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INSTALLATION AND STARTUP MULTI AXIS DIGITAL SERVO SYSTEM DM2020 TECHNOLOGY PN: L-MAM2-E-201 THIS DOCUMENT DESCRIBES THE INSTALLATION AND STARTUP FOR THE DM2020 SYSTEM www.moog.com...
Moog Casella DM2020 Installation and Startup Guide Table Of Contents Table Of Contents Table Of Contents Foreword About Moog Document Version Revision Record Reader Instructions 1 Introduction 1.1 Contents 1.2 Related Documents 1.3 Package Contents 1.4 Required Qualifications of Personnel 1.5 Applicable Laws...
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Moog Casella DM2020 Installation and Startup Guide Table Of Contents 2.8.1 Installation Risk Assessment 2.8.2 General Machine/System Safeguards Information 2.8.3 Safeguards Related to SCRF 3 System Overview 3.1 Product Structure 3.1.1 Product Description 3.1.2 Storage and Working Conditions 3.1.3 Standard power supply models 3.1.4 DM2020 Standard Models...
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Moog Casella DM2020 Installation and Startup Guide Table Of Contents 5.2 Mechanical Installation 5.2.1 Assembly of System Components 5.2.1.1 Assembling the PSU 5.2.1.2 Assembling the Axes 5.2.1.3 Braking Resistor Positioning 5.3 Electrical Installation and Thermal Rating 5.3.1 Safety and General Instructions 5.3.2 Electrical Installation...
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Moog Casella DM2020 Installation and Startup Guide Table Of Contents 6.2.6 Firmware Update (BootLoader) 6.2.7 Accessing the Dx2020 GUI help on-line 6.3 Activate Power 6.4 System Configuration 6.4.1 Axis Identification 6.4.2 Motor Parameter Configuration 6.4.3 Transducer Configuration 6.4.3.1 Sensorless 6.4.4 I/O Configuration 6.4.4.1 Details of Possible Configurations...
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Moog Casella DM2020 Installation and Startup Guide Table Of Contents 8 Maintenance 8.1 Periodic Maintenance 8.2 What to Do If Repairs Are Required? 9 Troubleshooting 9.1 Power Section Anomalies 9.2 Drive Alarms (Faults) 9.2.1 Alarms on the Power Section 9.2.2 Alarm for VBUS Voltage Out of Tolerance 9.2.3 Drive or Motor Overtemperature...
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Moog Casella DM2020 Installation and Startup Guide Table Of Contents 10.9 Assembly and Serial Tests 10.10 Identification of the STO Function on the Drive Plate 11 System Disposital 11.1 What to Do If Repairs Are Required? 12 Appendix 12.1 Glossary 12.2 Metric/AWG Conversion Table...
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 DM2020 drives are CE, EAC and UL certified. Contact Moog for further details. The manual was written and checked by technical experts at Moog.
November 2020 Update February 2021 Reader Instructions The following table shows the symbols adopted in Moog documents: DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
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● / - This is a bullet list. 1., 2., ... These are steps in a procedure that must be performed in consecutive order. The following table shows the abbreviations adopted in Moog documents: Abbreviation Explanation Electro Mechanical Actuator Electro Hydraulic Actuator...
Moog Casella DM2020 Installation and Startup Guide 1.1 Contents 1.1 Contents This manual provides information on the correct installation and optimal operation of the DM2020 series of digital multi-axis servo drives. All information in this manual, including methods, technologies and concepts is the exclusive property of Moog-Casella, and may not be copied or reused without specific authorisation.
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 DM2020 drives are CE certified; certain models are also UL certified. Contact Moog for details. Standard products has been configured as No Dual Use device.
2. Read the related documents that are supplied with the DM2020 system, 3. Install the DM2020 drive, see Mechanical Installation section of this manual. 4. Install the supplied Moog motor, see the motor installation guide for your motor. 5. Install the cables and connect power, see Electrical Installation and Thermal Rating 6.
Moog Casella DM2020 Installation and Startup Guide 2.1 Safety and Usage Guidelines 2 Safety Information 2.1 Safety and Usage Guidelines Do not attempt to install, operate, maintain or inspect the DM2020 system until you have carefully read this guide and the other supplied documents, and you are properly trained in the correct use of the equipment.
Moog Casella DM2020 Installation and Startup Guide 2.3 Electrical Hazards IEC 60364 IEC 60664 Accident prevention national, regional and local regulations for the site where the system or machine will be operated 2.3 Electrical Hazards WARNING: Electrical hazard - AVERTISSEMENT: risque électrique High voltage may be present, which can result in death or serious injury to personnel, or damage to equipment.
Ø Follow these safety instructions. The motor must be properly mounted and anchored as specified in the Moog motor installation guide supplied with the DM2020 system motor. For details, consult the Moog motor installation guide.
Moog Casella DM2020 Installation and Startup Guide 2.6 STO Safety Feature 2.6 STO Safety Feature 2.6.1 Description The DM2020 drives include the STO (Safe Torque Off) function as a standard feature to ensure protection for personnel and equipment against accidental restart and re-enabling of the drive.
For more details on selecting the proper motor, see Motors on page 48. 2.7.4 Power Supply The drives of the DM2020 series (overvoltage category III according to EN 61800-5-1) can be powered by three-phase industrial AC supply, earthing systems (TN system, TT with grounded neutral and symmetrical rated current not more than 10KA 120V to 480V ±...
