Moog DS2020 Installation And Startup Manual
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Moog DS2020 Installation And Startup Manual

Moog DS2020 Installation And Startup Manual

Single axis digital servo system
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INSTALLATION  AND  STARTUP
SINGLE AXIS DIGITAL
SERVO SYSTEM
DS2020 TECHNOLOGY
THIS  DOCUMENT  DESCRIBES  THE INSTALLATION
AND STARTUP FOR THE DS2020 SYSTEM
www.moog.com
PN: L-MAS2-E-221, Rev. April 2022

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  • Page 1 INSTALLATION  AND  STARTUP SINGLE AXIS DIGITAL SERVO SYSTEM DS2020 TECHNOLOGY THIS  DOCUMENT  DESCRIBES  THE INSTALLATION AND STARTUP FOR THE DS2020 SYSTEM www.moog.com PN: L-MAS2-E-221, Rev. April 2022...
  • Page 2 PN: L-MAS2-E-221, Rev. April 2022 Page 2 of 171...

  • Page 3: Table Of Contents

    Moog Casella DS2020 Installation and Startup Guide Table Of Contents Table Of Contents Table Of Contents List of Figures 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...
  • Page 4 Moog Casella DS2020 Installation and Startup Guide Table Of Contents 2.8 Risk Assessment 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 DS2020 Standard Models...
  • Page 5 Moog Casella DS2020 Installation and Startup Guide Table Of Contents 5.2 Mechanical Installation 5.2.1 Assembly of System Components 5.2.1.1 Drive Installation 5.2.1.2 Power Line Filter Installation 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...
  • Page 6 Moog Casella DS2020 Installation and Startup Guide Table Of Contents 6.2.6 Firmware Update (BootLoader) 6.2.7 Accessing the Dx2020 GUI online help 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...
  • Page 7 Moog Casella DS2020 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...
  • Page 8 Moog Casella DS2020 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 Disposition 11.1 What to Do If Repairs Are Required? 12 Ordering Code 12.1 DS2020 Ordering Code 12.2 Moog Motor Ordering Code...

  • Page 9: List Of Figures

    Moog Casella DS2020 Installation and Startup Guide List of Figures List of Figures Figure 1: DS2020 Front View..............................28 Figure 2: DS2020 System Theory of Operation Flow Chart..................29 Figure 3: Example Drive Plate..............................31 Figure 4: Drive Model Codes..............................32 Figure 5: Drive Chassis Dimensions (L50 and L75).......................32 Figure 6: Drive Chassis Dimensions (L85 and L125)....................36...

  • Page 10: Foreword

    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; certain models are also UL certified. Contact Moog for details. The manual was written and checked by technical experts at Moog.

  • Page 11: Reader Instructions

    First release January 2020 Second release February 2022 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 WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
  • Page 12 Moog Casella DS2020 Installation and Startup Guide Reader Instructions Symbol Explanation Thermal hazard alert symbol. Mechanical hazard alert symbol. General hazard alert symbol. Notes about important operations and other useful information. Ø This is an action to be carried out.

  • Page 13: Introduction

    1  Introduction Moog Casella DS2020 Installation and Startup Guide 1 Introduction This chapter provides introductory information about this guide and the DS2020 system. 1.1 Contents 1.2 Related Documents 1.3 Package Contents 1.4 Required Qualifications of Personnel 1.5 Applicable Laws 1.6 Getting Started PN: L-MAS2-E-221, Rev.

  • Page 14: Contents

    1.2 Related Documents The following related documents are also available: DS2020 Safety Guide (shipped in the box with the DS2020 and also available on the Moog website) Moog motor installation guides (available on the Moog website)

  • Page 15: Required Qualifications Of Personnel

    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; certain models are also UL certified. Contact Moog for details. PN: L-MAS2-E-221, Rev. April 2022...

  • Page 16: Getting Started

    The process for getting the DS2020 system installed, configured and operational looks like this: 1. Read this guide. 2. Read the related documents that are supplied with the DS2020 system, see Related Documents on page 14. 3. Install the DS2020 drive, see Mechanical Installation on page 69.

  • Page 17: Safety Information

    2  Safety Information Moog Casella DS2020 Installation and Startup Guide 2 Safety Information This chapter provides safety information for the DS2020 system. 2.1 Safety and Usage Guidelines 2.2 Qualified Personnel 2.3 Electrical Hazards 2.3.1 Voltage Arcs and High Voltage 2.3.2 General Hazards and Safeguards 2.4 Thermal Hazards...

  • Page 18: Safety And Usage Guidelines

    Do not attempt to install, operate, maintain or inspect the DS2020 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. The DS2020 system may only be set up and operated in conjunction with this manual and the supplied documentation.

  • Page 19: Electrical Hazards

    Never attempt to remove safety covers, or loosen or disconnect the electrical connections when the DS2020 system is powered up, Never attempt to perform any cleaning or maintenance operations when the DS2020 system is powered up. Always ensure that the mains power supply is disconnected and locked out before attempting any work on the system.

  • Page 20: General Hazards And Safeguards

    Ø Follow these safety instructions. The motor must be properly mounted and anchored as specified in the Moog motor installation guide supplied with the DS2020 system motor. For details, consult the Moog motor installation guide.

  • Page 21: Sto Safety Feature

    2.6 STO Safety Feature 2.6.1 Description The DS2020 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. The STO function acts as an interlock against accidental motor rotations.

  • Page 22: Safe Use Of The Ds2020 System

    For more details on selecting the proper motor, see Motors on page 53. 2.7.4 Power Supply The drives of the DS2020 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 of not more than 10KA 120V to 480V ±...

