MOOG DS2000 USER'S MANUAL

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DS2000

GB-4534

USER'S MANUAL (rev.C)

INDEX

I.1

INDEX OF REVISIONS

Revision Date Description Updated section

0 Jul 99 Preliminary 1 Dec 99 Initial Release 2 Jan 00 Correct errors 3 Mar 00 Change fuses according UL, correct

miscellaneous errors 4 Jan 01 Changes of control board All 5 May 02 Update on new drives sizes, error correction All 6 Feb 04 Update on new SW release Index,

7 May 04 Update All 8 Jul 04 New UL requirement Table of contents 9 Oct 04 Deleted DSloader section, update All B Jan 06 New size E, update section 8 – Restart Interlock

Function, update new software releases, correct

miscellaneous errors

C Sep 06 G motor resolver connection, APHAPOS

parameter, update figures Size E, update section

8 – Restart Interlock Function, correct

miscellaneous errors

Section 3-4-7, Appendix

All

Par. 2.11.2.1,

2.11.3.2, 3.3.4,

6.2.1, 6.2.2, 6.3.1,

6.7.1.5 Fig. 2.4.1, 2.5, 2.6,

2.8, 2.8.1, 2.14,

3.5.1 Section 8

DS2000 USER’S MANUAL (rev.C)

I.2

Index

Section 1 Description

Section 2 Wiring and installation

Section 3 Electromagnetic compatibility (EMC)

INDEX

INDEX OF CONTENTS

Introduction Using the manual Accident protection EC declaration of conformity EC requirements UL authorization UL requirements ICEPI certificate Safety requirements (Restart Interlock Function) Legal aspects

Introduction Product range General features Technical data Standard versions codes Special versions codes Options Serial number – Nameplate

Introduction Dimensions and drilling jig External fuses Power dissipation Soft-start Recovery circuit Fans Reset Connection cables AWG/mm2 conversion Wiring and connectors Drive starting sequence Starting sequence times Dynamic braking Power off Mechanical braking

Introduction European directive (89/336/EEC) Filters Wiring and grounding Recovery resistor Screening Safety aspects

I.1 I.2 I.3 I.4 I.5 I.6 I.7 I.8 I.9

I.10

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

2.10

2.11

2.12

2.13

2.14

2.15

2.16

3.1

3.2

3.3

3.4

3.5

3.6

3.7

DS2000 USER’S MANUAL (rev.C)

Section 4 Starting

Section 5 Component description

Section 6 Commands

Section 7 Troubleshooting

Section 8 Restart interlock circuit (Optional)

Appendix

INDEX

Introduction Drive setting up information First Start-up Configuration for installation in electrical cabinet

Introduction High power input section High power output section Control section

Introduction Motor parameters menu Drive parameters menu Control loops parameters menu Drive enable menu Display variables menu Utility menu Keyboard lock menu Fault detection menu

Introduction Faults on drive power supply circuit Faults on drive output section Faults on feedback section Control loops troubles Motor troubles Recovery resistor troubles

Intended application Restart interlock function Safety requirements Restart interlock circuit Restart interlock connections Safety relays – Technical data Application example Sequence and procedure using the restart interlock Checking the restart interlock External plausibility tests Installation and routine test RIC identification on the nameplate

Appendix A - Motors technical data Appendix B - FC series technical data Appendix C - Active software release Appendix D - Obsolete software release

I.3

4.1

4.2

4.3

4.4

5.1

5.2

5.3

5.4

6.1

6.2

6.3

6.4

6.5

6.6

6.7

6.8

6.9

7.1

7.2

7.3

7.4

7.5

7.6

7.7

8.1

8.2

8.3

8.4

8.5

8.6

8.7

8.8

8.9

8.10

8.11

8.12

DS2000 USER’S MANUAL (rev.C)

I.4

INDEX

I.1 INTRODUCTION

This manual refers to DS 2000 “The Motion Solution” drive, with SW Release 3.20X.

The manuals from 0 to 3 release refers to DS2000 drives and SW release below 2.00X. The manuals from 4 to 5 release refers to DS2000 “The Motion Solution” drive, with SW release 3.00X and 3.10X.

New characteristics and added functionalities on DS2000 Software Release 3.200:

• I2T IGBT Protection. This functionality allows to protect IGBT modules from overheating,

due to excessive phase current flowing (particularly at low frequencies or locked rotor). When the protection activates the drive can be disabled or the current flowing can be limited. This functionality can be activated or deactivated from menu. Activating this protection the Notch Filter will be automatically deactivated. I2T IGBT Protection and NOTCH FILTER cannot be used together.

• Anti-Free-Wheeling (AFW). This functionality allows to have an emergency motor stop in

case of NO POWER, MOTOR OVERHEATING and DRIVE OVERHEATING. The motor will brake with the deceleration value eventually set in menu. This functionality can be activated or deactivated from menu.

• Regen Resistor Protection. Some customer applications have shown an intense

continuous utilization of the regen resistor that sometimes ends with its damage or even breaking. To avoid this problem a new functionality has been developed within the new DS2000 Firmware Release 3.200: this algorithm estimates the growing of the resistor temperature and, depending on the manufacturer data (nominal power, maximum power and time at peak power), protects it from dangerous overheating.

• FAS G Defluxing. This modification improves motor performances at high speed

introducing a defluxing component (sinusoidal current phase shifting) starting from a speed value and with a maximum angle value to be set in the menu. This functionality can be activated or deactivated from menu using its related parameter.

• Dead Band on analog reference. A dead Band on analog reference can be introduced

(centered on zero crossing and symmetric in both directions) with an amplitude selected with the menu. It eliminates possible offsets that can cause slow motor shaft drift rotations. This functionality can be activated or deactivated from menu using its related parameter.

• PTC/NTC Selection. PTC/NTC motor thermal sensor can be selected using menu.

• Automatic Current Offset Compensation. This functionality automatically auto-activates

when drive is disabled and it repeats its calculations until the drive is off. When the drive is enable, the last calculated offset value is memorized and used in current loop. When the drive is disabled again, this function activates and compensates also possible thermal drifts.

DS2000 USER’S MANUAL (rev.C)

INDEX

I.5

• ENC/OUT Zero Marker Calibration. This functionality is activated through the “ENC/OUT

MARKER CALIBRATION” in the UTILITY menu and shifts the Zero Marker on the electric turn. It can be useful to align the ENC/OUT Marker with mechanical zero of the machine.

• Digital speed reference parameter saving. Digital speed reference parameter set in

CURRENT LOOP PARAMETERS, SPEED LOOP menu can now be saved.

• Parameter range modification: motor speed and motor Rw.

- Motor speed parameter range has been changed from 300/9999 to 100/9999;

- Motor Rw parameter range has been changed from da 0/30.0 to 0/100.0;

- IOFFS U and V parameter range has been changed from -100/100 to -500/500;

- RECOVERY RESISTOR parameter has been changed from 5/100 to 3/100;

NOTE: this software can be installed on the DS2000 with 3.xxx software version: please contact Moog service before update the drives.

NOTE: this software is totally compatible with the interface Windrive GUI; with 3.1xx or previous release use DSLoader interface

I.2 USING THE MANUAL

This manual provides the necessary information for a proper installation and use of the DS2000 servodrive. The DS2000 was designed to be easily installed; it is not necessary any specific skill concerning servodrives to start it up. Anyway, the installer should have basics of electronics/electrotechnics, of servodrives, and of safety. The DS 2000 is a digital servodrive, which can be configured via software as a computer, according to the application requirements. It is recommended to read carefully the manual before the installation. After the installation, and before starting up the motor it is also recommended to check all the system parameters to ensure a correct system configuration. Particular attention must be used to safety instructions.

DS2000 USER’S MANUAL (rev.C)

I.6

INDEX

I.3 ACCIDENT PROTECTION

The safety instructions provided in this Manual are included to prevent injury

to personnel (WARNINGS) or damage to equipment (CAUTIONS).

WARNING: High Voltage. BUS BAR's can have voltage ≥810V

(capacitive voltage). Discharge Time approx. 6 Minutes.