Moog Casella DM2020 Installation and Startup Guide 2.7.5 Prohibited Use 2.7.5 Prohibited Use WARNING: Risk of death or serious injury to personnel, or damage to equipment - AVERTISSEMENT: Risque de mort ou de blessures graves pour le personnel ou de dommages matériels.
Moog Casella DM2020 Installation and Startup Guide 2.8 Risk Assessment 2.8 Risk Assessment In order to protect personnel from any safety hazards in the machine or system, the machine/system builder must perform a "Risk Assessment", which is often based on ISO standards. The...
Moog Casella DM2020 Installation and Startup Guide 2.8.2 General Machine/System Safeguards Information 2.8.2 General Machine/System Safeguards Information In general, the machine/system safeguards must: Provide a barrier to prevent unauthorized entry or access to the machine or system. The barrier must be designed so that personnel cannot reach into any identified danger zones.
Moog Casella DM2020 Installation and Startup Guide 2.8.3 Safeguards Related to SCRF 2.8.3 Safeguards Related to SCRF (Safety-Related Control Function) The manufacturer of the machine and/or final apparatus must perform, maintain and make available a Risk Assessment (risk analysis) of the machine in accordance with the ISO12100 and ISO14121 standards, and implement all necessary measures to avoid unforeseen movements that can cause damage to persons or objects.
3 System Overview 3.1 Product Structure 3.1.1. Product description The DM2020 drive is a new generation of digital servo drives manufactured by Moog-Casella for controlling brushless synchronous or asynchronous motors. The drives have a multi-axis rack configuration with a power supply module and various control modules positioned side by side.
To request any kind of information about a specific power supply, the details on the side plate identifying each individual power supply must be communicated to Moog-Casella. PN: L-MAM2-E-201...
Moog Casella DM2020 Installation and Startup Guide 3.1.3 DM2020 Standard Models 3.1.4 DM2020 Standard Models The following table shows the standard axis modules sizes. Model/Code CC111SNNLNNxxxx CC111ANNLNNxxxx CC121SSNLNxxxxx CC112BNNLNNxxxx CC122ASNLNxxxxx Mechanical dimensions 50 mm/1.97 inches configuration Single Single Double Single...
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Moog Casella DM2020 Installation and Startup Guide 3.1.3 DM2020 Standard Models Model/Code CC126CCNLNxxxxx CC126DSNLNxxxxx CC126DANLNxxxxx CC126DBNLNxxxxx Mechanical dimensions 75 mm/2.52 inches Configuration Double Double Double Double Type Module current @ 8 kHz Arms rated current Arms peak current Cooling Incorporated ventilation...
Moog Casella DM2020 Installation and Startup Guide 3.1.4 Model Codes 3.1.5 Axis Module coding To identify the axis models, refer to the following coding Version Special variations Standard model Value - Internal coding ( Special model Value Description Test model...
Moog Casella DM2020 Installation and Startup Guide 3.1.5 Connector Kits 3.1.6 Power supply units coding Version Special variations Standard model Value - Internal coding ( Special model Value Description Test model Special Reg. Res. (16 ohm/500 W Armoured) With power connectors & without Mechanical hardware conig uration R.R.
Moog Casella DM2020 Installation and Startup Guide 3.2 Features and Component Details 3.2 PSU Features and Details This section provides details on the features and components of the DM2020 power supply unit. 3.2.1 Electrical and Mechanical Data Model Type L50 (M)
Moog Casella DM2020 Installation and Startup Guide 3.2.2 Mechanical Data 3.2.2 Module Side Plate Types Hardware Revision Model code STO Function Serial Number Nominal data Example of axis module side plate (A) and front plate (B) Model code Serial Number...
Moog Casella DM2020 Installation and Startup Guide 3.2.3 Transducers 3.2.3 Transducers The DM2020 system can manage the following transducers: • Resolver (standard) • Encoder Incremental TTL • Encoder, Stegmann Sinusoidal Absolute Single/Multi-Turn with Hiperface communication • Encoder, Heidenhain Sinusoidal Absolute Single/Multi-Turn with ENDAT communication •...
Moog Casella DM2020 Installation and Startup Guide 3.2.3 Connectors 3.2.4 Connectors Status Led CAN connectors +24 Volt 0 Volt + DC bus Bus Bar - DC bus (Earth) X1 Brake resistor X2 Power connector PN: L-MAM2-E-201...
Moog Casella DM2020 Installation and Startup Guide 3.2.3.1 Connector Layout 3.2.4.1 Connector layout The tables below give details of connectors and the meaning of signalling LEDs X1: brake resistor +RR1 -RR2 X2: mains Earth BUSBAR connection +24 V 0 V DC...
If the motor power cables are shorter than 50 m, an EMC filter (code AT6013/AT6014 or equivalent can be positioned between the network and the drive. If cables are longer than 50 m, we recommend contacting Moog-Casella's Applications department. Filter code...
The braking resistor is not provided for the L150 power supply. The recommended resistor is 4.7 ohms/1000 watts (to be ordered separately using code AR5988). INFORMATION If the dissipated power exceeds 1000 W, contact the Applications Service at Moog-Casella for component sizing CAUTION For the L50 model, the braking resistor must always be connected as it also features a soft-start function.
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Use the distance MT/BT < line 100mt inductance Contact Moog Presence for evaluating of an EMC the impact of filter the filter Use of the line filter not necessary Contact the Applications Service at Moog-Casella for more information. PN: L-MAM2-E-201...
