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DS2020 L-MAS2-E-161 DS2020 MAINTENANCE AND USER MANUAL SINGLE AXIS DIGITAL SERVO DRIVE INDEX 1. OVERVIEW 1.1. Manual contents 1.2. Utilized symbols 1.3. Package content 1.4. Required qualifications of the users 1.5. Applicable laws 2. SYSTEM DESCRIPTION 2.1. Product structure Product description 2.1.1.
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DS2020 L-MAS2-E-161 2.4.1. General description of security features 2.4.2. STO safety feature 2.4.2.1. Description 2.4.2.2. Directives on safety 2.4.3. Usage Guidelines of the drivers 3. CERTIFICATIONS 3.1. CE 3.2. Safety and Safe Torque Off 4. ELECTRICAL AND MECHANICAL INSTALLATION 4.1 Tools and equipment 4.2.
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DS2020 L-MAS2-E-161 5.2.6. Firmware update (BootLoader) 5.2.7. How to access to Online Help 5.3. System configuration 5.3.1. Identifying an axis module 5.3.2. Motor parameters configuration 5.3.3. Trasducers configuration 5.3.3.1. Sensorless 5.3.4. I/O configuration 5.3.5. Control loops configuration 5.3.5.1 Control mode configuration 5.3.5.2 Torque loop parameters configuration...
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DS2020 L-MAS2-E-161 6.3.12. CAN Bus alarms 6.4. Alarm display in 'Analog' operating mode 6.5. Faults during the GUI-drive connection SAFE TORQUE OFF SAFETY FEATURE 7.1. Application 7.2. Installation risk assessment 7.3. Safe Torque Off 7.3.1. Characteristic values according to UNI EN ISO 13849-1 7.3.2.
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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.
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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).
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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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DS2020 L-MAS2-E-161 Control functions Implementation of the Torque, Speed and Position loops Command protocols EtherCAT, CANopen and “Analog” Via GUI : Dx2020GUI, allows to configure, calibrate and Configuration/Commissioning control the drive. Diagnostic Via GUI Positioning transducers • Resolver standard • Encoder Incremental TTL •...
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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.
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ENCODER SINCOS SERIAL ENCODER SINCOS TTL SINGLE ENDED SERIAL BC8902-R TTL FULL DIFFERENTIAL SERIAL TTL SINGLE ENDED TTL FULL DIFFERENTIAL Standard version The first two characters are "CH" and are used to identify the DS2020 family Values attributed by Moog...
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DS2020 L-MAS2-E-161 2.2. Features and components details 2.2.1. Electrical data Electrical data L50A L75A – L75B L85A L125A Network power From 120 Vac to 480 Vac +/- 10 % supply voltage Auxiliary voltage 24 Vdc +/-10% Rated currentArms from 2 to 4...
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DS2020 L-MAS2-E-161 2.2.3. Trasducers The DS2020 can manage the following 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 2.2.4 Connectors...
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DS2020 L-MAS2-E-161 Below is the list of connectors Connector Function + 24 Volt Auxiliary power supply Resolver or Encoder motor feedback Interface USB or RS422 Programmable digital connector Analog digital I/O All sizes Interface STO Can Open Fieldbus (Optional) Ethercat Out Fieldbus (Optional)
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DS2020 L-MAS2-E-161 X3 - Serial (RS422) or USB Interface The X3 connector can be either a 9-pin RS422 or a USB type B Function Definition Data+ reception Definition Function N.C. Non connected USB_+5V Power Data+Transmission USBDM USB- data channel Non connected...
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DS2020 L-MAS2-E-161 X5 Analog digital I/O connector PIN DEFINITION FUNCTION Positive Analog Input 1, 12 bit resolution, sampling IN AN 1 + 3.9 us (256 kHz) Analog negative input 1, 12 bit resolution, sampling 3.9 IN AN 1 - us (256 kHz)
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DS2020 L-MAS2-E-161 Reset button When pressed causes the initialization of the drive control section; a long press (> 3 seconds) causes access to the boot routine of the drive and the ability to download a different version of the control SW, through the GUI.
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DS2020 L-MAS2-E-161 X8 – X9 EtherCat Option The cable used is an Ethercat standard one, the connector is a RJ45. Nome Descrizione - The drive is in the state INIT BLINKING - The drive is in the state PRE-OPERATIONAL EtherCAT...
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DS2020 L-MAS2-E-161 X11, X12, X13 - Power connections X11 connection - sizes L50 and L75 Definition Function U2, V2, W2, Motor connection Connection to power ground through M5 stud Ground stud M5 U1, V1, W1 Connection to the three-phase network...