WARNING: High Voltage. The recovery resistor is connected to the BUS BAR’s and can

have voltage ≥810Vdc.

WARNING: do not touch recovery resistor during operation to avoid scalds.

CAUTION: it is recommended to disconnect the drive and the EMC filters to carry out the AC

Voltage Tests of EN 60204-1 (1997), par.19.4, in order to not damage the Y-type capacitors between phases and ground. Moreover the DC voltage dielectric test required by EN 50178 (1997), product family standard, has been carried out in factory as a routine test. The DC Insulation Resistance Tests of EN 60204-1 (1997), par.19.3, may be carried out without disconnecting the drive and the EMC filters.

CAUTION: when required for an emergency stop, opening U2-V2-W2 pins and closing motor

phases to resistors, must be preceded by disabling the axis. The delay time must be at least 30 ms.

CAUTION: in case of repetitive switching on and off, waits 1 minute between off and on. CAUTION: do not exceed the tightening torque of the table (but see proper data sheets for

the tightening torque of input capacitors and power modules and see section 2 of this manual for the tightening torque of terminal blocks).

Screw thread

Tightening torque

[Nm] [lb in]

M3 1.00 8.85 M4 3.00 26.55 M5 6.00 53.10 M6 8.00 70.80 M8 20.00 177.00

even after switching off

DS2000 USER’S MANUAL (rev.C)

INDEX

I.4 EC DECLARATION OF CONFORMITY

I.7

DS2000 USER’S MANUAL (rev.C)

I.8

INDEX

I.5 EC REQUIREMENTS

 Cautionary Marking. See previous page.  Protection against electric shock. Electronic Equipment intended for installation in

closed electrical operating areas kept locked. Where Electronic Equipment requires manual intervention, 412.2.1 of HD 384.4.41 S2 shall be consulted.

 Fixed connection for protection. The equipment may have a continuous leakage

current of more than A.C. 3.5 mA or D.C. 10 mA in normal use and a fixed ground connection is required for protection.

 RCD. When the protection in installations with regard to indirect contact is achieved by

means of an RCD, their appropriate function/combination shall be verified. In any case only a residual-current-operated protective device (RCD) of Type B is allowed. In fact a D.C component can occur in the fault current in the event of a fault connection to earth.

 Climatic Conditions. Equipment intended to operate within its performance specification

over the range of Class 3K3, as defined in table 1 of EN 60721-3-1, EN 60721-3-2, EN 60721-3-3, EN 60721-3-4, partly modified.

 Pollution Degree 2 Installation. The equipment shall be placed in a pollution degree 2

environment, where normally only non-conductive pollution occurs. Occasionally, however, a temporary conductivity caused by condensation is to be expected, when the electronic equipment is out of operation.

 EMC Requirements. The installer of the equipment is responsible for ensuring

compliance with the EMC standards that apply where the equipment is to be used. Product conformity is subjected to filters installation and to recommended procedures, as from section 3 of this manual.

 Second Environment (EMC). Equipment intended to be connected to an industrial low-

voltage power supply network, or public network that does not supply buildings used for domestic purposes (second environment, according to EMC Standards). It is not intended to be used on a low-voltage public network that supplies domestic premises (first environment). Radio frequency interference is expected if used on such a network.

 Recovery Resistor Cable. Shielding of the recovery resistor cable, provided in kit for test

purposes, is recommended for ensuring compliance with the EMC standards.

 Large-Scale Stationary Industrial Tools (WEEE, RoHS). Equipment intended for

installation as part of large-scale stationary industrial tools, covered by the exception of Annex IA, No.6, of the European Directives 2002/96/EC (WEEE) and 2002/95/EC (RoHS).

DS2000 USER’S MANUAL (rev.C)

I.6 UL AUTHORIZATION (page 1)

INDEX

I.9

DS2000 USER’S MANUAL (rev.C)

I.10

UL AUTHORIZATION (page 2)

INDEX

DS2000 USER’S MANUAL (rev.C)

INDEX

I.11

I.7 UL REQUIREMENTS

• These Brushless Servo-Drives shall be assembled with the guidelines specified in this Manual. Only the configurations with the components tested and described in the UL Report, file E194181, Vol.1, Sec.1, Issue date 01-21-00 and following Revisions can bear the Listing Mark.

• These drives shall be used within their ratings, as specified in the marking of the equipment.

• Cautionary Marking. See Accident Protection page.

• Surrounding Air Temperature. "Maximum Surrounding Air Temperature 40°C". In the

final installation considerations shall be given for the need of repeating Temperature test if the unit is mounted with a different Surrounding Air conditions.

• Pollution degree 2 Installation. The drive must be placed in a pollution degree 2

Environment.

• Environmental designation. “Open Type Equipment”.

• Short Circuit Ratings.

 DS2000 3/9, 4/12, 6/15, 8/22, 14/42, 20/45, 25/70, 35/90, 50/140: “Equipment suitable

for use on a circuit capable of delivering not more than 5000 rms Symmetrical Amperes, 460 Vac +10% maximum”

 DS2000 60/180, 100/300: “Equipment suitable for use on a circuit capable of delivering

not more than 10000 rms Symmetrical Amperes, 460 Vac +10% maximum”

• Branch Circuit Protection. The Branch Circuit Protection for Short Circuit shall be

provided in the end-use applications by external R/C Fuses (JFHR2), manufactured by Busman Div Cooper (UK) LTD, Semiconductor fuse type, rated 660 Vac, 200 kA A.I.C., Mod. No. as follows:

 DS2000 3/9, 4/12, 6/15, 8/22, 14/42: Mod. No. 50 FE, rated 50 Amps  DS2000 20/45, 25/70, 35/90: Mod. No. 100 FE, rated 100 Amps  DS2000 50/140, 60/180: Mod. No. 160 FEE, rated 160 Amps  DS2000 100/300: Mod. No, 315-FM, rated 315 Amps

• Overspeed Protection. The Power Conversion Equipment is incorporating an Overspeed

Protection. See MV command in section 6.

• Overvoltage Control. In the equipment the Overvoltage is controlled by a Transient

Suppressive device, with 1500 V Clamping Voltage and min 120 J (10x1000 us or 2 ms) Energy Handling Capability. See also “Bus not normal” protection in section 6.

• Overload Protection. The equipment does not incorporate internal overload protection

for the motor load. The drive is intended to be used with motors that must have integral thermal protection through a PTC or NTC. The overtemperature fault of the drive will trip when the PTC reaches 2 kW or 6.5kW for the NTC. See J4 connector in section 2 of this manual for wiring.

DS2000 USER’S MANUAL (rev.C)

I.12

INDEX

• Over-Current Protection. The drive is provided with a current limiting circuitry. See

ANALOG ILIMIT and I2T commands in section 6.

• Wiring. Wiring shall be made by stranded and/or solid, copper (Cu), 60/75°C (140/167°F)

conductor only, and, for terminal blocks, the tightening torque values specified in section 2 of this manual shall be applied. These requirements do not pertain to control circuit terminals.

• Wiring of Recovery Resistor. The Dynamic Brake Unit Recovery Resistor, when

external, shall have the connection wiring made with R/C (AVLV2) or insulated with R/C (YDPU2) or R/C (UZCW2) in the end-use installation.

• Transient Suppression Devices. Input power wiring, only for size A and B, shall be

protected by external Transient Suppression Devices, such as varistors or transient voltage surge protections, evaluated to the component requirements in UL1449. the following devices are recommended:

Rating

Drive

A and B

size

Ref.

Code

AS5046

Manufacturer

Littelfuse Inc

Epcos Ohg

S A BC

Components NV

TVSS

Mod. No.

V-575-LA-40-

S14-K-550

S20-K-550

2322 595.551

Operating

Voltage

)

575 V

rms

max

550 V

rms

max

550 V

rms

max

550 V

rms

max

Clamping

Voltage

(Vac)

1500

Maximum

Energy (J)

120

(10x1000µs)

120

(2ms)

210

(2ms)

160

(10x1000µs)

Max

Op.