  • Page 23: Prohibited Use

    Does not conform to the machine's Risk Assessment. The control of the brake by the DS2020 drive alone is prohibited in applications where the safety of personnel must be ensured through the brake. PN: L-MAS2-E-221, Rev. April 2022...

  • Page 24: Risk Assessment

    2.8.1 Installation Risk Assessment The safety functional requirements of a DS2020 system depend on the application and should be considered during the evaluation of the overall risk of the installation. The designer of the installation...

  • Page 25: General Machine/System Safeguards Information

    2.8.2  General Machine/System Safeguards Information Moog Casella DS2020 Installation and Startup Guide 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.
  • Page 26 2.8.3  Safeguards Related to SCRF Moog Casella DS2020 Installation and Startup Guide The frequency of operation of each SCRF Requested response time of each SCRF Description of each SCRF SCRF interface with other functions of the machine Description of the reactions related to machine reboot failures and constraints, when the...

  • Page 27: System Overview

    3  System Overview Moog Casella DS2020 Installation and Startup Guide 3 System Overview This chapter provides an overview of the DS2020 system. 3.1 Product Structure 3.1.1 Product Description 3.1.2 Storage and Working Conditions 3.1.3 DS2020 Standard Models 3.1.4 Model Codes 3.1.5 Connector Kits...

  • Page 28: Product Structure

    It is comprised of a single stand-alone drive powered directly by a 3-phase AC mains supply and by a separate +24 VDC control power supply. The digital control system of the motors and the diagnostic functions of the DS2020 system are made possible through microprocessor technology.

  • Page 29: Figure 2: Ds2020 System Theory Of Operation Flow Chart

    Generation Feedback Acquisition Torque • Encoder Loop • Resolver Feedback Figure 2: DS2020 System Theory of Operation Flow Chart Feature/Function Implementation Control functions Implementation of the Torque, Speed and Position loops Command protocols EtherCAT, PROFINET, PROFIBUS, CANopen and “Analog” Configuration/Commissioning Through GUI : Dx2020 software allows to configure, calibrate and con- trol the drive.

  • Page 30: Storage And Working Conditions

    Motor brake control Integrated Integrated (external optional) Braking resistor Electromagnetic External EMC filter is required com-patibility Forced air with integrated fans in each DS2020 system Cooling 3.1.2 Storage and Working Conditions Item Description Operating from 0 °C to 40 °C environment up to 55 °C with current derating...

  • Page 31: Ds2020 Standard Models

    L355 Dimension [width, mm] The DS2020 drive code is found on an identification (ID) plate on the side of the drive. To request information about a specific DS2020 drive, it is essential to communicate to Moog Casella all the data indicated on the drive ID plate, refer to the following figure.

  • Page 32: Model Codes

    3.1.4  Model Codes Moog Casella DS2020 Installation and Startup Guide 3.1.4 Model Codes To identify the available models, refer to the following codes. The first two characters are "CH" and are used to identify the DS2020 family Version Special variation Standard model Value –...

  • Page 33: Connector Kits

    Moog Casella DS2020 Installation and Startup Guide 3.1.5 Connector Kits 3.1.5 Connector Kits To order a connector kit, refer to the following table. For cable information, see Cables on page 54. Drive size Connector kit code Type of transducer BC8901-R...

  • Page 34: Features And Component Details

    3.2  Features and Component Details Moog Casella DS2020 Installation and Startup Guide 3.2 Features and Component Details This section provides details on the features and components of the DS2020 system. 3.2.1 Electrical Data Electrical data L125 L165 L355 From 120 VAC to 480 VAC +/- 10 %...

  • Page 35: Figure 5: Drive Chassis Dimensions (L50 And L75)

    3.2.2  Mechanical Data Moog Casella DS2020 Installation and Startup Guide The following figures are provided to show external dimensions only. The front panel shown may not represent the particular option(s) ordered on your drive. Module 50 mm (1.97 inch) 50 (1.97) 199.40 (7.85)

  • Page 36: Figure 6: Drive Chassis Dimensions (L85 And L125)

    3.2.2  Mechanical Data Moog Casella DS2020 Installation and Startup Guide Module 85 mm (3.35 inch) (3.35) . 0 ( 7.5 (0.30) 50 (1.97) 4.5 (0.18) 34.5 (1. Module 125 mm (4.92 inch) . 0 ( 7.5 (0.30) 0 (3.54) 4.5 (0.18) 34.5 (1.

  • Page 37: Figure 7: Drive Chassis Dimensions (L165 And L355)

    3.2.2  Mechanical Data Moog Casella DS2020 Installation and Startup Guide Module 165 mm (6.49 inch) Module 355 mm (13.97 inch) Figure 7: Drive Chassis Dimensions (L165 and L355) PN: L-MAS2-E-221, Rev. April 2022 Page 37 of 171...

  • Page 38: Transducers

    Moog Casella DS2020 Installation and Startup Guide Figure 6: Drive Chassis Dimensions (L85 and L125) 3.2.3 Transducers The DS2020 system can manage the following transducers: • Resolver (standard) • Encoder Incremental TTL • Encoder, Stegmann Sinusoidal Absolute Single/Multi-Turn with Hiperface communication •...

  • Page 39: Connectors

    3.2.4  Connectors Moog Casella DS2020 Installation and Startup Guide 3.2.4 Connectors X1:+24V Control power X2: Resolver or Encoder interface X3: Serial link or USB X4: Simulated interface Encoder or RS-232 interface X5: Input/Output Bottom view (connector layout for sizes L85 - L125 and L165)

  • Page 40: Figure 9: Top And Bottom Connectors L355

    3.2.4  Connectors Moog Casella DS2020 Installation and Startup Guide Top view (connector layout for sizes L355) Front view (connector layout for sizes L355) W1 - V1 - U1 = AC Power Supply IN = Connection to earthing system J24VF = 24V Power Fan...