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DS2020 L-MAS2-E-161 2.2.6. Braking resistor When the motor accelerates, the energy is dissipated as heat in the braking resistor. The table shows the values of the brake resistors, broken down by size Size Power [Watt] Position Internal L50A L75A – L75B...
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2.4.2. STO Safety feature 2.4.2.1. Description The DS2020 drives include as standard the STO function (Safe Torque Off) that shall ensure personnel protection against accidental restart of the drive. The DS2020 standard version contains the STO function to be used as interlock against accidental motor starts.
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The conductor cross sections must comply with the norm IEC 60204. Motors The DS2020 drives have been designed to control brushless asynchronous and synchronous motors with torque control, speed and / or position. The rated voltage of the motors must be at least the same level of the...
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It does not comply with the Directives on EMC or Low Voltage Directives • It does not conform to national directives The control of the brake by the drive DS2020 alone is not considered sufficient in those applications in which the safety of personnel must be ensured via the brake. Storage The storage of DS2020 for a consecutive period of up to one year does not require special limitations and actions;...
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• EMC 2004/108/CE directive • Low Voltage Directive 2006/95/CE The DS2020 has been tested in a laboratory for the verification of the parameters of compliance of the above Directives. Regarding electromagnetic compatibility the DS2020 refers to C3 industrial environments. Notice In a domestic environment, the DS2020 can emit radio frequency interferences.
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DS2020 L-MAS2-E-161 3.2. Safe Torque Off (Re-start lock) The DS2020 integrates the Safe Torque Off (STO) function according to standards EN 61800-5-2; EN / ISO 13849-1. SILCL 3 PL "e" (as per certificate). function also corresponds to an uncontrolled stop in accordance with stop category 0 of IEC / EN 60204-1 standard.
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Braking resistors positioning The drives DS2020 L50 and L75 sizes are equipped with internal braking resistors while the L85 and L125 sizes have external resistors (available for all sizes, if the application requires it) placed at the top of the electrical panel to facilitate the dissipation of the generated heat .
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DS2020 L-MAS2-E-161 4.3. Electrical installation and thermal rating 4.3.1. Safety and general instructions Attention While the Drive is running there is danger of death, serious injury or serious material damage. Auxiliary power supply 24 volts Three-phase network Contactor Fuse protection...
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DS2020 L-MAS2-E-161 Requirements for laying the connecting cables: • Avoid crossing power cables with signal cables • The shielding cover must be greater than 70% • Avoid laying the power and signal cables side by side with each other, especially near the line filter whilst maintaining physical separation •...
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DS2020 L-MAS2-E-161 4.3.2.1 Drive axis module dissipation Power dissipated from the Type Rated size module to the rated current [W] L125 4.3.2.2. Thermal dissipation of the accessories Device Dissipated power (W) Network filter From 9 to 30 External braking resistor...
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DS2020 L-MAS2-E-161 4.3.4. Grid connection Attention It is necessary to ground the drive properly to avoid risk of injury or death. In the case of networks ungrounded or asymmetrically grounded you need to insert an isolation transformer 4.3.4.1. Types of electrical networks...
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DS2020 L-MAS2-E-161 TT grid The electrical network shown in the figure is not widespread and presents problems for the EMC requirements, which can only be met fully with precautions and measurements in the field. The following are the main features:...
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DS2020 L-MAS2-E-161 4.3.5. Drive wiring Proceed as follows: 1. Ground the drive mounting plate, the casing of the motor and the control unit ground 2. Lay separately the power and the control signal cables 3. Connect the auxiliary power on X1 4.
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DS2020 L-MAS2-E-161 4.3.5.4. Auxiliary power connection An auxiliary voltage of 24VDC, must be provided externally to the terminals +24 V and 0 V on the front, connector 4.3.5.5. Signal connection For connection of the control signals, transducer interface, linear communication, see paragraph 2.2.4.
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DS2020 L-MAS2-E-161 • The internal devices are protected from short circuit between the terminals (between 3 and 4) and to ground. • The drive detects the correct execution of the command, the possible short-circuit condition is indicated as the absence of output on terminal 4.
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DS2020 L-MAS2-E-161 4.3.5.8. I/O signal connection For the connector pin assignment see paragraph 2.2.4. Notice The analog inputs and outputs are referenced to ground 0 V ext. present on pin 16 of X5; the 0 Volt. present on pin 8 of X5 is used for the power supply of the digital inputs and outputs.
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If the connection cables of the STO function are located outside the installation site they must be protected (for example passing them through a conduit) and routed in a secured way. 4.3.5.10. Transducers connection The DS2020 is able to handle the most common of the motor position transducers shown in the folowing table Resolver standard X2 Connector...