Temp

85°C

Qty

DS2000 USER’S MANUAL (rev.C)

I.8 ICEPI CERTIFICATE

INDEX

I.13

DS2000 USER’S MANUAL (rev.C)

I.14

INDEX

I.9 SAFETY REQUIREMENTS (RESTART INTERLOCK FUNCTION)

• Complete Standstill. The Restart Interlock safety function prevents motor unexpectedly

starting from standstill. This circuit can be used in the “Safe Standstill” machine function. When the motor is rotating, the switching-on of the Restart Interlock provides an

uncontrolled stop (category 0 according to EN 60204-1:1997). When a controlled stop of

category 1, according to EN 60204-1:1997, is requested, the condition of stopped motor must be assured. The final machine must be able to stop the motor.

WARNING: The designer must evaluate the machine stopping time during the risk assessment even in case of failure. The machine can present a dangerous overrun in case of failure of the drive. Other protective measure are needed to achieve a safe condition.

• Environmental Conditions. Equipment intended to operate within the following environmental conditions:

◊ Ambient temperature: 0 to +40°C ◊ EMC immunity: according to EN 61800-3/A11:2000 (Adjustable speed electrical power

drive systems. Part 3: EMC product standard including specific test methods). Second environment (industrial)

◊ Vibration immunity: 2 to 12Hz, 1.5 mm amplitude (peak); 12 to 200Hz, 1 g acceleration ◊ Shock immunity: 10 g, half sine, 11 ms, according to EN 60721-3-3:1995, Class 3M4

• Enlosure. Electronic Equipment intended for installation in an enclosure providing at least

IP54 protection.

• Pollution Degree 2. The equipment shall be installed in a pollution degree 2 environment,

where normally only non-conductive pollution occurs. Occasionally, however, a temporary conductivity caused by condensation is to be expected, when the electronic equipment is out of operation.

WARNING: When the Restart Interlock Circuit is activated, the motor can no longer generate a torque. Motors which are not automatically clamped when powered down (e.g. vertical/inclined axes), must be clamped using a mechanical brake

DS2000 USER’S MANUAL (rev.C)

INDEX

I.15

I.10 LEGAL ASPECTS

This manual can be used only by final Customers/Users of the Moog product it describes and only for proper installation purposes. This manual cannot be reproduced in whole or in part without the prior written consent of Moog. No transmission or diffusion of this manual, under electronic, mechanical, or printed form, is allowed. Moog issued this manual attempting to ensure a complete information; anyway, Moog shall not be liable for errors or omissions contained herein and for incidental or consequential damages due to the above mentioned errors and omissions. Moog reserves the right to change and update this manual without notice. This manual has a merely information purpose. There is no obligation for Moog as regard the correspondence of the product features described in the manual with the features of the real product purchased by the final Customer/User. No statement or sentence contained in this manual implies further legal obligations different from the ones contained in each single sale or supply contract concerning Moog products.

DS2000 USER’S MANUAL (rev.C)

I.16

INDEX

THIS PAGE INTENTIONALLY BLANK

DS2000 USER’S MANUAL (rev.C)

SECTION ONE – DESCRIPTION

1.1

1. DESCRIPTION

1.1 INTRODUCTION

This section describes the DS2000 drive series, providing information about the coding system. Such data allow understanding the DS2000 characteristics and makes clear the necessary concepts to access the following sections.

DS2000 USER’S MANUAL (rev.C)

1.2

SECTION ONE – DESCRIPTION

1.2 PRODUCT RANGE

DS2000 is a full digital drive series for permanent magnet synchronous servomotors (hereinafter: brushless) and for vector control asynchronous servomotors (hereinafter: asynchronous). The range is made up of 11 models, corresponding to 3, 4, 6, 8, 14, 20, 25, 30, 50, 60 and 100 A

nominal currents.

rms

The standard transducers provided with the motor are the incremental encoder or the resolver (with its simulated encoder). The recovery resistors are placed outside the drive; only the 3, 4, and 6 A models can be equipped with built-in recovery resistor (optional). DS2000 drive is provided together with this manual and the Application Notes in the Appendix of DS2000 user’s manual, for a deep understanding and the best use of the product.

1.3 GENERAL FEATURES

The DS2000 features provide the automation industry with the best response to the hardest requirements related to motion control:

FULL DIGITAL:

• Speed and current control loops and many other functions, as the DC BUS status monitoring, the soft-start and recovery circuit management, and the protections thresholds detection are carried out through numeric algorithms.

• The digital mode allows a maximum stability related to the aging, the temperature and the various application cases.

• Settings are carried out through numbers calculated by means of analytic models and do not depend upon analog calibrations.

FLEXIBLE:

• Any brushless motor can be very well driven by entering a maximum of 8 parameters which adjust the current loop and identify the motor electromechanical characteristics (peak current, electromotive force, inductance, resistor, poles number, voltage rating, speed).

• Any asynchronous motor can be very well driven by vector control, working as a brushless servomotor; by entering the magnetization current (ID) and the slip gain (frequency) additional parameters it is possible to use any kind of asynchronous motor. The other parameters, the ones in connection with the hardware features in common with brushless motors, remain active.

• The motor transducer can be both a resolver (2 to 24 poles) and an incremental encoder (1024 to 8192 pulses).

• It is possible to program the device in 2 different languages: Italian and English. The required language should be specified in the purchase order.

• The power supply voltage range can be from Three-phase 65 Vac to 510 Vac with no previous setup.

• With power supply voltages lower than 120 Vac Three-phase, it is necessary to supply a 24 Vdc auxiliary voltage.

DS2000 USER’S MANUAL (rev.C)

SECTION ONE – DESCRIPTION

ADVANCED PERFORMANCE:

• The current loop, based on a traditional PI structure, is provided with automatic compensation algorithms of the EMF and of the KP/KI ratio, as a function of the motor characteristics.

• Hardware calibrations are not necessary for the current loop, but they are necessary for parameters setting.

• Current loops are closed at 10kHz.

• The speed loop is closed at 5kHz.

• Additional phase advance is provided.

1.4 TECHNICAL DATA

1.4.1 ELECTRICAL AND MECHANICAL SPECIFICATIONS

Three-phase input voltage rating: 230V Min/max Three-phase input voltage

- With 24 V

- Without 24 V

auxiliary input voltage: 65 / 510 Vac (DC-BUS: 80 / 720 Vdc)

auxiliary input voltage: 120 / 510 Vac (DC-BUS: 150 / 720 Vdc)

Auxiliary voltage: 24 V Configurable analog references: 3.2 to 10 V Max dynamic with encoder: 200 Hz Switching frequency: 10 kHz Speed adjustment: 0 to 9999 rpm Anti-resonance low-pass filter: 20 to 800 Hz Filter on reference: 1 to 800 Hz Notch filter (programmable): 50 to 1500 Hz

Output current

Model

Nominal

)

rms

3/9 3 6.4 9 4.5 A 4/12 4 8.5 12 4.5 A 6/15 6 10.6 15 4.5 A 8/22 8 15.6 22 4.5 A

14/42 14 29.7 42 6 B 20/45 20 31.8 45 10 C 25/70 25 49.5 70 10 C

30/90 30 63.6 90 10 C 50/140 50 99.0 140 23 D 60/180 60 127.3 180 23 D

100/300 100 212.7 300 40 E

Tab. 1.0 – Mechanical and electrical characteristics

to 460Vac ±10%, 50/60 Hz

±10% , 1.5A

Max

rms

)

Peak

(A)

Mass

(kg)

Size

1.3

DS2000 USER’S MANUAL (rev.C)

1.4

SECTION ONE – DESCRIPTION

1.4.2 CLIMATIC CONDITIONS

1.4.2.1 AMBIENT TEMPERATURE

0°C to +40°C (exceeding EN 60204-1:1997, par.4.4.3).

1.4.2.2 AMBIENT HUMIDITY

5% to 85% with no condensation and no formation of ice (according to EN 50178:1997, weather protected site).