  • Page 41: Connector Layout

    3.2.4.1  Connector Layout Moog Casella DS2020 Installation and Startup Guide Below is the list of connectors. Size Connector Function +24 VDC Control Power In Resolver or Encoder motor feedback USB or RS-422 interface Programmable digital connector Analog and digital I/O...
  • Page 42 Motors with a thermal sensor on the position feedback connector, such as the Moog Fastact G Servomotors, can be conveniently connected on the X2 inputs. Motors with a thermal sensor on the power connector can use the inputs on the X10 connector.
  • Page 43 3.2.4.1  Connector Layout Moog Casella DS2020 Installation and Startup Guide X4 Programmable Digital I/O The digital inputs on X4 connector are not "single ended". Their input stage meets the RS-485 (3.3V) standard. Therefore, a simple RS-485 transceiver must be used to convert a single ended signal into a differential signal.
  • Page 44 Digital I/O ground on pin 8 is isolated from other system grounds. Drive OK (pins 11 and 12) are a relay contact in the DS2020 drive; its contacts are closed when the drive is ready to move the motor. This is the same information shown in Status Word 0, bit 0.
  • Page 45 3.2.4.1  Connector Layout Moog Casella DS2020 Installation and Startup Guide The digital inputs on the X5 connector are “standard” ones. For example, for positive and negative limit inputs, simply connect the input signal to pin 13 (for input 1) or pin 14 (for input 2) and 0 reference to pin 8.
  • Page 46 3.2.4.1  Connector Layout Moog Casella DS2020 Installation and Startup Guide X7 CAN Option Name Function Not associated with a function in the drive Reserved CANL Negative terminal CAN line CAN_GND Logic 0 CAN line Reserved Not associated with a function...
  • Page 47 3.2.4.1  Connector Layout Moog Casella DS2020 Installation and Startup Guide X8 - X9 EtherCAT Option The cable used is standard EtherCAT, the connector is RJ45 Name Description - The drive is in the state INIT BLINKING - The drive is in the state...
  • Page 48 3.2.4.1  Connector Layout Moog Casella DS2020 Installation and Startup Guide WARNING WARNING: Mechanical hazard. Large motors can generate very high torque and impact or trapping hazards, which can result in death or serious injury to personnel, or damage to equipment. Ø Follow these safety instructions.
  • Page 49 3.2.4.1  Connector Layout Moog Casella DS2020 Installation and Startup Guide Definition Function U2, V2, W2 , Motor connection Connection to earthing system U1, V1, W1 Connection to the three-phase AC supply DC BUS – (Optional L355) RR, DC+ Connection to the external brake resistor (L355)

  • Page 50: Power Line Filters

    3.2.5  Power Line Filters Moog Casella DS2020 Installation and Startup Guide 3.2.5 Power Line Filters To ensure proper compatibility with the EMC standards, insert a power line EMC filter, code AT6009 or AT6010 (or equivalent), between the AC supply and drive.
  • Page 51 3.2.5  Power Line Filters Moog Casella DS2020 Installation and Startup Guide Drive Model / Code Mfr. No Current AT6050 Schaffner FN3288-10-44-C34-R65 Dimension AT6055 Schaffner FN3258-7-44 AT6065 FINMOTOR FIN538S1.007.M Current AT6074 FINMOTOR FIN1500.10.V 2/4A 4/8A AT6051 Schaffner FN3288-16-44-C35-R65 Dimension AT6056 Schaffner...

  • Page 52: Braking Resistor

    3.2.5  Power Line Filters Moog Casella DS2020 Installation and Startup Guide 3.2.6 Braking Resistor When the motor accelerates, the energy is dissipated as heat in the braking resistor (or recovery resistor). The table shows the values of the brake resistors listed by size.

  • Page 53: Line Inductors

    For details, see the DS2020 Drive Systems Guide. 3.3.2 Selecting a Non-Moog Motor Moog offers a wide variety of compatible motors for use in the DS2020 system. However, if you wish to use a non-Moog motor with the drive, please contact Applications Engineering for assistance.

  • Page 54: Cables

    3.3.2  Selecting a Non-Moog Motor Moog Casella DS2020 Installation and Startup Guide 3.4 Cables NOTICE Part Number Description Motor CVM-Pxx-2020-21 CD Motor Series Power cable, flex rated, 1.5 mm (Size G1-G3 1 connector) CVM-Pxx-2030-31 CD Motor Series Power cable, flex rated, 2.5 mm...
  • Page 55 3.4  Cables Moog Casella DS2020 Installation and Startup Guide If you are building your own cables or using motors from other manufacturers, please consult the following table for recommended cable specifications. DS2020 L50/L75 L125 L165 L355 Feature 2A - 4A - 6A...
  • Page 56 3.4  Cables Moog Casella DS2020 Installation and Startup Guide 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.

  • Page 57: Certifications

    4  Certifications Moog Casella DS2020 Installation and Startup Guide 4 Certifications This chapter provides information about the DS2020 system certifications. 4.1 CE Certificate 4.2 Safe Torque Off (STO) 4.3 Certification Compliant System Installation Requirements 4.3.1 Environmental Ratings 4.3.2 Short Circuit Protection 4.3.3 Primary Circuit Overvoltage Protection...

  • Page 58: Ce Certificate

    According to the European Community Directives, drives must conform to: EMC 2014/30/EU directive Low Voltage Directive 2014/35/EU The DS2020 system has been tested in a laboratory for the verification of the parameters of compliance with the above Directives. Regarding electromagnetic compatibility, the DS2020 system refers to C3 industrial environments.

