Moog DS2000 BROCHURE

DS2000

Full digital servodrives for brushless motors
suitable for universal power supply

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OVERVIEW

EXCELLENCE IN MOTION CONTROL

Electronic motion control and actuation of all types of production
machinery is becoming more reliant upon the continued advancement
of modern technological solutions in terms of cost, performance,
reliability and flexibility. As a leading designer of motion control
solutions, Moog has provided world-class Electro-Mechanical Actuators,
Servomotors, Servodrives and other components meeting each
customer’s challenge. Moog Servodrives are a proven option for
customers that need high dynamic performance and control accuracy.
They are user-friendly for easy installation and maintenance, and
reliable for heavy-duty applications.

DS2000 SERVODRIVE CONTROL SOLUTION

The DS2000 servodrive, our fully digital brushless servodrive, introduced
onto the world market in 1999, has now been enriched by new
important characteristics. Thanks to enhanced control features and
rationalised design, OEMs now have the optimal and economic solution
for their accurate, rapid and demanding applications, as well as a
product that offers an excellent flexibility and performance / cost ratio.

To fully capitalise on the latest digital controller hardware coupled to the
latest software control algorithms, we have incorporated many user­friendly features to the DS2000. Within the speed and torque loops,
digital filters are incorporated for greater control; we have the capability
for both synchronous and asynchronous motor control methods; both
resolver and encoder feedback devices can be employed; the facility to
control from analogue or digital speed reference signals (CAN protocol)
and also the ability to connect to any input supply voltage. The drive can
be configured for any of these features without any hardware changes
and every aspect is customisable as a consequence of the drive resident
parameter and configuration management software program
(WinDrive).
DS2000 is a truly universal and cost effective servodrive controller with
global appeal.

- Very high signal sampling rates to achieve greater control accuracy
and maximise dynamic performance.

- Advanced, innovative product resulting from the use of ‘state of the
art’ hardware and software design tools and fully industrialised
construction.

- Standardised and totally interchangeable digital front card with
integral fully functional keypad.

- Universally understood parameter names in a user-friendly format.

- Fully rationalised control circuitry design and layout yields greater
functionality and flexibility.

- High reliability resulting from optimised use of circuit components.

- Three-phase universal power connection between 65 and 605 Vac

TYPICAL APPLICATIONS

- General Automation

- Metal forming machines

- Injection and blow-molding machines

- Textile machines

- Handling and assembly systems

- Conveying and storage technology

- Packaging and food processing machines

- Machines tools

Section Page

Overview 2

Features 3

Connections 6

Technical Data 9

Models 12

Ordering Information 14

This catalog is for users with technical
knowledge. To ensure that all necessary
characteristics for function and safety
of the system are given, the user has to
check the suitability of the products
described herein.
The products described herein are
subject to change without notice. In
case of doubt, please contact Moog.

Moog is a registered trademark of
Moog Inc. and its subsidiaries.
All trademarks as indicated herein are
the property of Moog Inc. and its
subsidiaries.
©Moog Inc. 2005. All rights reserved.
All changes are reserved.
For the most current information, visit
www.moog.com/servomotorsanddrives

Dimensions in mm

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FEATURES

GENERAL FEATURES

The entire design of the DS2000 embodies the concept
that failures are exponentially related to the number of
components which have been, therefore, dramatically
reduced. We have only selected leading edge technology
components and have employed an extremely high
percentage of SMD components, implementing a very
highly automated assembly and test process.

INTEGRAL POWER SUPPLY

In order to make the DS2000 a self-contained stand-alone
servodrive, we have integrated the following control
and monitoring circuits into its on-board power supply:

- Input power rectification and conditioning section.

- Inrush current limiting ‘soft start’ circuitry to reduce
power supply current on power up.

- High frequency Switch Mode Power Supply (SMPS)
circuitry to feed all auxiliary control circuits.

- IGBT motor regenerative power control circuit to
ensure the excess motor energy is safely dissipated via
a braking resistor. The braking resistors supplied with
the DS2000 have been sized on medium-heavy duty
cycles. Special ballast resistors can be required in case
of particularly heavy duty cycles.

- Auxiliary 24 Vdc control power input available for
customer use.