1.4.2.3 ALTITUDE

The electrical equipment is able to operating correctly at altitudes up to 1000m above sea level (according to EN 60204-1:1997, par.4.4.5)

1.4.2.4 TRANSPORTATION AND STORAGE

The electrical equipment withstands the effects of transportation and storage temperatures within a range of –25°C to +55°C and for short periods not exceeding 24 h at up to +70°C (according to EN 60204-1:1997, par.4.5).

1.4.2.5 POLLUTION

The equipment has been designed according to pollution degree 2, where normally only non-conductive pollution occurs. Occasionally, however, a temporary conductivity caused by condensation is to be expected, when the electronic equipment is out of operation.

1.4.3 OTHER MECHANICAL SPECIFICATIONS

1.4.3.1 IMMUNITY TO MECHANICAL VIBRATION

0.075mm amplitude from 10 Hz to 57 Hz, 1g acceleration from 57 Hz to 150 Hz (according to EN 50178:1997 and to IEC 68-2-6:1995, Fc test).

DS2000 USER’S MANUAL (rev.C)

SECTION ONE – DESCRIPTION

1.4.4 INTERFACES

• Analog

 Speed (or current) reference differential input: 0 +/- 10V (adjustable scale)  Auxiliary input voltage: 24Vdc ±10%  Output Voltage: 15Vdc  Analog output (configurable)  Tachometric signal (adjustable scale)  Peak current limit (trough adjustable analog signal)  Motor temperature (trough PTC or NTC)  Resolver interface  Sine Encoder Interface (optional)

• Digital

 RS485 full-duplex serial link  Encoder input (incremental)  Encoder output (incremental)  Reset  Drive OK output  Drive enable input (torque)  Reference enable input (speed)  CAN BUS (optional)

1.4.5 PROTECTIONS

• Motor over temperature

• Drive over temperature

• Input voltage out of tolerance

• Encoder or resolver signal missed

• Encoder or resolver faulty connections

• Axis short circuit (motor and recovery resistor output)

• Recovery resistor missed (overvoltage)

• Recovery resistor overload (software selectable)

• Over speed in torque mode control (if speed is 12% above max set value).

• IGBT over temperature (software selectable)

• Anti-free-wheeling (software selectable)

• Safety – Restart interlock function (optional).

1.5

DS2000 USER’S MANUAL (rev.C)

1.6

SECTION ONE – DESCRIPTION

1.5 STANDARD VERSIONS CODES

DS2000 drives are marked by a code identifying both the current supplied by the Model and the eventual internal recovery resistor. Codes correspond to:

• Standard Italian software drives

• 6 poles resolver (transformation ratio:0. 29), ¼ marker configured, 1024 simulated

encoder pulses

• External recovery resistor, provided with the drive together with mating connectors.

The following table summarizes the drive codes:

Model

Code Type

CZ1000C0A 3/9 A CZ1001C0A 4/12 A CZ1002C0A 6/15 A CZ1003C0A 8/22 A CZ1008C0A 14/42 B CZ1005C0A 20/45 C CZ1006C0A 25/70 C CZ1007C0A 30/90 C CZ1009C0A 50/140 D CZ1010C0A 60/180 D CZ1011C0A 100/300 E

Size

Tab. 1.1 – Standard versions codes

Besides the coding in Tab. 1.1, a new coding formed by a descriptive code has been introduced, which univocally and directly identifies a drive and its configuration. Fig. 1.1 shows the new codifications .

DS2000 USER’S MANUAL (rev.C)

SECTION ONE – DESCRIPTION

1.7

1.6 SPECIAL VERSIONS CODES

For a limited braking power dissipation application, special versions of 3/9, 4/12, and 6/15 Size drives have been realized with built-in recovery resistor. Their codes are different, but all the other features and the operation remain the same. Codes correspond to:

• Standard Italian software drives

• 6 poles resolver (transformation ratio:0. 29), ¼ marker configured, 1024 simulated

encoder pulses

• Mating connectors provided with the drive

The following table summarizes the drive codes:

Model

Code Type

CZ1100C0A 3/9 A CZ1101C0A 4/12 A CZ1102C0A 6/15 A

Size

Tab. 1.2 – Special versions codes

Additional informations can be found in Section 2 and Section 5.

DS2000 USER’S MANUAL (rev.C)

1.8

SECTION ONE – DESCRIPTION

Fig. 1.1 – Table of DS2000 codification

DS2000 USER’S MANUAL (rev.C)

SECTION ONE – DESCRIPTION

1.9

1.7 OPTIONS

Optional devices can be built-in or separately supplied. Built-in drive devices are:

• CAN BUS interface on speed reference (SW Release 4.X00)

• Safety – Restart interlock function

• 24V fans internal power supply (only size E)

Separately supplied devices are:

• RS232/422/485 Converter (Moog code CZ5200)

1.8 SERIAL NUMBER – NAMEPLATE

Each drive is provided with a serial number identifying the Model, any eventual option and the manufacturing date. This number is a useful tool to verify, through the Moog Database, the original software and firmware revision. Using these data it is possible to carefully support the final Customers. It is recommended to take note of the serial number, which is present on each drive, before shipment.

CODE: CZxxxxYYz Product code S/N: AASSNNNNYYA Serial number, where

AA= year, SS= week, NNNN= progressive number,

YYA= option (C0A= standard version) Vin: xxx V Input voltage rating Iin: xxx Arms Nominal effective input current Iout: xxx Arms Nominal effective output current Iout: xxx Apeak Output peak max current

Fig. 1.2 – Nameplate

DS2000 USER’S MANUAL (rev.C)

1.10

SECTION ONE – DESCRIPTION

THIS PAGE INTENTIONALLY BLANK

DS2000 USER’S MANUAL (rev.C)

SECTION TWO – WIRING AND INSTALLATION

2.1

2. GENERAL INFORMATION

2.1 INTRODUCTION

This section describes the installation, wiring and cabling of the Moog DS2000 servo drive series. Such information allows the understanding of DS2000 functionality and makes clear the necessary concepts to access the following sections.

DS2000 USER’S MANUAL (rev.C)

2.2

SECTION TWO – WIRING AND INSTALLATION

2.2 DIMENSIONS AND DRILLING JIG

Fig. 2.1 – Size A dimensions and drilling jig (mm)

DS2000 USER’S MANUAL (rev.C)

SECTION TWO – WIRING AND INSTALLATION

2.3

Fig. 2.2 – Size B dimensions and drilling jig (mm)

DS2000 USER’S MANUAL (rev.C)

2.4

SECTION TWO – WIRING AND INSTALLATION

Fig. 2.3 – Size C dimensions and drilling jig (mm)

DS2000 USER’S MANUAL (rev.C)

SECTION TWO – WIRING AND INSTALLATION

2.5

Fig. 2.4 – Size D dimensions and drilling jig (mm)

DS2000 USER’S MANUAL (rev.C)

2.6

SECTION TWO – WIRING AND INSTALLATION

Fig. 2.4.1 – Size E dimensions and drilling jig (mm)

DS2000 USER’S MANUAL (rev.C)

SECTION TWO – WIRING AND INSTALLATION

2.7

2.3 EXTERNAL FUSES

It is recommended to use the Short Circuit protection in the final application with UL certified external fuses (cat. JFHR2), manufactured by Bussmann Div. Cooper (UK) Ltd, semiconductor type, 660 V

As alternate fuses by different manufacturers can be used but UL approved (cat. JFHR2) with the same data of the fuses shown in table taking care that the Peack-let-trough-current (A.I.C) and clearing I2T are equal or lower.

3/9 4/12 6/15 8/22 14/42

Short Circuit Rating Power line fuse 50 – FE Semiconductor 24 Vdc auxiliary power supply fuse

20/45 25/70 30/90 50/140 60/180

Short Circuit Rating Power line fuse 100 – FE 160 – FEE Semiconductor 24 Vdc auxiliary power supply fuse

, 200 kA symmetrical A.I.C..