  • Page 59: Figure 10: Ce Declaration Of Conformity

    4.1  CE Certificate Moog Casella DS2020 Installation and Startup Guide Figure 10: CE Declaration of Conformity PN: L-MAS2-E-221, Rev. April 2022 Page 59 of 171...

  • Page 60: Safe Torque Off (Sto)

    Moog Casella DS2020 Installation and Startup Guide 4.2 Safe Torque Off (STO) The DS2020 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.

  • Page 61: Figure 11: Ce "Safe Torque Off" Certificate Of Conformity

    4.2  Safe Torque Off (STO) Moog Casella DS2020 Installation and Startup Guide Figure 11: CE "Safe Torque Off" Certificate of Conformity PN: L-MAS2-E-221, Rev. April 2022 Page 61 of 171...

  • Page 62: Figure 12: Ec-Type Examination Certificate

    4.2  Safe Torque Off (STO) Moog Casella DS2020 Installation and Startup Guide Figure 12: EC-Type Examination Certificate PN: L-MAS2-E-221, Rev. April 2022 Page 62 of 171...

  • Page 63: Certification Compliant System Installation Requirements

    4.3  Certification Compliant System Installation Requirements Moog Casella DS2020 Installation and Startup Guide 4.3 Certification Compliant System Installation Requirements 4.3.1 Environmental Ratings Environmental designation: “Open Type drive – Suitable for Pollution degree 2 Installation Environment” "(Eng. Note: Provided by end use installation enclosure)”...

  • Page 64: Short Circuit Protection

    4.3.2  Short Circuit Protection Moog Casella DS2020 Installation and Startup Guide 4.3.2 Short Circuit Protection The “Short Circuit Protections” are provided by both: Internal “Solid State Short Circuit Protection” External “Branch Circuit Protection (BCP) – Fuses (R/C Special Purpose Fuses (JFHR2/8)”...

  • Page 65: Primary Circuit Overvoltage Protection

    Moog Casella DS2020 Installation and Startup Guide 4.3.3 Primary Circuit Overvoltage Protection The “Open Type, Servo Drives – DS2020 Series” are protected from Transient-Overvoltage in the Power Supply Primary Circuit of the end-use applications by: R/C Surge-Protective Device (VZCA2, VZCA8 or CSA certified), Internally provided and Externally required in the “Main Line Supply”.

  • Page 66: Dynamic Brake Unit Ratings

    Moog Casella DS2020 Installation and Startup Guide 4.3.4 Dynamic Brake Unit Ratings For the “Open Type, Servo Drives – DS2020 Series” the “Dynamic Brake Unit – Chopper (IGBT)” transistor is connected to the following “Internal / External Resistors” (suitable also as “Soft start resistors”).

  • Page 67: Electrical And Mechanical Installation

    5  Electrical and Mechanical Installation Moog Casella DS2020 Installation and Startup Guide 5 Electrical and Mechanical Installation This chapter provides information about the electrical and mechanical installation of the DS2020 system. 5.1 Tools and Equipment 5.1.1 Tools 5.1.2 Electronic Equipment 5.2 Mechanical Installation...
  • Page 68 5  Electrical and Mechanical Installation Moog Casella DS2020 Installation and Startup Guide 5.3.6.11 Connecting the Fieldbus - X8, X9, X10 Connectors PN: L-MAS2-E-221, Rev. April 2022 Page 68 of 171...

  • Page 69: Tools And Equipment

    Moog Casella DS2020 Installation and Startup Guide 5.1 Tools and Equipment This section lists the special tools and equipment needed to install the DS2020 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.

  • Page 70: Braking Resistor Positioning

    Ø The external resistor must be properly guarded to prevent accidental contact. The DS2020 L50 and L75 sizes are equipped with internal braking resistors (or recovery resistors); the L85, L125, L165 and L355 sizes have external braking resistors. If the application requires it, external braking resistors are available for all sizes;...

  • Page 71: Electrical Installation And Thermal Rating

    5.3  Electrical Installation and Thermal Rating Moog Casella DS2020 Installation and Startup Guide 5.3 Electrical Installation and Thermal Rating This section provides information on the electrical installation and thermal rating of the DS2020 system. 5.3.1 Safety and General Instructions WARNING WARNING: Electrical hazard.

  • Page 72: Electrical Installation

    5.3.2  Electrical Installation Moog Casella DS2020 Installation and Startup Guide 5.3.2 Electrical Installation Control power input +24 VDC Three-phase AC power supply Contactor Fuse protection ‘Thermal’ 0 EMC grid filter Figure 14: Structure of the Electrical Panel with the Components of a Servo System...
  • Page 73 5.3.2  Electrical Installation Moog Casella DS2020 Installation and Startup Guide EMC Ground (high frequency) using unpainted areas of the metal panel, where the drives and the filters are positioned, to create an adequate electrical contact for the mitigation of high frequency noise.

  • Page 74: Thermal Rating Of The Electrical Panel

    The second column indicates the value of the power dissipated by the DS2020 system under nominal operating conditions. The value of maximum power that can be dissipated from the radiator is useful to estimate the power dissipated on the internal braking resistors.

  • Page 75: Drive Axis Power Dissipation

    5.3.3  Thermal Rating of the Electrical Panel Moog Casella DS2020 Installation and Startup Guide 5.3.3.1 Drive Axis Power Dissipation and PWM Frequency Dissipated power (W) Rated size Type PWM frequency [Amps] for the DS2020 system 8 KHz L125 L165 4 KHz...

  • Page 76: Control Power Requirements

    The control power supply must provide 24 VDC with a tolerance of +/- 10%, and "ripple" of less than 200 mV. The current consumption will depend on number and type of DS2020 drives in the system. The maximum required current will be the sum of the currents required by all components. Refer to the following table.

