Moog DS2020 Mounting instructions
DS2020
MAINTENANCE AND USER MANUAL
SINGLE AXIS DIGITAL SERVO DRIVE
INDEX
1. OVERVIEW 5
5
5
5
6
1.1. Manual contents
1.2. Utilized symbols
1.3. Package content
1.4. Required qualifications of the users
1.5. Applicable laws 6
2. SYSTEM DESCRIPTION 7
7
9
9
10
10
11
11
12
14
14
15
20
21
21
21
2.1. Product structure
2.1.1. Product description
2.1.2. Storage and working conditions
2.1.3. Standard models of modules
2.1.4. Module codification
2.2 Features and components details
2.2.1 Electrical data
2.2.2 Mechanical data
2.2.3 Trasducers
2.2.4 Connectors
2.2.4.1 Connectors layout
2.2.5 Filters
2.2.6 Braking resistence
2.2.7 Line inductors
2.3 Cables
2.4. Safety and usage guidelines 22
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2.4.1. General description of security features
22
2.4.2. STO safety feature
22
2.4.2.1. Description
22
2.4.2.2. Directives on safety
23
2.4.3. Usage Guidelines of the drivers
23
3.CERTIFICATIONS25
25
3.1. CE
3.2. Safety and SafeTorque Off
26
4. ELECTRICAL AND MECHANICAL INSTALLATION 27
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36
36
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4.1 Tools and equipment
4.2. Mechanical installation
4.2.1. Assembly of the various components
4.3. Electrical Installation and thermal rating
4.3.1 Safety and general instructions
4.3.2. Thermal rating of the electrical panel
4.3.2.1. Drive axis module dissipation
4.3.2.2. Thermal dissipation of the accessories
4.3.3. Auxiliary power characteristics
4.3.4. Grid connection
4.3.4.1. Types of electrical networks
4.3.4.2. Protection components
4.3.4.3. Ground connection
4.3.5. Drive wiring
4.3.5.1. Grounding
4.3.5.2. Connecting the Power cable
4.3.5.3. Braking resistor connection
4.3.5.4. Auxiliary power connection
4.3.5.5. Signal connection
4.3.5.6. Motor cable connection
4.3.5.7. Brake cable connection
4.3.5.8. I / O signal connection
4.3.5.9. STO signal connection
4.3.5.10. Transducer connection
4.3.5.11. Connecting the Fieldbus - X8, X9, X10 connectors
38
5. COMMISSIONING VIA GUI 39
39
40
40
40
41
42
5.1. Safety
5.2. Dx2020 GUI
5.2.1. Overview
5.2.2. Minimum PC requirements
5.2.3 Dx2020GUI installation
5.2.4 GUI-drive connection
5.2.5 Layout
43
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5.2.6. Firmware update (BootLoader) 45
5.2.7. How to access to Online Help
45
5.3. System configuration 45
5.3.1. Identifying an axis module 46
5.3.2. Motor parameters configuration 46
5.3.3. Trasducers configuration
47
5.3.3.1. Sensorless
47
5.3.4. I/O configuration
48
5.3.5. Control loops configuration
51
5.3.5.1 Control mode configuration
51
5.3.5.2 Torque loop parameters configuration
51
5.3.5.3 Speed loop parameters configuration
51
5.3.5.3.1 Filter configuration
52
5.3.5.4 Configuration of the position loop parameters
53
5.3.6. Fault configuration
54
5.3.7. Application parameters
55
5.3.8. Commands and modes configuration
56
5.4. Power Supply
58
5.5 STOactivation
58
5.5.1 Autophasing
59
5.6 Axis enablement
59
5.7. Oscilloscope function and log files (*.UCX)
60
5.7.1 Log configuration
60
5.7.2 Start logging
60
5.7.3 View logs
61
5.7.4 UCX file management
61
5.8 Using the GUI in OFFLINE mode
62
5.9 Contextual help menus for parameter management
62
6. TROUBLESHOOTING 63
63
63
63
64
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66
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68
6.1. Introduction
6.2. Power section anomalies
6.3. Drive anomalies
6.3.1. Alarms on the power section
6.3.2. Alarm for out of tolerance VBUS voltage
6.3.3. Drive or motor overtemperature
6.3.4. Removal of STO signal
6.3.5. Errors on memory devices
6.3.6. Corrupted Data Fault
6.3.7. Brake Chopper Fault
6.3.8. Errors on feedback devices
6.3.9. Synchronization, Interrupt Time and Task Time Error
6.3.10. EtherCAT Faults
6.3.11. Alarms related to the control loops
68
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6.3.12. CAN Bus alarms
68
6.4. Alarm display in 'Analog' operating mode
69
6.5. Faults during the GUI-drive connection
72
7. SAFE TORQUE OFF SAFETY FEATURE 73
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81
81
7.1. Application
7.2. Installation risk assessment
7.3. Safe Torque Off
7.3.1. Characteristic values according to UNI ENISO 13849-1
7.3.2. Characteristic values according to CEI EN62061
7.4. Safety requirements
7.5. Safe Torque Off circuit
7.6. Safe Torque Off connections
7.7. Example of an application
7.8. Installation and maintenance procedure Safe Torqueo
Off 7.9. Assembly and serial tests
7.10. Identification of the STO function on the plate
8 Annexes
8.1 Glossary
8.2 Conversion Table Metric / AWG 84
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1. OVERVIEW
1.1. Manual contents
This manual provides information to the user to ensure proper installation and optimal functioning of the
digital servo drives, DS2020 series.