DS2000 MODEL

A size B size

5000 rms Amps symmetrical

3A / 250V Delayed

DS2000 MODEL

C size D size

5000 rms Amps

symmetrical

5000 rms

Amps symm.

3A / 250V Delayed

10000 rms

Amps symm.

Notes

DS2000 MODEL

E size

Notes

100/300

Short Circuit Rating

10000 rms Amps symmetrical

Power line fuse 315-FM Semiconductor 24 Vdc auxiliary power supply

3A / 250V Delayed

fuse

Tab. 2.1 – Recommended fuses

DS2000 USER’S MANUAL (rev.C)

2.8

SECTION TWO – WIRING AND INSTALLATION

2.4 POWER DISSIPATION

For the thermal sizing of the cabinet in which the drive is installed, it is necessary to refer to the table. If the application implies continuous braking, it is necessary to add the recovery resistor power dissipation (use the nominal power if the one required by the application is unknown).

DS2000 Model Power

3/9 60W 4/12 75W 6/15 90W 8/22 110W

14/42 180W 20/45 250W 25/70 300W

30/90 400W 50/140 650W 60/180 800W

100/300 1200W

Tab. 2.2 – Power dissipation at nominal current

2.5 SOFT-START

The soft-start circuit (current limit at start-up) is included in the drive input stage. Additional data about the soft-start circuit can be found in the Section 5.

DS2000 USER’S MANUAL (rev.C)

SECTION TWO – WIRING AND INSTALLATION

2.9

2.6 RECOVERY CIRCUIT

Standard recovery resistors are in the following table (see Section 5 for additional informations) :

Dynamic braking unit

DS2000 Standard recovery resistor for 400/460 Vac mains voltage

Model Resistor and power Max Current Max Duty Cycle 3/9 4/12 6/15 8/22 14/42 33Ω/250W (ext.) 22.7A 1.5% 20/45 25/70 30/90 50/140 60/180 100/300 3.9Ω/1000W (ext.) 192.3A 0.7% 3/9 4/12 6/15 56Ω/150W (int.) 13.4A 0.7%

75Ω/100W (ext.) 10A 1.3%

51Ω/200W (ext.) 14.7A 1.8%

12Ω/370W (ext.) 62.5A 0.8%

10Ω/750W (ext.) 75.0A 1.3%

82Ω/150W (int.) 9.1A 1.0%

Tab. 2.3 – Recovery resistor data

Dimensions declared by the supplier are in the following table:

Model 75Ω/100W 51Ω/200W 33Ω/250W 12Ω/370W 10Ω/750W 3.9Ω/1000W L [mm] 165 ± 2 215 ± 2.5 265 ± 3 265 ± 3 300 ± 5 400 ± 5 A [mm] 150 ± 2 200 ± 2.5 250 ± 3 241 ± 3 270 ± 5 370 ± 5 G [mm] 36 ± 2 46 ± 2 46 ± 2 53 ± 2 88 ± 2 88 ± 2 D [mm] 20.5 ± 1 30.5 ± 1 30.5 ± 1 39 ± 2 76 ± 2 76 ± 2

Tab. 2.4 – Mechanical data of recovery resistor

DS2000 USER’S MANUAL (rev.C)

2.10

SECTION TWO – WIRING AND INSTALLATION

2.7 FANS

DS2000 ventilation is provided by one or more fans mounted over the drive and under only for size E. The fans input power is internally supplied except for size E (option “internal 24V”)

CAUTION: A free air circulation must be ensured for a proper operation as per the following table..

DS2000

Size

Minimum Clearence Top

(mm)

Minimum Clearence Bottom

(mm)

A 60 100

B 60 100 C 80 160 D 100 200 E 200 300

Tab. 2.5A – Minimum Clearence around DS2000 Drives

2.8 RESET OR RESTART BUTTON

The reset (restart) button is on the drive front panel. It allows the digital control card reinitialization as well as the protections reset.

DS2000 USER’S MANUAL (rev.C)

SECTION TWO – WIRING AND INSTALLATION

2.11

2.9 CONNECTION CABLES

Connection cables must have precise electric characteristics in order to ensure a proper operation of the servosystem. It is recommended to use copper (Cu) cables, 75°C, UL certified, according to the cross sections indicated in the table 2.5. The following table shows the cables specification for each single function.

DS2000 MODEL

Cable

Size

D Size

50/140 60/180

Size

Line power 14 AWG 12 AWG 8 AWG 6 AWG 4 AWG 1 AWG Protective bonding 6 AWG 6 AWG 6 AWG 6 AWG 4 AWG 1 AWG Motor power cable 14 AWG 12 AWG 8 AWG 6 AWG 4 AWG 1 AWG Shielded DC BUS (+/-AT) 14 AWG 12 AWG 8 AWG 6 AWG 4 AWG 1 AWG Shielded Recovery resistor 14 AWG 12 AWG 8 AWG 6 AWG 4 AWG 2 AWG Shielded 24V fans cable 14 AWG Shielded Restart Interlock 22 AWG Shielded 24V power supply 14 AWG Shielded Motor encoder 22/20 AWG Shielded Motor resolver 22/20 AWG Shielded

Notes

Tab. 2.6 – Wiring size

CAUTION: To connect more than one drive through the DC BUS (+/-HV), please ask the Service Center.

2.10 AWG/mm2 CONVERSION

AWG mm

22 0.3 20 0.5 18 0.8 16 1.3 14 2.1 12 3.3 10 5.3

8 8.4 6 13 4 21 3 27 2 34 1 42

Tab. 2.7 – AWG/mm2 conversion

DS2000 USER’S MANUAL (rev.C)

2.12

SECTION TWO – WIRING AND INSTALLATION

2.11 WIRING AND CONNECTORS

NOTE: Moog DS2000 drives are equipped with all the necessary connectors for a proper operation. It is not necessary to indicate the connectors, or the recovery resistor in the purchase order. All of them are included in the drive code.

All the drives (except D size and E size) are equipped with plug-in connectors to ensure a quick connection of the drive to the switchboard and for Service activities (if applicable).

2.11.1 POWER CONNECTORS

Connectors differ according to the different drive sizes: please, refer to the following descriptions and tables to detect the corresponding pin configuration; power connectors bear a pinout label which makes pin detection easier.

2.11.1.1 SIZE A and B POWER CONNECTOR

Note: Pin 1 is marked with the symbol “■”

Fig. 2.5 – Size A and B power connector

• J6 connector

- Mating connector: female. 12 pins, supplied with the drive, model Tyco 1-282960-2 or 1-796981-2 (Moog code AK4987). Wire stripping: 7 mm. Tightening torque: 0.5Nm.

Pos. Name Function

1 ■ -AT - DC BUS AT 2 RR (+AT) External recovery resistor and +AT of DC BUS 3 RR External recovery resistor 4 U1 Phase "L1", three-phase voltage input 230/460Vac ±10% 5 V1 Phase "L2", three-phase voltage input 230/460Vac ±10% 6 W1 Phase "L3", three-phase voltage input 230/460Vac ±10% 7 GND Motor ground (see also Ground screw) 8 W2 Phase "W2", motor three-phase output 9 V2 Phase "V2", motor three-phase output 10 U2 Phase "U2", motor three-phase output 11 +24V 12 0V (24)

Auxiliary voltage inputs 24 Vdc ±10%, 2A (pin 12 is connected to drive logic 0)

Tab. 2.8 – J6 connector, size A and B

DS2000 USER’S MANUAL (rev.C)

SECTION TWO – WIRING AND INSTALLATION

• Ground screw

Use a lug for M5 screw.

Pos. Name Function

Ground screw GND Equipotential protection circuit.

Tab. 2.9 – Ground screw, size A and B

NOTE: In an especially noisy environment (from an electromagnetic point of view) it can be useful to connect the motor ground (pin 7 of J6 connector) to the ground screw.