  • Page 77: Ac  Mains Power/Ground Connection

    Ø Follow these safety instructions. It is necessary to properly ground the DS2020 system to avoid risk of injury or death to personnel. In the case of AC power supply circuits that are ungrounded or asymmetrically grounded, you must insert an isolation transformer.

  • Page 78: Protection Components

    It is recommended to implement protection against short circuit in the final application using external semiconductor type fuses, 660 VAC, 200 kA M.A.H., or other with the same characteristics. The sizing of the mains fuses can be achieved using the next size larger than the single DS2020 system current.

  • Page 79: Ground Connection

    5.3.5.4 Ground Stud The DS2020 drive (L50 - L75 - L85 - L125 - L165) provides a ground stud (M5) at the bottom of the chassis. The DS2020 drive (size L355) provides a ground connector at the bottom and top of the chassis Refer to the following figure.

  • Page 80: Figure 17: Location Of The Ground Connector Size L355

    5.3.5.3  Ground Connection Moog Casella DS2020 Installation and Startup Guide  Location of the Ground Connector size L355 Top view (connector layout for sizes L355) Ground connector Botton view (connector layout for sizes L355) Ground connector Figure 17: Location of the Ground Connector size L355 PN: L-MAS2-E-221, Rev.

  • Page 81: Drive Wiring

    Do not mount the DS2020 drive on painted or insulated surfaces. A ground stud (M5 is located on the bottom of the DS2020 housing for connection to the earthing system. For grounding details, see AC Mains Power/Ground Connection on page 71.

  • Page 82: Figure 19: Connector - [W1-V1-U1] Sizes L355

    5.3.6.3  Braking Resistor Connection Moog Casella DS2020 Installation and Startup Guide Figure 16: Connector X13 – [W1-V1-U1] sizes L85 L125 L165 Top view (connector layout for sizes L355) Figure 19: Connector – [W1-V1-U1] sizes L355 PN: L-MAS2-E-221, Rev. Aa2 February 2022 PN: L-MAS2-E-221, Rev.

  • Page 83: Braking Resistor Connection

    5.3.6.3  Braking Resistor Connection Moog Casella DS2020 Installation and Startup Guide 5.3.6.3 Braking Resistor Connection The following figures show the braking resistor connection points. Figure 20: Connector X11 – [RRe – RRi - RR] size L50 and L75 Figure 21: Connector X11 – [RRe-RRi-RR] sizes L85 L125 L165...

  • Page 84: Signal Connection

    5.3.6.5  Signal Connection Moog Casella DS2020 Installation and Startup Guide 5.3.6.5 Signal Connection For connection of the control signals, transducer interface, linear communication, see Connectors on page 39. 5.3.6.6 Motor Cable Connection Details The following figures show the motor cable connection points. For the motor cable specifications, see Cables on page 54.

  • Page 85: Brake Cable Connection

    5.3.6.7  Brake Cable Connection Moog Casella DS2020 Installation and Startup Guide 5.3.6.7 Brake Cable Connection This connection is required only when the motor is equipped with a brake. When specifying the brake connections, see the following figure, Take into account the possible voltage drop for any cable runs over 10 m long and select the proper cables to avoid that.

  • Page 86: Figure 26: Brake Activation Timing Diagram

    5.3.6.7  Brake Cable Connection Moog Casella DS2020 Installation and Startup Guide Motor speed Stopped motor Brake tension command Brake activation A: Deceleration time of the machine (variable) B: Brake activation (300 ms) Figure 26: Brake Activation Timing Diagram The same considerations relating to the motor cable also applies. Therefore, pay special attention to the use of shielding, even if the conductors are not already incorporated in the motor cable.

  • Page 87: I/O Signal Connection

    5.3.6.8  I/O Signal Connection Moog Casella DS2020 Installation and Startup Guide 5.3.6.8 I/O Signal Connection All I/Os on the X5 connector are isolated from the rest of the system. Digital I/Os are referenced to 0 V Digital (pin 8 of the X5 connector).

  • Page 88: Figure 27: Detail Of The Feedback Contact Circuit

    5.3.6.9  STO Signals Connection Moog Casella DS2020 Installation and Startup Guide +24 Volt CH 1 0 Volt CH 1 +24 Volt CH 2 0 Volt CH 2 Feedback Feedback +24 Volt Safety Chain 1 Safety Chain 2 Safety Module or PLC...

  • Page 89: Transducer Connection

    "fixed" manner and pro- tected (for example through a raceway). 5.3.6.10 Transducer Connection The DS2020 system is able to handle most common motor position transducers, as shown in the following list. • Resolver (standard) •...

  • Page 90: Connecting The Fieldbus - X8, X9, X10 Connectors

    5.3.6.11  Connecting the Fieldbus - X8, X9, X10 Connectors Moog Casella DS2020 Installation and Startup Guide 5.3.6.11 Connecting the Fieldbus - X8, X9, X10 Connectors Depending on the type of fieldbus, you must install a different firmware. If the connection is via EtherCAT the file will have the suffix _ecat; if it is via CAN bus, the file will have the suffix _can.

  • Page 91: Commissioning With Dx2020 Software

    6  Commissioning with Dx2020 Software Moog Casella DS2020 Installation and Startup Guide 6 Commissioning with Dx2020 Software The commissioning of the system is performed through the operator Dx2020 GUI. For a detailed description of the menus and procedures, please refer to the Dx2020 GUI online help in the GUI.
  • Page 92 6  Commissioning with Dx2020 Software Moog Casella DS2020 Installation and Startup Guide DS2020 State Machine 6.5 STO Activation 6.6 Auto-Phase Procedure 6.7 Drive (Axis) Enable and Limit Switch Enable/Disable 6.8 Oscilloscope Function and Log File (.UCX) 6.8.1 Log Configuration 6.8.2 Start Logging 6.8.3 View Logs...