All information contained herein, including methods, techniques and concepts are the exclusive property
of Moog Casella and may be neither copied nor used without specific authorization. Moog reserves the
right to modify products, and related documentation, at any time, without notice.
The following materials are also available:
•QUICK GUIDE - INSTRUCTIONS AND GUIDELINES FOR FIRST START
•MAINTENANCE AND USER MANUAL (this document)
•FIELDBUS MANUAL
•SOFTWARE Dx2020 GUI
1.2. Utilized symbols
Danger that can result in death or serious injury
Notification of an important information
Danger that can result in minor injury and / or property damage
1.3. Package contents
The complete supply of DS2020 drives includes:
•One DS2020 drive module
•Anchoring support for the screens
Note: a possible connector kits must be ordered
individually and is supplied separately.
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1.4. Required qualifications of the users
This manual is intended for qualified personnel, that is having the following skills, depending on the tasks performed:
Transport: The staff must have notions of handling components sensitive to electrostatic charges
Unpacking: The staff must have knowledge of handling of components sensitive to shock and electrostatic discharge
Installation: The staff must have notions of installation of electrical equipment
Startup: The staff must have extensive technical knowledge of electrical drives and their technology.
Info
The qualified personnel must know and observe the following standards: IEC 60364, IEC
60664, and all relevant national accident prevention regulations.
ATTENTION
When the drive is in operation there is a risk of death, serious injury or serious damage to property.
Therefore, the installer is required to ensure that the safety instructions detailed in this manual are read,
understood and observed by all personnel responsible for the operation of the drive.
1.5. Applicable laws
The DS2020 drives meet the Low Voltage Directive (2006/95 / EC) and EMC Directive (2004/108 / EC).
The safety function "Safe Torque Off" (STO) integrated in the drive complies with the Machinery Directive
(2006/42 / EC).
To comply with the European Directives, the drive meets the requirements of the relevant harmonized
installation standards EN 50178 (LVD), EN61800-3 (EMC) and EN 61800-5-2 (Safety of machinery).
The DS2020 drives are CE certified.
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2. SYSTEM OVERVIEW
2.1. Product structure
2.1.1. Product description
The DS2020 drive represents Moog Casella's new generation of digital servo drives for the control of brushless
synchronous or asynchronous motors. It is constituted by a single stand alone module powered directly by an
AC network and by an auxiliary voltage of 24 Vdc
The digital control system of the motors and the diagnosis functions of the DS2020 series, are realized using a
microprocessor.
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Control functions Implementation of the Torque, Speed and Position loops
Command protocols EtherCAT, CANopen and “Analog”
Configuration/
Commissioning
Via GUI : Dx2020GUI, allows to configure, calibrate and
control the drive.