3.2.3.5 Position transducers Moog Casella DM2020 Installation and Startup Guide 3.2.7.1 Position transducers The DM2020 can manage the following position transducers, both when these are fitted on the motor and when they are positioned on the machine and used as secondary transducers: •...
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Moog Casella DM2020 Installation and Startup Guide 3.2.4.1 Connector Layout Module L200 double axis: front (A) and bottom (B) view. Note that the arrangement of the front connector remains unchanged as in L50, L75 and L100 modules (See previous page for details)
Moog Casella DM2020 Installation and Startup Guide 3.2.4.1 Connector Layout 3.3 Layout of connectors and other interfaces on the axis module The tables of connector pins relative to the axis module are shown below in the various possible coni gurations.
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Moog Casella DM2020 Installation and Startup Guide 3.2.5 Power Line Filters X2 (X12) connector Digital encoder function “Full digital” encoder function n.c. 0 V supply 0 V supply n.c. Up supply Up supply Data + Data + n.c. n.c. Term A...
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2 digital inputs and 1 digital output INFORMATION The maximum current that can be drawn from PIN 1 (output +24 V) is 200 mA If you need more details or clarifications on motor/drive connections, please contact Moog assistance. PN: L-MAM2-E-201...
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Moog Casella DM2020 Installation and Startup Guide 3.3.2 Selecting a Non-Moog Motor DETAILS OF MODES: Description of mode 0 In this mode, the three channels are configured as 2 digital inputs plus the RS232 serial line. Description of mode 1 In this mode, the three channels are configured as 1 digital output, 1 digital input, plus the RS232 serial line.
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Moog Casella DM2020 Installation and Startup Guide 3.3.2 Selecting a Non-Moog Motor X6, X16 connector Analogue and digital I/Os are present: Designation Function Positive analogue input 1, 12-bit resolution, sampling 3.9 us IN AN 1 + (256 kHz) Negative analogue input 11, 12-bit resolution, sampling 3.9...
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Moog Casella DM2020 Installation and Startup Guide 3.3.2 Selecting a Non-Moog Motor Digital Out 1/2 options • Halt is active • Stop is active • Motor dir. clockwise • Motor dir. counterclockwise • Motor null speed Digital Input options •...
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Moog Casella DM2020 Installation and Startup Guide 2.8.3 Safeguards Related to SCRF X8 (X9) connector: EtherCAT interface The cable is a standard EtherCAT cable and the connector is an RJ45. Name Description Drive status is INIT FLASHING Drive status is PRE-OPERATIONAL...
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Moog Casella DM2020 Installation and Startup Guide 2.8.3 Safeguards Related to SCRF Connector X20 and connector X21 Motor power supply Function phase U phase V phase W The cable must be shielded. The connection of the shield to the earth can be closed with a conduction clamp, with which the cable can be connected to the metal bracket to be fixed under the drive.
Moog Casella DM2020 Installation and Startup Guide 3.4 Cables The brake can be enabled in four different modes: According to a logical condition defined by the user (disabling/enabling of the axis) Using a fieldbus command Using appropriately programmed digital input...
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Moog Casella DM2020 Installation and Startup Guide 3.4 Cables The power and control cables (except those that go from the AC power supply to the filter) must be shielded. To minimize noise, it is recommended that they are separated from each other at a distance greater than 200 mm.
Moog Casella DM2020 Installation and Startup Guide 4.1 CE Certificate 4 Certifications 4.1 CE Certificate According to the European Community Directives, drives must conform to: EMC 2014/30/EU directive Low Voltage Directive 2014/35/EU The DM2020 system has been tested in a laboratory for the verification of the parameters of compliance with the above Directives.
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Moog Casella DM2020 Installation and Startup Guide 4.1 CE Certificate CE Declaration of Conformity PN: L-MAM2-E-201...
Moog Casella DM2020 Installation and Startup Guide 4.2 Safe Torque Off (STO) 4.2 Safe Torque Off (STO) The DM2020 integrates the Safe Torque Off (STO) function according to standards EN 61800-5-2; UNI EN ISO 13849-1:2016. SILCL 3 PL "e" (as per certificate). The function also corresponds to an uncontrolled stop in accordance with stop category 0 of IEC/EN 60204-1 standard.
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Moog Casella DM2020 Installation and Startup Guide 4.2 Safe Torque Off (STO) CE "Safe Torque Off" Certificate of Conformity PN: L-MAM2-E-201...
6000 60820 Please note: The brushless AC motor servo drives “DM2020 series” may be protected by any equivalent UL listed (JDDZ) or UL recognised external semiconductor fuses (JFHR2). These fuses must have the same ratings as the above fuses evaluated during the short circuit test and in particular with “peak-let-through current Ip” and “clearing I2t”...
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4.3.2 Short Circuit Protection 4.3.2 Overvoltage control Overvoltage control • In the equipment open-type brushless AC motor servo drives “DM2020 series”, the transient overvoltage in the power supply primary circuit of the end-use applications, is controlled by the following transient-voltage-surge suppressors devices: •...
700 Vrms #3 - #4 Please note: The brushless AC motor servo drives “DM2020 series” may be protected by any equivalent external UL listed (VZCA) or UL recognised surge protective device (VZCA2) and CSA certified. These SPDs shall have the same or better ratings as the ratings of the SPDs recommended in the above table.