  • Page 93: Safety

    Ø Follow these safety instructions. Before attempting to commission the DS2020 system, you must review the Safety and Usage Guidelines on page 18. In addition, be aware that: Only qualified, properly trained and certified personnel are authorized to set the parameters of a running drive.

  • Page 94: Dx2020 Gui

    6.2  Dx2020 GUI Moog Casella DS2020 Installation and Startup Guide 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.

  • Page 95: Dx2020 Gui Installation

    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.

  • Page 96: Gui Drive Connection

    Dx2020 GUI icon will be displayed on the desktop. 6.2.4 GUI Drive Connection Run the executable Dx2020 GUI with the DS2020 system powered up. The GUI can connect to the drive through: Serial RS-422/RS-232 or USB (connector X3); the GUI automatically detects whether it is used on RS-422 or RS-232.
  • Page 97 6.2.4  GUI Drive Connection Moog Casella DS2020 Installation and Startup Guide 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...

  • Page 98: Layout

    6.2.5  Layout Moog Casella DS2020 Installation and Startup Guide In the Select Node window, confirm the Node and ID values, then click OK In case of failure during connection, refer to Troubleshooting on page 127 and follow the suggested actions.
  • Page 99 Main area: This area displays the information and the parameters associated with the selected view in the navigation area. This window is used to view and set the DS2020 drive parameters. For more information, refer to the Dx2020 GUI online help.

  • Page 100: Firmware Update (Bootloader)

    6.2.6  Firmware Update (BootLoader) Moog Casella DS2020 Installation and Startup Guide 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).

  • Page 101: Accessing The Dx2020 Gui Online Help

    6.2.7  Accessing the Dx2020 GUI online help Moog Casella DS2020 Installation and Startup Guide For more information, refer to the Dx2020 GUI online help. 6.2.7 Accessing the Dx2020 GUI online help The Dx2020 GUI online help can be accessed as follows: Use Interface Dx2020 GUI: from the Menu bar, select "?"...

  • Page 102: System Configuration

    Follow the instructions in the Dx2020 GUI online help related to the specific modes of communication and identification. For multiple axis DS2020 systems that are simultaneously connected, there must be a correspondence between the nodes listed in the "Navigation Area" of the GUI and the physically installed DS2020 drives in the application.
  • Page 103 6.4.2  Motor Parameter Configuration Moog Casella DS2020 Installation and Startup Guide 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.

  • Page 104: Transducer Configuration

    (angle Theta). 6.4.3 Transducer Configuration The DS2020 can handle various types of feedback transducers to close the control loops. • Resolver (standard) • Encoder Incremental TTL single and differential •...

  • Page 105: Sensorless

    6.4.3.1  Sensorless Moog Casella DS2020 Installation and Startup Guide 6.4.3.1 Sensorless The DS2020 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.

  • Page 106: I/O Configuration

    6.4.4  I/O Configuration Moog Casella DS2020 Installation and Startup Guide 4. Finally, set the fault interface X3 - Missing Transducer Configuration to "No" as shown in the following figure. 6.4.4 I/O Configuration Through the interface, you can set the various configurations for the X4 and X5 connectors.

  • Page 107: Details Of Possible Configurations

    6.4.4.1  Details of Possible Configurations Moog Casella DS2020 Installation and Startup Guide 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.

  • Page 108: Programming Analog And Digital I/O Connector X5

    6.4.4.2  Programming Analog and Digital I/O Connector X5 Moog Casella DS2020 Installation and Startup Guide 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 The X4 connector is not opto-isolated.

  • Page 109: Control Loops Configuration

    6.4.5 Control Loops Configuration 6.4.5.1 Control mode configuration The DS2020 operates up to three control loops according to the drive operation mode: torque, speed, and position. These are nested so that torque is the inner loop, speed is intermediate loop, and position is the outermost loop.

  • Page 110: Torque Loop Parameter Configuration

    6.4.5.2  Torque loop parameter configuration Moog Casella DS2020 Installation and Startup Guide 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.

  • Page 111: Filter Configuration

    Moog Casella DS2020 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).
  • Page 112 Moog Casella DS2020 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.

  • Page 113: Configuration Of The Position Loop Parameters

    6.4.5.4  Configuration of the position loop parameters Moog Casella DS2020 Installation and Startup Guide 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).

  • Page 114: Fault Configuration

    6.4.6  Fault Configuration Moog Casella DS2020 Installation and Startup Guide 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).

  • Page 115: Application Parameters Configuration

    6.4.7  Application Parameters Configuration Moog Casella DS2020 Installation and Startup Guide 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.

  • Page 116: Commands And Modes Configuration

    6.4.8  Commands and Modes Configuration Moog Casella DS2020 Installation and Startup Guide Details about the events and reactions are described in the Dx2020 GUI online help. 6.4.8 Commands and Modes Configuration This menu allows to set the source of commands/controls and the drive operating mode.
  • Page 117 6.4.8  Commands and Modes Configuration Moog Casella DS2020 Installation and Startup Guide 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.
  • Page 118 6.4.8  Commands and Modes Configuration Moog Casella DS2020 Installation and Startup Guide 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.

  • Page 119: Ds2020 State Machine

    For details on the FSA, refer to the Dx2020 GUI online help, Dx2020 Gui > Configuration View > Modes and Commands. The following figure shows the DS2020 drive state machine. PN: L-MAS2-E-221, Rev. Aa2 February 2022 PN: L-MAS2-E-221, Rev. April 2022...