2.13

DS2000 USER’S MANUAL (rev.C)

2.14

SECTION TWO – WIRING AND INSTALLATION

2.11.1.2 SIZE C POWER CONNECTOR

Note: Pin 1 is marked with the symbol “■”

Fig. 2.6 – Size C power connector

• J6 connector

- Mating connector: female, 5 pins, crimp, supplied with the drive, model Molex 42816 0512 (Moog code AK4991).

Pos. Name Function

1 ■ W1 Phase "L3", three-phase voltage input 230/460Vac ±10% 2 V1 Phase "L2", three-phase voltage input 230/460Vac ±10% 3 U1 Phase "L1", three-phase voltage input 230/460Vac ±10% 4 RR (+ATP) External recovery resistor and +HV of DC BUS 5 RR External recovery resistor

Tab. 2.10 – J6 input power connector, size C

DS2000 USER’S MANUAL (rev.C)

SECTION TWO – WIRING AND INSTALLATION

• J7 connector

- Mating connector: female, 4 pins, crimp, supplied with the drive, model Molex 42816 0412 (Moog code AK4990).

Pos. Name Function

1 ■ U2 Phase "U2", motor three-phase output 2 V2 Phase "V2", motor three-phase output 3 W2 Phase "W2", motor three-phase output 4 GND Motor ground (see also Ground screw)

Tab. 2.11 – J7 output motor power connector, size C

• J8 connector

- Mating connector: female, 2 pins, supplied with the drive, model Wago 231-102/026 000 (Moog code AK4967).

Pos. Name Function

1 ■ +24V 2 0V (24V)

Auxiliary voltage inputs 24 V

±10%, 2A

(pin 2 is connected to drive logic 0)

2.15

Tab. 2.12 – J8 auxiliary input power supply connector, size C

• J9 connector

- Mating connector: female, 2 pins, crimp, supplied with the drive, model Molex 42816 0212 (Moog code AK4989).

Pos. Name Function

1 ■ -AT 2 +AT

DC BUS (see Application Engineer for details)

Tab. 2.13 – J9 DC BUS output connector, size C

• Ground screw

Use a lug for M5 screw.

Pos. Name Function

Ground screw GND Equipotential protection circuit.

Tab. 2.14 – Ground screw, size C

NOTE: In an especially noisy environment (from an electromagnetic point of view) it can be useful to connect the motor ground (pin 4 of J7 connector) to the ground screw.

DS2000 USER’S MANUAL (rev.C)

2.16

SECTION TWO – WIRING AND INSTALLATION

• WIRING NOTES FOR J6, J7, J9 CONNECTORS (SIZE C)

The relevant contacts (Molex type 42815-0031) are supplied together with J6, J7, and J9 mating connectors for C size DS2000 drives. These contacts are sized for an 8 AWG (8.4 mm2) cable with a 10 mm wire stripping. It is recommended the use of a Molex crimping tool type 63814-0000, or Molex type 63811-1500, or equivalent. The crimping does not affect the insulating plastic tubing. As an alternative it is possible to sold the contacts, taking care of folding the contact wings. After the crimping (or soldering), the contact must be inserted into the Mating connector following the proper direction and must be kept in position by the TPA (Terminal Position Assurance) jumper, according to Fig. 2.7.

Fig. 2.7 – Fixing Molex connectors

DS2000 USER’S MANUAL (rev.C)

SECTION TWO – WIRING AND INSTALLATION

2.11.1.3 SIZE D POWER CONNECTOR

2.17

Note: Pin 1 is marked with the symbol “■”

Fig. 2.8 – Size D power connector

• J8 connector

- Mating connector: female, 2 pins, supplied with the drive, model Wago 231-102/026 000 (Moog code AK4967).

Pos. Name Function

1 ■ +24V 2 0V (24V)

Auxiliary voltage inputs 24 V

±10%, 2A

(pin 2 is connected to drive logic 0)

Tab. 2.14D – J8 auxiliary input power supply connector, size D

DS2000 USER’S MANUAL (rev.C)

2.18

SECTION TWO – WIRING AND INSTALLATION

• J9 Terminal block

- Pos.1 to 12 Phoenix - HDFK16: Wire stripping: 16 mm. Tightening torque: 2 Nm.

Pos. Name Function

1 ■ RR External recovery resistor 2 RR (+AT) External recovery resistor and +HV of DC BUS 3 GND Housing ground 4 U1 Phase "L1", three-phase voltage input 230/460Vac ±10% 5 V1 Phase "L2", three-phase voltage input 230/460Vac ±10% 6 W1 Phase "L3", three-phase voltage input 230/460Vac ±10% 7 U2 Phase "U2", motor three-phase output 8 V2 Phase "V2", motor three-phase output 9 W2 Phase "W2", motor three-phase output 10 GND Motor ground 11 +AT 12 -AT

DC BUS (see Application Engineer for details)

Tab. 2.15D – J9 power connector, size D

• Ground screw

Use a lug for M5 screw.

Pos. Name Function

Ground screw GND Equipotential protection circuit.

Tab. 2.16D – Ground screw, size D

NOTE: In an especially noisy environment (from an electromagnetic point of view) it can be useful to connect the motor ground (terminal 10 of J9 connector) to the ground screw.

DS2000 USER’S MANUAL (rev.C)

SECTION TWO – WIRING AND INSTALLATION

2.11.1.3.1 SIZE E POWER CONNECTOR

2.19

Note: Pin 1 is marked with the symbol “■”

Fig. 2.8.1 – Size E power connector

• J8 connector

- Mating connector: female, 2 pins, supplied with the drive, model Wago 231-102/026 000 (Moog code AK4967).

Pos. Name Function

1 ■ +24V 2 0V (24V)

Auxiliary voltage inputs 24 Vdc ±10%, 2A (pin 2 is connected to drive logic 0)

Tab. 2.14E – J8 auxiliary input power supply connector, size E

DS2000 USER’S MANUAL (rev.C)

2.20

SECTION TWO – WIRING AND INSTALLATION

• J9 Terminal block

- Pos. 1,2 Phoenix – HDFK4 : Wire stripping: 9 mm. Tightening torque: 0.7 Nm.

- Pos. 3,4 Phoenix – HDFK25 : Wire stripping: 19 mm. Tightening torque: 4 Nm.

- Pos. 5 to 14 Phoenix – HDFK50 : Wire stripping: 24 mm. Tightening torque: 8 Nm.

Pos. Name Function

1 ■ 24V fans 2 0V fans

Voltage inputs 24V

fans ±10%, 2A

3 RR External recovery resistor 4 RR (+AT) External recovery resistor and +HV of DC BUS 5 GND Housing ground 6 U1 Phase "L1", three-phase voltage input 230/460Vac ±10% 7 V1 Phase "L2", three-phase voltage input 230/460Vac ±10% 8 W1 Phase "L3", three-phase voltage input 230/460Vac ±10% 9 GND Motor ground 10 U2 Phase "U2", motor three-phase output 11 V2 Phase "V2", motor three-phase output 12 W2 Phase "W2", motor three-phase output 13 +AT 14 -AT

DC BUS (see Application Engineer for details)

Tab. 2.15E – J9 power connector, size E

2.11.1.4 POWER WIRING NOTES

It is recommended to use motor phases wiring with low capacitance (max 500 pF/m).

CAUTION: do not parallel power connection cables to achieve requested section: this will increase the capacitance value at levels that may irreversibly damage the drive. If the value of capacitance of motor and cables, seen from drive output, exceeds 30 nF it is necessary to verify with Moog technicians the need of an adequate choke in series.

DS2000 MOTOR

GND

Grounding of shield via connector clamp (or RF connection to metallic PG gland in case of terminal board)

Grounding of shield

via connector clamp

GND

Fig. 2.9 – Three phase motor supply wiring

DS2000 USER’S MANUAL (rev.C)

SECTION TWO – WIRING AND INSTALLATION

2.11.2 CONTROL CONNECTORS

The connectors are common to all drives sizes and are all located on the control card.