Moog Casella DM2020 Installation and Startup Guide 4.3.4 Dynamic Brake Unit Ratings 4.3.3 Dynamic Brake Unit Ratings • The maximum current and the related duty cycle of the dynamic brake unit are as follows. Max current amps Model no. Max duty cycle (%)
Moog Casella DM2020 Installation and Startup Guide 5.1 Tools and Equipment 5 Electrical and Mechanical Installation 5.1 Tools and Equipment This section lists the special tools and equipment needed to install the DM2020 system components. Note that other tools may be needed, for example, to work in the control panel, terminate cables, mount safety and/or mechanical components at the machine, etc.
Moog Casella DM2020 Installation and Startup Guide 5.2.1.3 Braking Resistor Positioning 5.2.1.3 Braking Resistor Positioning WARNING: Electrical hazard - AVERTISSEMENT: risque électrique High voltage may be present, which can result in death or serious injury to personnel, or damage to equipment.
Moog Casella DM2020 Installation and Startup Guide 5.3 Electrical Installation and Thermal Rating 5.3 Electrical Installation and Thermal Rating This section provides information on the electrical installation and thermal rating of the DM2020 system. 5.3.1 Safety and General Instructions WARNING: Electrical hazard - AVERTISSEMENT: risque électrique...
Moog Casella DM2020 Installation and Startup Guide 5.3.2 Electrical Installation 5.3.2 Electrical Installation Structure of the Electrical Panel with the Components of a Servo System Particular attention should be given to grounding, shielding and the use of the filter to reduce or suppress particularly steep voltage surges (derived by PWM modulation), which are capable of generating significant unwanted currents through capacitive couplings and grounded systems.
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Moog Casella DM2020 Installation and Startup Guide 5.3.2 Electrical Installation Avoid crossing power cables with signal cables Use a shielding cover that is greater than 70% Avoid laying the power and signal cables side by side with each other, especially near the line filter —...
Moog Casella DM2020 Installation and Startup Guide 5.3.3 Thermal Rating of the Electrical Panel Connection Cables EMC Bracket 5.3.3 Thermal Rating of the Electrical Panel For a thermal rating of the electrical panel, refer to the following table. The first column indicates the value of the maximum power that can be dissipated from the radiator, The second column indicates the value of the power dissipated by the DM2020 system under nominal operating conditions.
Moog Casella DM2020 Installation and Startup Guide 5.3.3.2 Thermal Dissipation of Accessories 5.3.3.2 Power Supply Unit (PSU) Dissipation % Rated Type L50 Type L150 current The first column shows the percentage of current delivered compared to the rated current. The second column shows dissipation data in watts in operating conditions.
Moog Casella DM2020 Installation and Startup Guide 5.3.5 AC Mains Power/Ground Connection 5.3.5 AC Mains Power/Ground Connection WARNING: Electrical hazard - AVERTISSEMENT: risque électrique High voltage may be present, which can result in death or serious injury to personnel, or damage to equipment.
Moog Casella DM2020 Installation and Startup Guide 5.3.5.2 Protection Components TT system The TT earthing system, shown in the following figure, is NOT widespread and presents problems for the EMC requirements, which can only be fully met with precautions and measurements in the field.
Moog Casella DM2020 Installation and Startup Guide 5.3.5.3 Ground Connection To use a single protection with three fuses on the input line to a system consisting of several DM2020, the size required will be the one that is the next size larger than the sum of the currents of the individual systems.
Moog Casella DM2020 Installation and Startup Guide 5.3.6 Drive Wiring 5.3.6 Drive Wiring The steps for wiring the DM2020 drive are as follows: 5.3.6.1 Grounding Mount the DM2020 drive to the control cabinet's metal structure, ensuring that the contact surface is adequate and that the connection is at low resistance and inductance.
Moog Casella DM2020 Installation and Startup Guide 5.3.6.3 BUSBAR Connection 5.3.6.3 BUSBAR connection The +DC bus and -DC bus terminals of the power supply and axis modules must be connected in parallel. In this way, the power from the power supply and power from regeneration are divided between all axis modules.
Moog Casella DM2020 Installation and Startup Guide 5.3.6.5 Signal Connection 5.3.6.5 Signal Connection For more details on signal connectors X5, X15, X6, X16, see Layout of connectors and other interfaces on the axis module section 5.3.6.6 Motor Cable Connection Details The following figures show the motor cable connection points.
Moog Casella DM2020 Installation and Startup Guide 5.3.6.7 Brake Cable Connection 5.3.6.7 Brake Cable Connection Motor speed Stopped motor Brake voltage command Brake activation A: Deceleration time of the machine (variable) B: Brake activation (300 ms) Brake Activation Timing Diagram The same considerations relating to the motor cable also applies.
Moog Casella DM2020 Installation and Startup Guide 5.3.6.8 I/O Signal Connection 5.3.6.8 I/O Signal Connection Connectors X5, X15, X6, X16 CAUTION Analogue inputs are referred to 0 Volt analogue earth on pin 16; the 0 Volt digital earth is used for the power...
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Moog Casella DM2020 Installation and Startup Guide 5.3.6.9 STO Signals Connection By including the two STO commands in series in the “safety device” circuit, the axis enable command is operated only when the PLC controls both S1 and S2 signals, and at the same time all machine safety devices are “closed”.
Moog Casella DM2020 Installation and Startup Guide 5.3.6.10 Transducer Connection 5.3.6.10 Transducer Connection The DM2020 is able to handle most of the common position motor transducers in the table below: Resolver X3- / X13 Stegmann absolute single-turn sinusoidal encoder with/without hiperface...