UNIVERSAL POWER CONNECTION

The drive will accept any voltage between 65 and 506 Vac,
three-phase, 50 or 60 Hz without any adjustment. This is
achieved thanks to the continuous DC BUS detection
circuit controlled from the Digital Signal Processor (DSP);
all device protection thresholds are adjusted automatically.
Obviously all circuit components are selected and rated
for continuous use at the maximum ratings.

INTEGRAL RESOLVER AND ENCODER INTERFACES

Our standard digital control board provides both
interface circuits and connectors to utilise either
incremental encoder or resolver as a motor feedback
device.

- The resolver pole range covers from 2 to 24; the motor
poles have to be an integer multiple of the resolver
poles.

- A simulated encoder signal is available that uses the
resolver interface and provides user programmable
encoder pulses (range: 64, 128, 256, 512 and 1024) and
programmable marker pulse duration (range: 1, 1/2
and 1/4).

- The incremental encoder interface is able to manage
1024, 2048, 4096 and 8192 pulses per motor
mechanical revolution.

POWER SECTION COMPONENTS

The DS2000 is able to provide unrivalled performance
with respect to the duration and capacity of its current
power capabilities. This has been achieved by employing
an optimally designed power section created from our
substantial experience in the design of servodrives. We
have extensive experience in providing customers with
electric servo control solutions as working and viable
alternatives to the normal and traditional hydraulic
methods used in injection moulding, metal forming and
blow moulding applications which demand superlative
control and management of high peak torque and
power amalgamated with peak long duration
requirements. All our drive ratings are based on an
ambient heatsink temperature of 40°C, with the over
temperature threshold set to 71°C and the I

2

T software

protection.

CONFIGURABLE CURRENT LOOP

The current loop is the ‘true core’ of the servodrive
system: it can be configured to suit the motor
characteristics and is automatically adjusted according
to variations in the DC BUS. B.E.M.F. compensation and
phase shift correction routines are also provided. The
result is a ‘very wide bandwidth’ with the advantages of
digital technology.

SPEED CONTROL LOOP

We have achieved a speed loop capable of a very high
level of dynamic control with a bandwidth up to 200Hz.
The structure is a classic PI configuration but we have
incorporated 3 programmable digital filters:

- Low pass filter on the speed error signal (20 to 800Hz).

- Low pass filter on the speed reference signal (1 to 800Hz).

- Notch filter to remove mechanical resonance
originating from the motor load (50 to 1500Hz).

These filters permit the use of high gain values that
result in minimised overshoot, improved stiffness, high
dynamic responses and excellent servo-control performance.

AUTOMATIC POWER OPTIMIZATION

This algorithm automatically increases the torque of a
motor up to its maximum speed rating, resulting in a
true constant torque servomotor. Consequently motors
wound with higher torque factors can be used.

INDIRECT FIELD ORIENTED CONTROL (IFOC)

With this vector control software algorithm the DS2000
will control induction motors fitted with a resolver
feedback device (as defined at “Resolver interface”).
Servomotor type performance is achieved while a much
wider constant power range is available than with a
synchronous servomotor. Motor selection (brushless or
induction) is software programmable.
All the normal parameters are retained, e.g.
programmable filters, speed or torque control, etc.

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FEATURES

CHARACTERISTICS OF THE SOFTWARE (RELEASE 3.200)

This software, evolved from the previous version 3.100,
has the following new functions:

- Anti-Free-Wheeling Function: When the servodrive is in
the speed-control mode, this function enables
emergency braking controlled by the motor during
power outages and in case of motor over-temperature
or drive over-temperature.

- I

2

T IGBT Protection: This protects the power modules

from overheating by cutting off or limiting the delivery
of the drive current peak.

- Protection of the Ballast Resistor: This enables protection
of the ballast resistor when subjected to particularly
critical cycles, in which there is an unfavourable
imbalance between the applied power and the
dissipated power.

- Programmable Servomotor Torque Increase: to
optimise performance of the motors at high speeds,
introducing progressive user-configurable shifting of
the phase angle of the simple harmonic current.

- Selection of Motor PTC/NTC: the user can select the
type of motor temperature sensor and its threshold

- Automatic Current Offset Compensation: any offsets
introduced by the current-measuring system are
automatically compensated by means of a cyclic mean
numerical algorithm.