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DS2020 L-MAS2-E-161 The connector X2 is for all, but can be of different types depending on the transducer, for the pin description see paragraph 2.2.4.1 Notice The cable for the incremental encoder must be at least 6 and possibly individually shielded twisted pairs for incremental signals A, B, C and Hall signals U, V, W.
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DS2020 L-MAS2-E-161 5. COMMISSIONING VIA GUI The commissioning of the system is performed via the operator Dx2020 GUI. For a detailed description of the menus and procedures please refer to the Help on line on the GUI itself. 5.1. Safety Attention The drive can generate potentially lethal voltages up to 900 V.
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DS2020 L-MAS2-E-161 5.2. Dx2020 GUI 5.2.1 Overview A graphic interface software called Dx2020 GUI is associated with each drive. It allows to set and change the parameters and configure the drives. The main features are: • System Configuration with access to the basic parameters of the system (sensors, digital and analog I / O, motor parameters, etc.)
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UAC (User Account Control). This system every time you start any program that needs more administrative rights asks if you want to proceed The installation software may be obtained from Moog-Casella. Windows 7 Click Yes or Allow to proceed with the installation.
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DS2020 L-MAS2-E-161 5.2.4 GUI-Drive connection Run the executable Dx2020GUI with the drive powered. The GUI can connect to the drive via: • Serial RS422/RS232 or USB (connector X3) • EtherCAT (X9-IN) • CanBus (connector X7-IN) Note: The GUI automatically detects whether it is used on RS422 or RS232.
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DS2020 L-MAS2-E-161 CANBus: from the connection selection window choose Port and Baud Rate. Then press "OK". In the "Select node" window confirm the values "Node" and "ID". Then press "OK" Info In case of failure during connection, refer to the chapter "Troubleshooting" and follow the suggested actions.
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• Main area: This area displays the information and the parameters associated with the selected view in the navigation area. This window allows to view and set the DS2020 drive parameters. For more information refer to the Help Online. •...
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DS2020 L-MAS2-E-161 5.2.6 Firmware update (BootLoader) The firmware update can take place via a serial RS422, USB or via EtherCAT. The download file extension is *.zhm. The firmware update occurs through dedicated applications (BootLoader EtherCat and BootLoader RS232) which simultaneously install with the Dx2020 GUI.
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"Navigation Area" of the GUI and the physically installed modules in the application. 5.3.2 Motor parameter configuration The DS2020 can be used to control: • Synchronous motors with permanent magnets (brushless) •...
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L-MAS2-E-161 DS2020 L-MAS2-I-161 5.3.3. Transducers Configuration The DS2020 can handle various types of feedback transducers to close the control loops. Resolver standard Encoder Incremental TTL Encoder Stegmann Sinusoidal Absolute Single / Multiturn with HYPERFACE communication Encoder Hedenhain Sinusoidal Absolute Single / Multiturn with ENDAT communication ➡...
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DS2020 L-MAS2-E-161 Finally set the fault Interface X3 - Missing Transducer Configuration to "No" as in the image below. 5.3.4 I/O Configuration Through the interface you can set the various configurations available for X4 and X5 connectors. Programming analog and digital I / O connector X4:...
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DS2020 L-MAS2-E-161 Information: The maximum extractable current from PIN 1 (Output +24 Volt) is 200 mA. DETAILS OF VARIOUS POSSIBLE CONFIGURATIONS: Configuration description 0 In this mode the three channels are configured as 2 digital inputs plus the serial line RS232.
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DS2020 L-MAS2-E-161 Programming analog and digital I / O connector X5: Analog Input 1 and 2 Torque reference Speed reference Position reference Current limitation (maximum output torque) Analog Output 1 and 2 Measured voltage DC BUS Current measured Iq Current reference Iq...
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5.3.5.1. Control mode configuration The DS2020 operates up to three control loops according to the drive operation mode: torque, speed, position, each one inside the other, with the torque as the inner loop, the speed as intermediate and the position as the outermost in a manner that the output of each loop will become the reference for the next one.
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DS2020 L-MAS2-E-161 The variable saturation block serves to prevent the formation of a stationary axis instability of position (zero speed reference acting in practice as a filter "low pass" with very limited bandwidth. To set the parameters, from the Navigation Area select "Speed loop": it will open the window that shows the block diagram of the loop .
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DS2020 L-MAS2-E-161 Info Maintain the filter disabled until all the other parameters of the filter are inserted Info You must enter the parameters following an established order 1° Dumping 2° Frequency 3° Filter type Examples of filters Example of a Notch filter configuration: insert a Notch filter centered at 30 Hz Example of configuration of a low pass filter of 2nd order 5.3.5.4.
