clamp type ferrite cores on the I/O lines to attenuate unwanted signals. For CD series drives, in order to meet CE requirements, a specific magnetic core (such as Fair Rite 2643167251) must be applied on the 24V input power line and remote enable line (C3 connector pins 7&8), and wound around the constraint for 3 turns.

4.4 Filtering and Overlapping System Diagram

The document provides a key schematic diagram of system wiring, filtering, and bonding, summarizing all best practices from power input, single point grounding, high-frequency grounding, filter grounding, motor/feedback cable bonding to strong and weak current separation wiring. It is the core reference for system integration.

5. Detailed explanation of connectors and wiring diagrams

SERVOSTAR-CD provides a wide range of connectors for power supply, motor, feedback, communication, and I/O.

5.1 Main connector functions

C1: RS-232/RS-485 communication port.

C2: Motor feedback connector (supporting rotary transformers, digital encoders, sine encoders).

C3: User I/O connector (analog input, remote enable, configurable input/output, fault relay, etc.).

C4: Encoder Equivalent Output (EEO) or SERCOS Interface (Fiber Port).

C8: Remote encoder input (for electronic gears or dual feedback).

C9 (Series 5 specific): Extended I/O interface.

Power terminals: main power input (L1, L2, L3), motor output (Ma, Mb, Mc), regenerative braking (B+, C -), logic power supply (24VDC), and ground (GND).

5.2 Wiring precautions

All AC power cords should use twisted pair cables.

It is best to connect the driver and motor grounding at a star shaped grounding point to minimize ground current and noise.

The cable shielding layer is only connected at one end (preferably the driver end), and if overlapping has been implemented, the end of the shielding layer does not need to be connected to the star point again.

Add a freewheeling diode to the inductive load output of O1 on C3.

Recommended wire specifications, terminal models, and torque values must be followed (such as power terminal screw torque typically being 20 lb in/2.26 N-m).

6. Feedback system configuration

The driver supports multiple feedback devices and needs to be configured according to the type.

6.1 Rotary Transformer

Requirement: Control transformer type, transformation ratio 0.47, excitation frequency 7-8 kHz.

Cable: It is recommended to use twisted pair shielding, with a length of up to 75 feet (22.9 meters). For longer distances, please consult the factory.

Resolution and accuracy: The system automatically configures the R/D converter resolution (up to 16 bits/65536 counts/rev) based on the speed limit (VLIM). The system accuracy is affected by factors such as R/D converter, mechanical, and installation errors, with a typical worst-case scenario of about 19 arcminutes.

6.2 Digital Incremental Encoder

Requirement: Differential A/B signal (with or without Index and Hall signals), 5VDC power supply, maximum input frequency of 3 MHz (before fourth harmonic).

Cable length: It is recommended not to exceed 50 feet (15 meters), as being too long can cause voltage drop. When traveling long distances, it may be considered to provide separate power supply for the encoder at the motor end.