2.21

Drive control panel – Frontal view Drive control panel – bottom view

Note: Pin 1 is marked with the symbol “■”

Fig. 2.10 – Control card connectors

DS2000 USER’S MANUAL (rev.C)

2.22

SECTION TWO – WIRING AND INSTALLATION

2.11.2.1 RS485 SERIAL LINK (CAN BUS OPTION) (J1)

RS485 serial interface signals are available on the J1 connector. Up to 63 drives can be connected through the RS 485 serial link (see Section 6 for additional data). Please contact Service Center if more than 4 (up to 63) drives must be connected. As an alternative to the serial interface, the J1 connector can contain the CAN BUS serial interface with the same external connector. For Can Option make reference to the applicative Can Open manual.

• Mating connector: female, Sub-D 9 pos. (Moog code AK4751)

Pos. Name Function

1 ■ RX+ RX+ (RS485) 2 N.C. Not Connected 3 TX+ TX+ (RS485) 4 N.C. Not Connected 5 N.C. Not Connected 6 RX- RX- (RS485) 7 0V Digital 0V 8 TX- TX- (RS485) 9 N.C. Not Connected

Tab. 2.16 – J1 RS485 serial link

DS2000 USER’S MANUAL (rev.C)

SECTION TWO – WIRING AND INSTALLATION

2.11.2.2 INPUT REFERENCES CONNECTOR (J2A)

Analog references (speed and current limit references) are available on the J2A connector. The conductors are fastened by insertion, opening the connector using a screwdriver.

• Mating connector: insertion type, 4 poles (Moog code AK4714).

Pos. Name Function

Differential, non-inverted input of speed or torque reference signal (0÷

1 ■

Ref

±10V, corresponding to 0÷ ±Max input reference). The end of scale is

adjustable via software from ±3.2 to ±10V in steps of 0.1V

Ref

Differential, inverted input of speed or torque reference signal

Differential, non-inverted input of analog current limit (0÷ ±10V,

limit

corresponding to 0÷ 100%Max set current). The end of scale is adjust-able

via software from ±3.2 to ±10V in steps of 0.1V

limit

Differential, inverted input of analog current limit

2.23

Tab. 2.17 – J2A input references connector

CNC-PLC

OUT+

OUT-

Housing

GND

DIFFERENTIAL SIGNALS

CNC-PLC

OUT+

GND_0V

GND

DS2000

1_J2A_V

2_J2A_V

Housing

2_J2B_0V

DS2000

1_J2A_V

2_J2A_V

HousingHousing

2_J2B_0V

Ref

SINGLE ENDED SIGNALS

NOTE: J2A and J2B are two different (separate) connectors. NOTE: shields of cables must be 360° clamped to the cabinet wall

Fig. 2.11 – Example of connections

DS2000 USER’S MANUAL (rev.C)

2.24

SECTION TWO – WIRING AND INSTALLATION

2.11.2.3 DRIVE ENABLE CONNECTOR (J2B)

Drive enable, Drive OK signals, Tacho out, Analog out, and Reference enable are available on the J2B connector. The conductors are fastened by insertion, opening the connector using a screwdriver.

• Mating connector: insertion type, 12 pin (Moog code AK4722).

Pos. Name Function

1 ■ +15V OUT +15Vdc output, max 100 mA 2 0V Logic Zero 3 ANL OUT Configurable output (see Analog out configuration)

Tachometric signal output

4 TCH OUT

(0 ÷ ±10V, corresponding to 0 ÷ ± Max speed rpm). The end of scale is adjustable via software from ±5 to ±10V in steps of 0.1V

5 RESTART+

Opto-insulated Reset input (15 ÷24 Vdc/12mA) By means of a > 20 ms duration pulse the re-initialization of the

6 RESTART-

7 DRV EN+ 8 DRV EN-

9 REF EN+

digital control card and the protections reset are carried out Opto-insulated Drive Enable input (15 ÷ 24 Vdc/12mA) When signal is missing the drive does not supply current Opto-insulated Reference Enable input (15 ÷ 24 V

/12mA)

When signal is missing the motor is in standstill position, at zero

10 REF EN-

speed if in speed control mode, it has zero torque if in torque control mode. This input can be used for emergency braking

11 DRV OK

Drive OK outputs. Contact closed (24Vdc relays, max 100 mA) indicates that Drive is OK.

It is recommended to logically connect the DRIVE OK isolated output

12 DRV OK

presence to the power contactor, so that the power supply is disabled in case of fault

CNC-PLC

+24V

DRIVE O

Tab. 2.18 – J2B drive enable connector

WITH EXTERNAL 24Vdc POWER SUPPLY

24V POWER SUPPLY

DS2000

RST.+ RST.-

DRV. EN.+ DRV. EN.-

REF. EN.+ REF. EN.-

DRV OK

Fig. 2.12 – Example of wiring

WITH INTERNAL ALIMENTATION

DS2000

+15V

RST.+

RST.-

DRV. EN.+

DRV. EN.-

REF. EN.+

REF. EN.-

DS2000 USER’S MANUAL (rev.C)

SECTION TWO – WIRING AND INSTALLATION

2.11.2.4 ENCODER OUTPUT CONNECTOR (J2C)

Encoder simulated output are available on the J2C connector. The conductors are fastened by insertion, opening the connector using a screwdriver.

• Mating connector: insertion type, 6 pin (Moog code AK4716).

Pos. Name Function

1 ■ A+ Encoder output: A channel 2 A- Encoder output: A channel denied 3 B+ Encoder output: B channel 4 B- Encoder output: B channel denied 5 C+ Encoder output: C channel 6 C- Encoder output: C channel denied

Tab. 2.19 – J2C encoder output connector

2.25

DS2000 USER’S MANUAL (rev.C)

2.26

SECTION TWO – WIRING AND INSTALLATION

2.11.2.5 ENCODER INPUT CONNECTOR (J4) NOTES: The motor control encoder is formed by two sections.

• The first one (UVW signals) only generates signals used by the drive to power the motor phases; this section is defined by the number of motor poles.

• The second one (ABC signals) generates reference signals also available for motion control through external CNC; the number of pulses in this section is defined according to final the Customer needs as well as to the application requirements.

All the motor encoder channels and the PTC/NTC for the motor temperature control must be connected to J4 connector located on the bottom side of the drive. The same incremental encoder signals are available as output on J2C connector. The mating encoder connector at drive side is a Sub-D 15 pos., to be soldered (Moog code AK5221). It is recommended to use a low capacitance, multipolar cable with 22 AWG (0,30 mm2) or 20 AWG (0,50 mm2) conductors, shielded (with 85% min. coverage). Cable length should not exceed 40 m. It is recommended that the cable and the power connection cable must be separated through the use of independent duct and by a distance of 30 cm. It is also recommended not to make intermediate connections on the encoder cable.

Pos. Name Function

1 ■ +5V +5 Vdc (max 100 mA) output 2 0V Encoder ground and motor PTC/NTC 3 W- Switching signal: W phase denied 4 W+ Switching signal: W phase 5 V+ Switching signal: V phase 6 V- Switching signal: V phase denied 7 A+ A Channel 8 A- A Channel denied 9 C+ C Channel 10 C- C Channel denied 11 U+ Switching signal: U phase 12 U- Switching signal: U phase denied 13 B- B Channel denied 14 B+ B Channel 15 PTC_MOTOR Motor PTC/NTC

Tab. 2.20 – J4 encoder input connector

DS2000 USER’S MANUAL (rev.C)

SECTION TWO – WIRING AND INSTALLATION

(

)

2.27

DS2000MOTOR

PTC GND

GND

PTC

B+

B-

C+

C-

U+

U-

V+

V-

W+

W-

+5V

GND PTC

B+ B-

C+ C-

U+ U-

V+ V-

W+ W-

PTC

Shield connected to the housing by connector clamp

Shield connected to

the housing b

connector shell

Fig. 2.13 – Encoder connections

DS2000 USER’S MANUAL (rev.C)

2.28

SECTION TWO – WIRING AND INSTALLATION

2.11.2.5.1 LIMIT SWITCHES CONNECTOR (J4)

When the special software 3.203 is used , the J4 connector becomes the Limit Switches connector. An option card is needed together with this special software. The encoder cannot be used as transducer and the ENC/OUT calibration of zero motor function is removed. See Appendix C for other informations

Pos. Name Function

1 ■ N.C. Not Connected 2 N.C. Not Connected

3 CW LS

Input for CW Limit Switches. Normally connected to +24Vdc. When the connection to +24Vdc is opened, the CW rotation is disabled.