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DS2020 L-MAS2-E-161 The integration term cancels the steady-state error. About the setting of the parameters, from the Navigation Area select "Position loop": it will open the window showing the loop diagram in question. It recognizes the standard corrector network (PID) characterized by four parameters. There is then a sequence of filters that allows the implementation of more complex control structures.
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• calibration_data_memory_corrupted Contact the Moog Casella Support center for advice or controls 5.3.7 Application parameters From this menu you can configure the reaction of the drive in case of particular events. Details about the events and the type of reaction are described in the Help Online.
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L-MAS2-I-161 DS2020 L-MAS2-E-161 5.3.8. Commands and modes configuration This menu allows to determine the origin of the controls and the role played by the drive. Operating mode Info Check that the firmware installed supports the fieldbus selected (in the case of EtherCAT fieldbus firmware will have _ecat suffix, in case of fieldbus Can the firmware will have _can suffix).
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More Application-specific modes are available and are not described in this document When the drive commands come from inside (eg: Operating mode = Local, Operational Mode = Internal speed) is possible to characterize different reference profiles (Square, Triangulate, Sawtooth, Keystone, Sin, Profile, Jog). DS2020 state machine ➡ ➡...
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DS2020 L-MAS2-E-161 Transition Event(s) Action(s) Automatic transition after switching on or Automatic verification of drive and / or automatic initialization is performed resetting the application Automatic transition Communication is activated. Shutdown command sent from drive or from the GUI Ignition control command received from the drive or from If possible, the high-level output is enabled.
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DS2020 L-MAS2-E-161 5.5.1. Autophasing procedure The phasing is driven by the software Dx2020GUI. To set the motor parameters select "Modes and Commands" in the Navigation Area Check that the power supply and STO are present then from the "Command" field, press in sequence: •...
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DS2020 L-MAS2-E-161 5.7. Oscilloscope function and log File (“.UCX”) It is possible record and display numerous drive internal variables from the navigation selecting "Digital Oscilloscope" 5.7.1 Log configuration Select the tab "Channels" for each channel in the drop down menu to choose the variable to display.
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DS2020 L-MAS2-E-161 5.7.3 View logs Select the tab "View" After the acquisition, the data appears on the display. In the top left there are the functions of Cursor Activation (Cursor ), Displacement of the Graph(Pan Magnification of the details (Zoom ) and printing of the image (Screenshoot );...
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DS2020 L-MAS2-E-161 5.8 Using the GUI in OFF LINE mode The GUIDE can also be used in offline mode in the absence of the drive to prepare the drives configuration file, to edit them or to verify their contents. ➡...
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L-MAS2-E-161 6. TROUBLESHOOTING 6.1. Introduction The following list describes the main malfunctions and provides a series of recommendations on how to fix them. If the problem persists, contact Moog Casella. 6.2. Power section anomalies Cause Action Check the continuous current...
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DS2020 L-MAS2-E-161 6.3.1. Alarms on the power section • Short_Circuit_Phase_x_Low • Short_Circuit_Phase_x_Hi Identifies the IGBT affected by the phase x: (U, V or W) This type of alarm occurs when the drive detects an excessive current or a short circuit on one of the six IGBT output stage.
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DS2020 L-MAS2-E-161 6.3.2. Allarme per Tensione VBUS fuori tolleranza Fault Cause Action Misurare la tensione su bus Voltage lower than the DC_Link_Under Voltage dc e confrontare con quella Fault of the sensing circuit minimum threshold set misurata dall’azionamento Brake resistor not...
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DS2020 L-MAS2-E-161 6.3.4. Removal of STO signal • Safety_stage_low_voltage: STO protection intervention In case of STO circuit removal of power it releases the axis disabling the output power. In case of discrepancy between the command and the feedback signal, the STO circuit inside the drive may be damaged; verify that the absorption at 24 Vdc at both inputs is approximately 50 mA per input.
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DS2020 L-MAS2-E-161 6.3.8. Errors on feedback devices For a correct operation all the feedback signals must arrive to the drive in an appropriate manner; if this does not happen the causes are indicated by the alarm that identifies in detail what functionality of the transducer is wrong or missing.
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DS2020 L-MAS2-E-161 6.3.10. EtherCAT Fault Fault Cause Action communication error EtherCAT_communication_fault EtherCAT_link_fault link eth not present pdo data received incorrect EtherCAT_rpdo_data pdo data not received or EtherCAT_rpdo_time_out received after the time out Check wiring configuration of the drive communication and / or...