Moog Casella DM2020 Installation and Startup Guide 5.3.6.11 Connecting the Fieldbus - X8, X9, X10 Connectors 5.3.6.11 Connecting the Fieldbus - X8, X9, X10 Connectors INFORMATION Depending on the type of ieldbus, a different type of irmware may need to be installed. If the...
Moog Casella DM2020 Installation and Startup Guide 6.1 Safety 6 Commissioning with Dx2020 Software 6.1 Safety WARNING: Electrical hazard - AVERTISSEMENT: risque électrique High voltage may be present, which can result in death or serious injury to personnel, or damage to equipment.
Moog Casella DM2020 Installation and Startup Guide 6.2 Dx2020 GUI 6.2 Dx2020 GUI 6.2.1 Overview A graphic interface software called Dx2020 GUI is associated with each drive. It provides controls for setting and changing the parameters, and configuring the drives.
6.2.3 Dx2020 GUI Installation After downloading the installer, start by double clicking it. , The installation software may be obtained from Moog Casella. If the software is installed for the first time on the PC, you are prompted for the desired language. By default, if available, the program will automatically select the operating system language as the first choice.
Moog Casella DM2020 Installation and Startup Guide 6.2.4 GUI Drive Connection If an error occurs during installation, report the error message to Applications Engineering. Once the program is installed, the Dx2020 GUI icon will be displayed on the desktop. 6.2.4 GUI Drive Connection Run the executable Dx2020 GUI with the DM2020 system powered up.
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Moog Casella DM2020 Installation and Startup Guide 6.2.4 GUI Drive Connection Select the Connect command from the toolbar or through the drop-down menu Network. The LED in the Statusbar turns green if the connection is successful; otherwise, it is red. Depending on the type of...
Moog Casella DM2020 Installation and Startup Guide 6.2.5 Layout In the Select Node window, confirm the Node and ID values, then click OK In case of failure during connection, refer to the Troubleshooting section and follow the suggested actions. 6.2.5 Layout...
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Moog Casella DM2020 Installation and Startup Guide 6.2.5 Layout Menu: Contains the following menus: File, Network, Tools, Options, ? For more information, refer to the Dx2020 GUI help on-line. Toolbar: Navigation area: This area provides access to all information organized into views. The axis has a submenu that lists the parameters by function (transducer, motor, speed loop, etc.) Clicking...
Moog Casella DM2020 Installation and Startup Guide 6.2.6 Firmware Update (BootLoader) Notification window: This area is dedicated to display messages that may have different meanings. A filter can be applied to display messages based on the type (ERROR, WARNING, INFO, DEBUG).
Moog Casella DM2020 Installation and Startup Guide 6.2.7 Accessing the Dx2020 GUI help on-line For more information, refer to the Dx2020 GUI help on-line. 6.2.7 Accessing the Dx2020 GUI help on-line The Dx2020 GUI help on-line can be accessed as follows: Use Interface Dx2020 GUI: from the Menu bar, select "?"...
Moog Casella DM2020 Installation and Startup Guide 6.4 System Configuration 6.4 System Configuration The following steps are used for the DM2020 system configuration: • Axis Identification • Motor Parameter Configuration • Transducer Configuration • I/O Configuration • Control Loops Configuration •...
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Moog Casella DM2020 Installation and Startup Guide 6.4.2 Motor Parameter Configuration If the drive is connected while the motor is hot, the thermal image provided by the Dx2020 GUI will return a false estimate. This protection supports but doesn't completely replace the thermal switch in the motor.
Moog Casella DM2020 Installation and Startup Guide 6.4.3 Transducer Configuration 6.4.3 Transducer Configuration The DM2020 can handle various types of feedback transducers to close the control loops. • Resolver (standard) • Encoder Incremental TTL • Encoder, Stegmann Sinusoidal Absolute Single/Multi-Turn with Hiperface communication •...
Moog Casella DM2020 Installation and Startup Guide 6.4.3.1 Sensorless 6.4.3.1 Sensorless The DM2020 provides a sensorless mode, i.e., without a speed transducer. To enable it, 1. Select Feedback from the Navigation Area. 2. In Tab Sources feedback, set the fields as indicated in the following figure.
Moog Casella DM2020 Installation and Startup Guide 6.4.4 I/O Configuration 4. Finally, set the fault interface X3 - Missing Transducer Configuration to "None" as shown in the following figure. 6.4.4 I/O Configuration INFORMATION A “deadband” can be applied to all analogue inputs; this is a band of signal below which the two inputs will be ignored.
Moog Casella DM2020 Installation and Startup Guide 6.4.4.1 Details of Possible Configurations 6.4.4.1 Details of Possible Configurations Configuration description 0 In this mode, the three channels are configured as 2 digital inputs plus the serial line RS-232. Configuration description 1 In this mode, the three channels are configured as 1 digital output, 1 digital input, and the RS-232 serial line.
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Moog Casella DM2020 Installation and Startup Guide 6.4.4.2 Programming Analog and Digital I/O Connector X5 All digital outputs can be configured as follows: Copy of limit switch (if programmed on the digital inputs, available on J6). Warning motor temperature Warning for motor I Warning drive temperature 6.4.4.2 Programming Analog and Digital I/O Connector...
Moog Casella DM2020 Installation and Startup Guide 6.4.5 Control Loops Configuration Reference enable command Quick stop command DX limit switch SX limit switch Each analog input can be configured with a different parameter. The digital outputs are active if +24 V power is supplied on the X5 connector pin 7 with ground on pin 8.