  • Page 120: Figure 28 : Ds2020 Drive State Machine

    Moog Casella DS2020 Installation and Startup Guide DS2020 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 Figure 28 : DS2020 Drive State Machine...
  • Page 121 Moog Casella DS2020 Installation and Startup Guide DS2020 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.

  • Page 122: Sto  Activation

    The auto-phasing is set through the Dx2020 GUI software. The DS2020 system provides an auto-phasing procedure that is useful for unknown motors. This procedure finds the right phasing angle (THETA) to properly run the motor. At the end of the procedure the THETA parameter is automatically set.
  • Page 123 6.6  Auto-Phase Procedure Moog Casella DS2020 Installation and Startup Guide Check that the power supply and STO are present, then from the "Command" field, select in sequence: 1. “Shutdown”. 2. “Startup”, leaving the drive in this state. The drive signals the activation with an "S" on the display. See the following figure.

  • Page 124: Drive (Axis) Enable And Limit Switch Enable/Disable

    6.7  Drive (Axis) Enable and Limit Switch Enable/Disable Moog Casella DS2020 Installation and Startup Guide 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).

  • Page 125: Oscilloscope Function And Log File (.Ucx)

    6.8  Oscilloscope Function and Log File (.UCX) Moog Casella DS2020 Installation and Startup Guide 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.

  • Page 126: View Logs

    6.8.3  View Logs Moog Casella DS2020 Installation and Startup Guide 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;...

  • Page 127: Ucx File Management

    6.8.4  UCX File Management Moog Casella DS2020 Installation and Startup Guide On the top left are the Cursor Activation (Cursor) and Displacement of the Graph (Pan) functions. Magnification of the details (Zoom) and printing of the image (Screenshot); mouse cursor shall show the legend of the 4 buttons when hovering above them.

  • Page 128: Using The Gui In Offline Mode

    6.9  Using the GUI in Offline Mode Moog Casella DS2020 Installation and Startup Guide 6.9 Using the GUI in Offline Mode The Dx2020 GUI can be used in offline mode, in the absence of the drive, to create the drive configuration file, edit the file, or verify its contents.

  • Page 129: Contextual Help For Parameter Management

    6.10  Contextual Help For Parameter Management Moog Casella DS2020 Installation and Startup Guide 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.

  • Page 130: Decommissioning Procedure

    6.11 Decommissioning Procedure WARNING WARNING: Electrical hazard. The DS2020 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. Ø Before attempting this operation, follow the safety information and procedures in General Hazards and Safeguards on page 20.
  • Page 131 Moog Casella DS2020 Installation and Startup Guide 5. Remove the DS2020 drive from the electrical panel. 6. To decommission the DS2020 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.

  • Page 132: Shipment And Storage

    This will ensure that they arrive safely. 7.2 Storage DS2020 system components can be stored for a consecutive period of up to one year without special requirements or actions. If you have retained the original packing materials that the DS2020 system was shipped in, the system components should be repackaged in those materials for safe storage.

  • Page 133: Maintenance

    There are no user-serviceable parts inside the DS2020 system. Do not attempt to disassemble the DS2020 drive, as doing so will void the warranty. Ø If your DS2020 drive needs to be serviced, return the faulty component(s) to the factory. See the next section.

  • Page 134: What To Do If Repairs Are Required

    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.

  • Page 135: Troubleshooting

    Ø Before attempting this operation, follow the safety information and procedures in General Hazards and Safeguards on page 20. Troubleshooting of the DS2020 system is primarily done through the Dx2020 GUI software, The following sections describe typical malfunctions and provides a series of recommendations on how to fix them.

  • Page 136: Alarms On The Power Section

    9.1  Power Section Anomalies Moog Casella DS2020 Installation and Startup Guide 9.1 Power Section Anomalies Cause Action The drive temperature Check the continuous current supplied to is high the axes Check the efficiency of the fans Failure recovery Check the braking resistor...

  • Page 137: Alarm For Vbus Voltage Out Of Tolerance

    9.2.2  Alarm for VBUS Voltage Out of Tolerance Moog Casella DS2020 Installation and Startup Guide 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.

  • Page 138: Removal Of Sto Signal

    9.2.4  Removal of STO Signal Moog Casella DS2020 Installation and Startup Guide 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;...

  • Page 139: Brake Feedback Fault

    9.2.7  Brake Feedback Fault Moog Casella DS2020 Installation and Startup Guide 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.
  • Page 140 9.2.8  Errors on Feedback Devices Moog Casella DS2020 Installation and Startup Guide 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...

  • Page 141: Synchronization , Interrupt Time And Task Time Error

    9.2.9  Synchronization , Interrupt Time and Task Time Error Moog Casella DS2020 Installation and Startup Guide 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...

  • Page 142: Alarm Display In Analog Operating Mode

    9.3  Alarm Display in Analog Operating Mode Moog Casella DS2020 Installation and Startup Guide Fault Cause Action after the timeout the drive communication and/or the CAN master CAN_rpdo0_time_out PDO data not received or received after the timeout CAN_rpdo1_time_out CAN_rpdo2_time_out CAN_rpdo3_time_out...
  • Page 143 9.3  Alarm Display in Analog Operating Mode Moog Casella DS2020 Installation and Startup Guide 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...
  • Page 144 9.3  Alarm Display in Analog Operating Mode Moog Casella DS2020 Installation and Startup Guide 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...
  • Page 145 9.3  Alarm Display in Analog Operating Mode Moog Casella DS2020 Installation and Startup Guide 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...