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DS2020 L-MAS2-E-161 6.4 Alarm display in Analog operating mode If the drive is in operation mode "Analog" (Mode and Commands / Mode Operation: Analog), the display on the front side indicates the presence of an alarm and an additional error index, consisting of 2 numerical digits. In this way, the operator can identify the cause of the error present without a PC.
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DS2020 L-MAS2-E-161 0x6315 0x01 calibration_data_memory_corrupted Not used 0x6316 0x01 diagnosis_data_memory_corrupted Not used 0x7110 0x01 brake_feedback_fault Brake status signal inconsistent 0x7124 0x08 motor_temperature_warning Warning motor temperature 0x7125 0x08 motor_over_temperature Fault motor temperature 0x73A2 0x01 Interface STD - Erroneous value Amplitude sinusoidal...
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DS2020 L-MAS2-E-161 0x8700 0x01 synchronization_error Internal interrupt frequency irregular 0x6102 0x01 interrupt_missing (era Internal interrupt frequency Interrupt_time_exceeded) not registered 0x6103 0x01 Task_time_exceeded Task exceeded the maximum time 0x8400 0x01 velocity_control_monitoring Error exceeding maximum speed 0x8611 0x01 following_error position tracking error...
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DS2020 L-MAS2-E-161 0x8244 0x10 CAN_rpdo3_data PDO3 data reception error 0x8235 0x10 CAN_tpdo0_time_out Time out PDO0 di trasmissione 0x8236 0x10 CAN_tpdo1_time_out Time out PDO1 transmission 0x8237 0x10 CAN_tpdo2_time_out Time out PDO2 transmission 0x8238 0x10 CAN_tpdo3_time_out Time out PDO3 transmission 0x8245 0x10...
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(SAFELY DISABLED TORQUE) 7.1. Application The safety function Safe Torque Off (STO) of the DS2020 has been designed with an integrated redundant circuit in the control board. The use of the STO function outside of the instructions contained in this Manual is considered misuse.
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L-MAS2-E-161 7.3. Safe Torque Off Function The Safe Torque Off safety function of the DS2020 has been validated according to the level of safety integrity SIL 3 as defined in the product standard CEI EN 61800-5-2: 2008 showing that: •...
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DS2020 L-MAS2-E-161 Service life 20 years Change the drive Repair Time 8 hours Diagnostic test interval 8 hours max See also the observation relative to the category 7.3.2 Characteristic values according to CEI EN 62061 • “Hardware Feedback” standard values according to CEI EN 62061...
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The DS2020 drive controls the movements of a three-phase AC motor by the generation of a rotating magnetic field. To this end, the microprocessor generates a complex pattern of pulses (PWM), which are amplified and used to pilot the power semiconductors.
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DS2020 L-MAS2-E-161 Name Function + 24Vdc input of Channel 1. This input must be high (+ 24V) to power the motor. When the input goes low (0V), the motor is not + “Channel 1” powered. - “Channel 1” 0V of Channel 1 + 24Vdc input of Channel 1.
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Q1 and Q2 with associated contacts. The NO contacts of Q1 and Q2 control the two input channels of the DS2020 security for the shutdown of the the motor power connections. The NC contacts of Q1 and Q2 are used in series to control the A1 safety PLC in the event of welding of a NO contact.
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PLC A1 has PL = e • DS2020 drive (STO circuit) has PL = e The security system can reach PL = e and the Category is 4. According to CEI EN 62061: 2005, the subsystem to the input and output devices can achieve SIL 3 because: •...
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Safe Torque Off function is active after the arrest. This should not cause dangerous situations. 7.9. Assembly and Serial tests The Safe Torque Off circuit (STO) is assembled and tested at Moog Casella. 7.10. Identification of the STO function on the plate...
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DS2020 L-MAS2-E-161 8 Annexes 8.1 Glossary Acceleration The rate of increase of velocity with respect to time Alarms Irregular operating situations highlighted by LED or DISPLAY, with subsequent analysis via GUI. Asynchronous Motor Motor in which the rotor and the magnetic field turn at different speeds.
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DS2020 L-MAS2-E-161 The Low Voltage Directive concerns machinery in which electric low voltage circuits are present. The manufacturer must compile a technical dossier, make a declaration of Directive (Low Voltage) conformity and affix the CE marking. Dispersion towards ground Current (usually of reduced intensity) flowing from a wire to the ground.
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DS2020 L-MAS2-E-161 Structure that allows communication between different devices; are connection lines on which the digital information is transferred from one or more sources to one or more destinations. Their aim is therefore to reduce the number of interconnections required. The bus techniques are of great...
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