Moog Casella DM2020 Installation and Startup Guide 6.4.5.2 Torque loop parameter configuration Feedforward Micro Position Speed Current − References Interpolator Controller Controller Controller Speed Retroaction Position (Position and Speed) Depending on the structure chosen, the reference for torque, speed or position must be provided.
Moog Casella DM2020 Installation and Startup Guide Filter configuration A standard correcting block (PI in the above image) is characterized by two parameters. It is followed by a sequence of filters, and a filter on the feedback chain. This allows the implementation of more complex control structures as well as filtering of known disturbances (Notch filter).
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Moog Casella DM2020 Installation and Startup Guide Filter configuration Keep the filter disabled until all the other parameters of the filter are entered. You must enter the parameters in the following order: 1. Damping 2. Frequency 3. Filter type Examples of filters Example of a Notch filter configuration: insert a Notch filter centered at 30 Hz.
Moog Casella DM2020 Installation and Startup Guide 6.4.5.4 Configuration of the position loop parameters 6.4.5.4 Configuration of the position loop parameters The position control must ensure that the motor position follows, as faithfully as possible, the position reference. The response quality of the system depends on the loop parameterization. The position control is PID (proportional-integral-derivative).
Moog Casella DM2020 Installation and Startup Guide 6.4.6 Fault Configuration 6.4.6 Fault Configuration From the navigation area select "Display Fault". The fault management display will appear. On the left side of the window there is a list of active alarms (Active Fault List), on the right there is another with the last 8 alarms (Fault History).
Moog Casella DM2020 Installation and Startup Guide 6.4.7 Application Parameters Configuration Reaction Effect None The alarm is ignored CAUTION: For use during commissioning or troubleshooting only. Not to be used in normal working or operating conditions. Emergency The drive sends an emergency message but does not stop or disable.
Moog Casella DM2020 Installation and Startup Guide 6.4.8 Commands and Modes Configuration Details about the events and reactions are described in the Dx2020 GUI help on-line. 6.4.8 Commands and Modes Configuration This menu allows to set the source of commands/controls and the drive operating mode.
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Moog Casella DM2020 Installation and Startup Guide 6.4.8 Commands and Modes Configuration Selects the command that will be tried by the drive state machine. The command will fact launch when the Enter key is pressed, this button is enabled only if the operating mode is set to Local Operating mode Sets the operating mode or function performed by the drive.
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Moog Casella DM2020 Installation and Startup Guide 6.4.8 Commands and Modes Configuration Through a drop-down sub-menu, it is possible to choose different types of references: constant (offset level), square, sinusoidal, trapezoidal, saw tooth, etc.; for each type of waveform it is possible to define the parameters of offset, square, frequency level.
Moog Casella DM2020 Installation and Startup Guide DM2020 State Machine Quick Stop Command The command called "quick stop" initiates the function of a controlled, rapid stop of motion. In other words, following a "quick stop" command, a rapid deceleration ramp is performed in a controlled manner and then the drive is placed in a disabled state.
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Moog Casella DM2020 Installation and Startup Guide DM2020 State Machine Start Not ready to switch on Switch on Fault disabled Ready to Fault reaction switch on active Switched on Power off or reset Quick stop Operation active FSA State Quick...
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Moog Casella DM2020 Installation and Startup Guide DM2020 State Machine Transition Event(s) Action(s) Ignition control command received from the If possible, the high-level output is drive or from the GUI enabled. Enable operation command received from The operating mode is enabled and all the the drive control or from the GUI set-point extensions will be cleared.
Moog Casella DM2020 Installation and Startup Guide 6.5 STO Activation 6.5 STO Activation To enable the axis, you must enable the STO circuit. The 24 V power of the STO circuit must be integrated within the emergency fail-safe loop. See Safe Torque Off Safety Function on page 140.
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Moog Casella DM2020 Installation and Startup Guide 6.6 Auto-Phase Procedure Check that the power supply and STO are present, then from the "Command" field, select in sequence: 1. “Shutdown”. 2. “Switch On”, leaving the drive in this state. The drive signals the activation with an "S" on the display. See the following figure.
Moog Casella DM2020 Installation and Startup Guide 6.7 Drive (Axis) Enable and Limit Switch Enable/Disable 6.7 Drive (Axis) Enable and Limit Switch Enable/Disable The drive implements profile DS402 (CIA standard). The enabling of the drive (axis) depends on the application of a command that can be received from remote EtherCAT or CAN fieldbus by hardware (Analog mode) or GUI (Local operation).
Moog Casella DM2020 Installation and Startup Guide 6.8 Oscilloscope Function and Log File (.UCX) 6.8 Oscilloscope Function and Log File (.UCX) It is possible record and display numerous drive internal variables from the Dx2020 GUI by selecting "Digital Oscilloscope". 6.8.1 Log Configuration Select the Channels tab for each channel in the drop down menu to choose the variable to display.
Moog Casella DM2020 Installation and Startup Guide 6.8.3 View Logs Displays on the GUI: the data are only displayed and not recorded Save Locally: the data are displayed and saved on the PC in the directory specified in Output Folder To start recording, click Start;...
Moog Casella DM2020 Installation and Startup Guide 6.9 Using the GUI in Offline Mode 6.8.4 UCX File Management When data is saved in Local, a file is created with the name, date and time of capture. The extension of these files is "* .UCX". To view archived recordings, go to the Tab "Load/Save File", accessing the file system using the Open UCX button.
Moog Casella DM2020 Installation and Startup Guide 6.10 Contextual Help For Parameter Management To check a parameter file, from the main menu: 1. Select the axis with the right mouse button. 2. Load the parameters as if there was a real drive connected.