  • Page 146: Faults During The Gui - Drive Connection

    Sync message timeout (CAN) 9.4 Faults During the GUI – Drive Connection If the communication between the PC and DS2020 system fails, an error message will appear. Other error messages are possible. See the SMI software online help for details. PN: L-MAS2-E-221, Rev. April 2022...
  • Page 147 9.4  Faults During the GUI – Drive Connection Moog Casella DS2020 Installation and Startup Guide 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...

  • Page 148: Safe Torque Off Safety Function

    10  Safe Torque Off Safety Function Moog Casella DS2020 Installation and Startup Guide 10 Safe Torque Off Safety Function This chapter describes the Safe Torque Off (STO) safety function for the DS2020 system. 10.1 Application 10.2 Installation Risk Assessment 10.3 Safe Torque Off Function 10.3.1 Characteristic Values According to UNI EN ISO 13849-1...

  • Page 149: Application

    Also, refer to Risk Assessment on page 24. 10.3 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:...

  • Page 150: Characteristic Values According To Uni En Iso 13849-1

    +A1:2013 +A2:2015, with a SIL limit requested SILCL3. The STO safety function of the DS2020 can also be used to ensuring the safe stop of the injection molding machines, for the interlocked guards in the area of the mold and in other less hazardous areas in compliance with the standard UNI EN 201:2010.

  • Page 151: Characteristic Values According To Cei En 62061

    The final machine must be able to stop the motor. WARNING WARNING: Electrical hazard. The DS2020 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.
  • Page 152 10.4.1  Full Stop Moog Casella DS2020 Installation and Startup Guide 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.

  • Page 153: Safe Torque Off Circuit

    The DS2020 system controls the movements of a three-phase AC motor through 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.

  • Page 154: Safe Torque Off Connections

    10.6  Safe Torque Off Connections Moog Casella DS2020 Installation and Startup Guide 10.6 Safe Torque Off Connections Management channels, including the "Hardware feedback" of the Safe Torque Off circuit, are controlled using the X6 Connector, also referred to as JRC1.

  • Page 155: Electrical Input/Output Specifications

    Moog Casella DS2020 Installation and Startup Guide WARNING WARNING: Electrical hazard. The DS2020 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.

  • Page 156: Example Application

    Q1 and Q2 are used in series to control the A1 safety PLC in the event of welding of a NO contact. The two output safety channels of the DS2020 are connected to an A1 safety PLC to allow the diagnostic coverage of the DS2020 subsystem.

  • Page 157: Example Requirements

    Subsystems: 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 +A1:2013 +A2:2015, the subsystem to the input and output devices can achieve SIL 3 because: All safety-related devices have PFHd <10...

  • Page 158: Safe Torque Off Installation And Maintenance Procedure

    10.8  Safe Torque Off Installation and Maintenance Procedure Moog Casella DS2020 Installation and Startup Guide 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.

  • Page 159: Assembly And Serial Tests

    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. For an example, see Example Drive Plate on page 31.

  • Page 160: System Disposition

    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.

  • Page 161: Ordering Code

    Moog motor part numbers are encoded to include the motor size, stack length, rated speed, and various options. To "decode" an existing part number or find the correct part number for a Moog motor you wish to order, see the Ordering Code section of the installation guide for your Moog motor.
  • Page 162 13  Appendix Moog Casella DS2020 Installation and Startup Guide 13 Appendix This chapter provides a glossary and metric/AWG conversion table. 13.1 Example I/O Connections on X5 13.2 Example RS-485 Driver on X4 13.1 Glossary 13.2 Metric/AWG Conversion Table PN: L-MAS2-E-221, Rev. April 2022...

  • Page 163: Example I/O  Connections On X5

    +24 Volt IN (pin 7) and 0V Digital (pin 8). Drive OK (pins 11 and 12) are a relay contact in the DS2020 drive, which is isolated from the rest of the system. You can supply one of the two pins (e.g., pin 12) with +24 VDC to get a Drive OK signal on the other pin (e.g., pin 11).

  • Page 164: Example Rs-485 Driver On X4

    An example RS-485 driver using the SN75176 IC is shown, refer to the following figure. Its purpose is to convert a single-ended Drive Enable signal into a differential signal used by the DS2020 system. Figure 33: Example RS-485 Driver Using the SN75176 IC A similar circuit can be built around any other RS-485 transceiver IC.

  • Page 165: Glossary

    13.1  Glossary Moog Casella DS2020 Installation and Startup Guide 13.1 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.
  • Page 166 13.1  Glossary Moog Casella DS2020 Installation and Startup Guide 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.
  • Page 167 13.1  Glossary Moog Casella DS2020 Installation and Startup Guide 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.
  • Page 168 13.1  Glossary Moog Casella DS2020 Installation and Startup Guide 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.

  • Page 169: Metric/Awg Conversion Table

    13.2  Metric/AWG Conversion Table Moog Casella DS2020 Installation and Startup Guide 13.2 Metric/AWG Conversion Table Ohmic Diameter Cross-section resistance at Weight 20 °C mils Circ. mils W/km 0.50 4.00 0.0020 8498 0.0180 0.055 4.84 0.0025 7021 0.0218 0.063 6.25 0.0032 5446 0.0281...
  • Page 170 13.2  Metric/AWG Conversion Table Moog Casella DS2020 Installation and Startup Guide Ohmic Diameter Cross-section resistance at Weight 20 °C mils Circ. mils W/km 101.9 2.588 10380 5.26 3.277 46.7232 114.4 2.906 13090 6.63 2.600 58.9248 125.5 3.264 16510 8.37 2.061 74.4000...
  • Page 171 Moog designs a range of motors and motion control products to complement those featured in this document. Moog also provides service and support for all of our products. Moog has offices around the world. For more information or the office nearest you, visit www.moog.com/contact-us/moog-facilities...

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