Diagnostic Via GUI
Positioning transducers • Resolver standard
• Encoder Incremental TTL
• Encoder Stegmann Sinusoidal Absolute Single/Multi-Turn with
HYPERFACE communication
• Encoder Hedenhain Sinusoidal Absolute Single/Multi-Turn with
ENDAT communication
Sensorless mode
User Interface
Dx2020GUI
Data logging
From GUI
AC/DC conversion Three-phase input bridge with soft start
Power range From 120 Vac to 480 Vac +/- 10 %
PWM frequency 8 kHz (from 2 to 16 kHz configurable by Software)
Encoder simulation Simulated encoder output with programmable number of pulses
Auxiliary power supply voltage
+ 24 Vac +/- 10 %
Rated current From 2 to 48 Arms
Peak current From 4 to 96 Arms
Analog inputs 2 inputs +/- 10 volt differential
Analog outputs 2 output +/- 10 volt single ended
Digital inputs 2 digital inputs opto isolated
Digital outputs 1 Digital output opto isolated
Communication interface for
set-up
• RS422 PC
• USB PC
• EtherNET or CANopen PC (option)
Motor brake control Integrated
Braking resistor Integrated (Esternal optional)
Electromagnetic compatibility EMC filters
Cooling
Forced air, with integrated fans in each module
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2.1.2. Storage and working conditions
Operating environment
temperature
from 0 °C to 40 °C
up to55 °C with current derating
Storage temperature
from -25 °C to 55 °C
Transport temperature
from -25 °C to 70 °C
Motor overheating protection PTC or NTC
Relative humidity
5...95 %
without condensation
Mounting altitude
Up to 1000 m, up to 2000 m with output current derating
Certification
CE
Protection
IP20
Pollution rating
Resistenza meccanica
conforme a EN 60721-3-3
Vibration: 3 mm for frequencies between 2 and 9 Hz
Vibration: 1 g for frequencies between 9 and 200 Hz
Shock: 98 m/s2 (10 g) for 11 ms
Machine safety
STO (Safe Torque Off) SIL3 PLe
2.1.3. Standard models of modules
L50A L50A L75A L75A L75B
Dimensions [mm]
50 50 75 75 75
Rated current [Arms]
2 4 6 8 12
Peak current [Arms] 4
8 12 16 22
The module code is found on a plate on the side of the module.
To request any kind of information about a specific module it is essential to communicate to Moog Casella all the
data indicated on the plate, which identifies each individual module.
The year and week of construction are identified by the field 'Date' The first two digits of the number are for the year
the second two indicate the week (example DATE 1607: 2016, week 7).
L85A L85A L125A L125A
85 85 125 125
16 24 32 48
32 48 64 96
Example of a drive plate
Model code
Rated data
STO function
Date
Serial Number
Moog Italiana S.r.l. - CASELLA SITE - Via Avosso 94, 16015 Casella (GE) - Italy
2 or less (normally allowed only non-conductive pollution. However, occasionally we
can expect a temporary conductivity caused by the condensation only when the drive
is idle or powered)
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2.1.4 Module codification
To identify the different models it is necessary to refer to the following codification
The first two characters are "CH" and are used to identify the DS2020 family
Version
1Standard model
ESpecial model
Mechanical configuration - Hardware
ValueType /
Width
Rated
Current
Peak
Current
02 Single / 50 mm
L50A 2 Arms 4 Arms
04 Single / 50 mm
L50A 4 Arms 8 Arms
06 Single / 75 mm
L75A 6 Arms 12 Arms
08 Single / 75 mm
L75A 8 Arms 16 Arms
12 Single / 75 mm
L75B 12 Arms 22 Arms
(1) Standard version
(2) Values attributed by Moog
X2 / X3 - Transducer type and Serial link type
RS422
ValueType
R (1)RESOLVER SERIAL
TRESOLVER USB
EENCODER SINCOS SERIAL
UENCODER SINCOS USB
G TTL SINGLE ENDED SERIAL
HTTL FULL DIFFERENTIAL SERIAL
L TTL SINGLE ENDED USB
MTTL FULL DIFFERENTIAL USB
Fieldbus configuration
ValueType
0Analog references (1)
1 CanBus configuration
(option)
2 EtherCAT configuration
(option)
Hardware Revision
Value - Internal coding (2)
Special configurations
00 Standard
Special variation
Value - Internal coding (2)
CH-
To order a connector kit
Connector kit code Transducer type and Serial link type
BC8901-R RESOLVER SERIAL
RESOLVER USB
BC8902-R
ENCODER SINCOS SERIAL
ENCODER SINCOS USB
TTL SINGLE ENDED SERIAL
TTL FULL DIFFERENTIAL SERIAL
TTL SINGLE ENDED USB
TTL FULL DIFFERENTIAL USB
16 Single / 85mm
L85A16 Arms 32 Arms
24 Single /85mm
L85A 24 Arms 48 Arms
32 Single / 125mm
L125A 32 Arms 64 Arms
48 Single / 125mm
L125A48 Arms 96 Arms
Value - Internal coding (2)
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