Moog Casella DM2020 Installation and Startup Guide 6.11 Decommissioning Procedure Disable Axis: Disable axis selected Enable Axis: Enable axis selected To open the menu, right click on the drive (axis) name. 6.11 Decommissioning Procedure WARNING: Electrical hazard - AVERTISSEMENT: risque électrique.
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Moog Casella DM2020 Installation and Startup Guide 6.11 Decommissioning Procedure 5. Remove the DM2020 drive from the electrical panel. 6. To decommission the DM2020 system's motor, follow the decommissioning procedure described in the motor's installation guide. 7. Repackage the system components in their shipping containers for safe storage or return.
Immediately report any discrepancies to Moog Casella. Retain all packing materials that the DM2020 system was shipped in, as those must be used if the system components need to be sent to Moog Casella for service. This will ensure that they arrive safely.
Moog Casella DM2020 Installation and Startup Guide 8 Maintenance 8 Maintenance There are no user-serviceable parts inside the DM2020 system. Do not attempt to disassemble the DM2020 drive or motor, as doing so will void the warranty. Ø If your DM2020 drive needs to be serviced, return the faulty component(s) to the factory.
8.2 What to Do If Repairs Are Required? If repair of a Moog drive is needed, an RMA (Return Material Authorization) number is required to return the motor. Instructions for packaging and shipping the drive back to Moog will be provided with the RMA.
Moog Casella DM2020 Installation and Startup Guide 9 Troubleshooting 9 Troubleshooting WARNING: Electrical hazard - AVERTISSEMENT: risque électrique. The DM2020 system and connected motor may present an electrical hazard if the safety precautions are not observed, which may result in death or serious injury to personnel, or damage to equipment.
Failure recovery Check the braking resistor Overvoltage If any of the above problems persist after implementing the suggested actions, please contact Moog Service 9.2 Drive Alarms (Faults) The drive-axis alarms (faults) are shown on the axis display by the letter F; to troubleshoot the condition, connect to the Dx2020 GUI software, in the software, select the item Fault Display, and then proceed with the analysis of the anomalies.
Moog Casella DM2020 Installation and Startup Guide 9.2.2 Alarm for VBUS Voltage Out of Tolerance This type of alarm occurs when the drive detects an excessive current or a short circuit on one of the six IGBT output stages. With this type of alarm, the reaction is always disabling, as appropriate control of the motor is no longer possible.
Moog Casella DM2020 Installation and Startup Guide 9.2.4 Removal of STO Signal In case of excessive drive or motor temperature warning, an analysis of the cause of the problem must be performed according to the following table. Cause Action The drive temperature is high (above 50 °C on the Check the efficiency of the cooling fans;...
Moog Casella DM2020 Installation and Startup Guide 9.2.7 Brake Feedback Fault Use the Dx2020 GUI software to verify the correct configuration of the drive, and then save the parameters. Reset the drive and restart the Dx2020 GUI software. If the problem persists, replace the drive.
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Moog Casella DM2020 Installation and Startup Guide 9.2.8 Errors on Feedback Devices Fault Cause Action Missing Transducer Interface transducer enabled but Configure it Configuration not configured Resolver Signals Fault Error resolver signal level Perform compensation of the (amplitude) cable Resolver synchronization fault...
Moog Casella DM2020 Installation and Startup Guide 9.2.9 Synchronization , Interrupt Time and Task Time Error 9.2.9 Synchronization , Interrupt Time and Task Time Error Fault Cause Action Synchronization error Internal interrupt irregular frequency Reprogram the drive (firmware and parameters). If the alarm...
Moog Casella DM2020 Installation and Startup Guide 9.3 Alarm Display in Analog Operating Mode 9.2.12 CAN Bus Alarms Fault Cause Action CAN_communication_fault PDO data not received or received after the timeout CAN_rpdo0_time_out PDO data not received or received after the timeout...
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Moog Casella DM2020 Installation and Startup Guide 9.3 Alarm Display in Analog Operating Mode Fault Error Error Fault Description Index Code Register 0x2346 0x04 short_circuit_phase_V_low IGBT fault, phase V, low arm 0x2347 0x04 short_circuit_phase_V_hi IGBT fault phase V, high arm...
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Moog Casella DM2020 Installation and Startup Guide 9.3 Alarm Display in Analog Operating Mode Fault Error Error Fault Description Index Code Register 0x7125 0x08 motor_over_temperature Fault - motor temperature 0x73A2 0x01 Interface STD - Erroneous Sinusoidal signal amplitude value of sincos signals...
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Moog Casella DM2020 Installation and Startup Guide 9.3 Alarm Display in Analog Operating Mode Fault Error Error Fault Description Index Code Register 0x8700 0x01 synchronization_error Internal interrupt frequency irregular 0x6102 0x01 interrupt_missing (was Internal interrupt frequency not Interrupt_time_exceeded) detected 0x6103...
Moog Casella DM2020 Installation and Startup Guide 9.4 Faults During the GUI – Drive Connection Fault Error Error Fault Description Index Code Register 0x8233 0x10 CAN_rpdo2_time_out Time out - PDO2 reception (CAN) 0x8234 0x10 CAN_rpdo3_time_out Time out - PDO3 reception (CAN)
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Moog Casella DM2020 Installation and Startup Guide 9.4 Faults During the GUI – Drive Connection For a serial connection, verify that: The correct COM port is selected The baud rate to 115200 For a CAN connection, verify that: The CAN bus is properly terminated The IXXATe CAN USB adapter is installed along with the appropriate drivers on the PC...