- Calibration of ENC/OUT Zero Marker: the zero output
signal from the ENC/OUT connector (simulated
encoder) can be changed at will to the electrical turn
by setting a specific parameter.

- Motor Code: WinDrive can be used to store in the drive
a code identifying the motor being used.

- Saving of Digital Speed Reference: if the drive is reset,
operations can be resumed with minimum set-up times.

WINDRIVE USER INTERFACE

Moog WinDrive is a graphical user interface application
running on the Microsoft Windows family of operating
systems. It allows the configuration of the Moog motor
controller family. It provides the following main features:

- configuration of various aspects of the drive via tabbed
panels and dialogs

- access to the Moog standard motor parameter
database, and downloading of motor parameter sets

- ability to create non standard motor parameter
databases

- ability to monitor faults and status

- drive configuration upload and download

- firmware upgrade

- for some controller types, a graphical oscilloscope

- access to the controller parameter database

DRIVE CONFIGURATION

The drive can be configured via the built-in keypad and
display or via a PC. Management via PC is extremely

flexible thanks to WinDrive, the graphic interface based
on the Windows operating system (95-98-2000-NT)

POSSIBILITY OF ADDING SPECIAL PROGRAMS
VIA SERIAL LINE

Special variants to the firmware can be loaded using the
WinDrive graphic interface, without intervening on the
hardware and without opening the drive.

ANALOG CONFIGURABLE OUTPUT

A proper control signal connector pin allows the
monitoring of the main characteristics:

- speed and reference errors

- current reference

- current limit

- phases electric position

- detected current

- B.E.M.F. and phase voltage

- DC BUS voltage and tacho output

CAN OPEN INTERFACE (optional)

This digital board mounted option is used where the
requirement for the master generated drive speed
reference signal is to be transferred via CANbus.
If several drives are to be linked by CAN, it is possible to
set the parameters for the entire group (by use of a PC
and the relevant program) without the utilization of the
master circuit.
Transmission procedure is according to ISO 11898 at a
maximum speed of 1Mbit/sec. and according to
CANopen standards DS301 (communication) and DSP402
(device configuration).

ROTARY TABLE CONTROL (optional)

This specially developed software routine controls a high
torque servomotor fitted with a high-resolution encoder,
suitable for applications that require directly coupled
motor and load.

V/f CONTROL

Special motor V/f control software.

LIMIT SWITCH MANAGEMENT

An optional card and a dedicated software can provide 3
optional digital inputs on the encoder connector: right
limit switch, left limit switch and on-the-fly switching of
the control type, from torque to speed and vice versa.
Available only in the Resolver version.

PROTECTIONS

- motor and drive over-temperature

- out of tolerance power supply detection

- encoder or resolver missing signal detection

- output short circuit detection

- ballast resistor missing

- self protected power modules

-I

2

B IGBT protection

- brake resistor protection

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FEATURES

OPTIONS

- separately provided:
RS232/422/485 (CZ5202 code) converter, including
WinDrive communication program

- built-in provided:
CANbus interface on speed reference
sinusoidal encoder interface
"direct drive mode" version
V/f control
Limit Switch Management

Note: the product code, including these options,

is assigned by the plant.

INTERFACES
Analog

- speed reference differential input from
0 to ± 10V (adjustable scale)

- auxiliary input voltage 24Vdc

- auxiliary output voltage 15Vdc

- analog configurable output (adjustable scale)

- tacho signal (adjustable scale)

- peak current limit (adjustable scale)

- resolver

Digital

- RS485 full-duplex serial or CANbus (optional)

- encoder input

- encoder output (resolver simulated)

- reset

- drive enable input

- drive OK output

- reference enable input

- inputs for right limit switch, left limit switch and
on-the-fly switch (optional)

DIAGNOSTICS

The local display provides data on drive status and
possible fault occurrence

TUNING

- automatic phasing

- programmability through built in keyboard
(7 double function pushbuttons); feasible by feeding
the drive with the auxiliary 24Vdc only. Main
parameters settings are speed, gains, acceleration,
torque and all motor and application characteristics.

EMC

DS 2000 drives meet the EMC product standard
EN 61800-3/A11:2000 for industrial environment
according to the Directive 89/336/EC.
Product conformity is subjected to filters installation and
to recommended procedures as from the Installation
Manual and the "Electromagnetic Compatibility"
booklet (available on request)