Moog Casella DM2020 Installation and Startup Guide 10.1 Application 10 Safe Torque Off Safety Function 10.1 Application The DM2020 system's safety function, Safe Torque Off (STO), has been designed with an integrated redundant circuit in the control board. It is considered misuse to use the STO function outside of the instructions provided in this guide.
Moog Casella DM2020 Installation and Startup Guide 10.3.1 Characteristic Values According to UNI EN ISO 13849-1 The STO function is located in a subsystem as defined by the Standard CEI EN 62061: 2005 +A1:2013 +A2:2015, with a SIL limit requested SILCL3.
Moog Casella DM2020 Installation and Startup Guide 10.3.2 Characteristic Values According to CEI EN 62061 10.3.2 Characteristic Values According to CEI EN 62061 Hardware Feedback standard values according to CEI EN 62061: 2005 +A1:2013 +A2:2015: Value Observations Levels of integrity of security...
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Moog Casella DM2020 Installation and Startup Guide 10.4.1 Full Stop assessment should include the possibility of a fault. The machine may have a dangerous overload in the event of failure of the motor and additional protective measures may be required to achieve a more secure state.
Moog Casella DM2020 Installation and Startup Guide 10.5 Safe Torque Off Circuit 10.5 Safe Torque Off Circuit The Safe Torque Off function is designed with redundant blocking devices, which act independently on the power modules. This is advantageous because it does not disable the power supply of the drive and avoids the normal restart process.
Moog Casella DM2020 Installation and Startup Guide 10.6 Safe Torque Off Connections 10.6 Safe Torque Off Connections Management channels, including the "Hardware feedback" of the Safe Torque Off circuit, are controlled using the X4 (X14) Connector, also referred to as JRC1. Optional circuit delivering a dry feedback contact can be connected through connector X1-X11.
Moog Casella DM2020 Installation and Startup Guide 10.6.2 Electrical Input/Output Specifications 10.6.2 Connector X1-X11 (Option) The following figure and table describes the connector pinouts: 4 contacts, Weidmüller model BLZF 3.50/04/180 SN BK BX. X1-X11 Feedback Channel Feedback Channel Optional STO feedback Connector Pinout: 4 Contacts, Model BLZF 3.50/04/180 SN BK BX Weidmuller...
Moog Casella DM2020 Installation and Startup Guide 10.6.2 Electrical Input/Output Specifications AVERTISSEMENT Pour être validé selon les catégories de 1 à 4, sur la base des principes de sécurité UNI norme EN ISO 13849-2: 2008, tableau D.2, les câbles externes qui fonctionnent dans le connecteur de JRC1 doivent avoir des boucliers connectés au circuit de mise à...
Moog Casella DM2020 Installation and Startup Guide 10.7 Example Application 10.7 Example Application The following figure illustrates an example circuit for Safe Torque Off after a controlled stop. CLOSED OPEN - SW1 - SW2 DRIVE - Q1 Ch 1 Verification Ch 2 Verification...
Moog Casella DM2020 Installation and Startup Guide 10.7.2 Example Requirements In the example, the controlled stop can be achieved using the delayed outputs of A1. The controlled stop is not an integrated security function in the drive. Therefore, its circuit is not shown in the figure.
Moog Casella DM2020 Installation and Startup Guide 10.8 Safe Torque Off Installation and Maintenance Procedure The multi-wired cables connected to the multi-pole connectors must be terminated with cable lugs or other appropriate devices. The verification of the two channels of the signal wiring must be protected from short circuit to voltage sources and should never be exposed to voltage external to the verification signal, even in case of failure.
10.9 Assembly and Serial Tests The Safe Torque Off (STO) circuit is assembled and tested at Moog Casella. 10.10 Identification of the STO Function on the Drive Plate The Safe Torque Off circuit is identified by the words "Safe Torque Off" on the drive plate.
If repair of a Moog drive or motor is needed, an RMA (Return Material Authorization) number is required to return the motor. Instructions for packaging and shipping the motor back to Moog will be provided with the RMA. Contact your Moog Casella representative for more information.
Moog Casella DM2020 Installation and Startup Guide 13.1 Glossary 12 Appendix 12.1 Glossary Acceleration The rate of increase of velocity with respect to time Alarms Irregular operating situations highlighted by LED or display message, with subsequent analysis through the Dx2020 GUI Asynchronous Motor Motor in which the rotor and the magnetic field turn at different speeds.
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Moog Casella DM2020 Installation and Startup Guide 13.1 Glossary which serve to provide the necessary requirements for health and safety relating to the design and construction of machinery present on the European market. It applies to fixed, mobile, transportable and hoisting/moving.
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Moog Casella DM2020 Installation and Startup Guide 13.1 Glossary stored in the encoder. It is compatible with the previous version, EnDat 21, but offers advantages such as the transfer of other data together with that of position without a separate request.
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Moog Casella DM2020 Installation and Startup Guide 13.1 Glossary Serial Transmission based on sending each signal at different times (i.e., one after Communication the other). Shield Devices designed to reduce electromagnetic emissions. Servodrive Drive that operates the regulation of torque, speed and position of a servomotor.
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TAKE A CLOSER LOOK Moog designs a range of products that complement the performance of those featured in this guide. Visit our website for more information and the Moog facility nearest you. Argentina India Singapore +54 11 4326 5916 +91 80 4057 6666 +65 677 36238 info.argentina@moog.com...
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