4 N.C. Not Connected

5 CCW LS

Input for CCW Limit Switches. Normally connected to +24Vdc. When the connection to +24Vdc is opened, the CCW rotation is disabled.

6 N.C. Not Connected

Input for torque/speed control.

7 Tc/Vc

When connected to +24Vdc the drive is in torque control.

When connected to 0L the drive is in speed control. 8 N.C. Not Connected 9 N.C. Not Connected 10 Common Common input for CW LS, CCW LS and Tc/Vc to be connected to 0L 11 N.C. Not Connected 12 N.C. Not Connected 13 N.C. Not Connected 14 N.C. Not Connected 15 N.C. Not Connected

Tab. 2.20A – J4 Limit Switches connector

DS2000 USER’S MANUAL (rev.C)

SECTION TWO – WIRING AND INSTALLATION

2.29

2.11.2.6 RESOLVER CONNECTOR (J5)

All the motor resolver cable and the PTC/NTC for the motor temperature control must be connected to J5 connector located on the bottom side of the drive. The mating resolver connector is a male Sub-D 9 pos., to be soldered, provided together with the drive (Moog code AK5220). It is recommended to use low capacitance, multipolar cable with 22 AWG (0,30 mm2) or 20 AWG (0,50 mm2) conductors, each pair twisted and shielded, with an independent overall shield (with 85% min. coverage). Cable length should not exceed 30 m. It is recommended that the cable and the power connection cable be separated through the use of independent duct and by a distance of 30 cm. It is also recommended not to make intermediate connections on the resolver cable. With the resolver interface it is possible to use the simulated encoder outputs to J2C connector. The standard pulse of the simulated encoder is 1024 (number of 64, 128, 256 or 512 is selectable via keypad). The standard width of the marker is 90° (width of 180° or 360° is selectable via keypad).

NOTE: DS2000 can be interface with resolvers with the following transformer ratios :

0.23, 0.26, 0.29, 0.47 e 0.50. The two calibration resistors must have the correct value (the drive is pre-set in factory

in according to the motor, see the trasformation rating in the information sheet-Casella report- of the drive).

In case of replacement/change of the application, verify the right calibration of DS2000. If not please ask the Moog Service Center

Pos. Name Function

1 ■ COS+

2 COS-

Differential COS signal non-inverted input amplifier proceeding from resolver windings. Differential COS signal inverted input amplifier proceeding from resolver windings.

3 SHIELD Shield (internally connected to 0V)

4 SEN+

5 SEN-

Differential SEN signal non-inverted input amplifier proceeding from resolver windings. Differential SEN signal inverted input amplifier proceeding from resolver windings.

6 PTC_MOTOR Motor PTC/NTC input

7 10kHz-

10 kHz, 20 V primary resolver winding.

sinusoidal “denied” output signal for supplying

8 PTC_MOTOR Motor PTC/NTC input

9 10kHz+

10 kHz, 20 V resolver winding (carrier).

sinusoidal output signal for supplying primary

Tab. 2.21 – J5 resolver connector

DS2000 USER’S MANUAL (rev.C)

2.30

SECTION TWO – WIRING AND INSTALLATION

Fig. 2.14 – Resolver connections

DS2000 USER’S MANUAL (rev.C)

SECTION TWO – WIRING AND INSTALLATION

2.11.3 MOTOR CONNECTION

2.11.3.1 FAS T/FAS K/FAS N/FAS Y/FAE CONNECTION MOTOR RESOLVER CONNECTOR

SIGNAL

TYPE

2.31

COS- E 2 COS+ C 1 SHIELD S 3 SEN- H 12 SEN+ G 11 PTC_MOTOR N 8 10kHz- B 7 PTC_MOTOR A 9 10kHz+ D 10

Tab. 2.22 – Resolver connectors

MOTOR ENCODER CONNECTOR

SIGNAL TYPE

+5V A 0V B and V W- C W+ D V+ E V- F A+ G A- H C+ J C- K U+ L U- M B- N B+ P PTC_MOTOR R

Tab. 2.23 – Encoder connector

DS2000 USER’S MANUAL (rev.C)

2.32

SECTION TWO – WIRING AND INSTALLATION

MOTOR POWER CONNECTOR

SIGNAL

TYPE

U A A D V B B E W C C F GND D D G PTC - - H PTC - - I

MOTOR POWER CONNECTOR

SIGNAL

TYPE

U A A A V B B B W C C C GND D D D PTC - - PTC - - -

Tab. 2.24 – Power connectors

DS2000 USER’S MANUAL (rev.C)

SECTION TWO – WIRING AND INSTALLATION

2.33

2.11.3.2

G MOTOR CONNECTION

To standardize the resolver connection it is recommended for the new applications to use the new resolver connection scheme of Tab.2.25A.

RESOLVER CONNECTION

Drive resolver connector

Pin No.

Name Pin name

Motor resolver connector

on G motor

Pin No.

1 ■ COS+ S2 3

2 COS- S4 4 3 SHIELD 4 SEN+ S1 1 5 SEN- S3 2 6 PTC_MOTOR THERM 1 5 7 10kHz- R2 8 8 PTC_MOTOR THERM 2 6 9 10kHz+ R1 7

Tab.2.25A – New resolver connection scheme

The old resolver connection scheme shown in the previous revisions of this Manual and reprinted in Tab. 2.25B is still valid.

CAUTION: It is recommended not to change the old connections in case of retrofitting motors or drives.

RESOLVER CONNECTION

Drive resolver connector

Pin No.

Name Pin Name on

Motor resolver connector

G motor

Pin No.

1 ■ COS+ S4 4

2 COS- S2 3 3 SHIELD 4 SEN+ S3 2 5 SEN- S1 1 6 PTC_MOTOR THERM 1 5 7 10kHz- R2 8 8 PTC_MOTOR THERM 2 6 9 10kHz+ R1 7

Tab.2.25B – Old resolver connection scheme

DS2000 USER’S MANUAL (rev.C)

2.34

SECTION TWO – WIRING AND INSTALLATION

The ground (pin 3, drive side) has to be connected to the motor connector housing. Several motor G have as standard a NTC for thermal feedback, the DS2000 can manage PTC sensor or NTC sensor without any hardware change (see Section 6 for additional data). The resolver is looked mechanically: the customer has to perform the AUTOPHASING with the drive utilities, checking that the value for the APHAPOS parameter is –209 (±5Units) for 8 poles motor with 2 poles resolver or 45 (±5Units) for 12 poles motor with 2 poles resolver (see Section 6 for additional informations).

MOTOR POWER CONNECTOR

DS2000

GND GND GND GND

U 2 U U

V 4 V V

W 1 W W

Tab. 2.26 – Power connector

DS2000 USER’S MANUAL (rev.C)

SECTION TWO – WIRING AND INSTALLATION

2.35

2.12 DRIVE STARTING SEQUENCE

In order to properly power and enable DS2000 “The Motion Solution” series drives, it is necessary to follow a start-up sequence, in which the minimum times to fall within are indicated in order to allow the internal circuits to reach the operating voltage levels and to make the internal devices ready for enabling. The chart here below summarizes the start-up sequence and describes the possible reasons for delays:

• t

Time delay required for the following operations:

 Switching on of the 24V power supplier and input voltages stabilization  Program loading and logic circuits initialisation  Internal protections check carried out by the internal microprocessor

• t

Reset pulse to allow the reading of reference voltages, as well as the internal offsets

initialisation with already stabilized voltages.

Time needed by the drive to allow the program start-up after the reset.

• t

Charge time of DC BUS capacitors determined by the soft-start circuit and DC BUS

voltage stabilization in order to avoid start-up self induction currents

• t

Time for DRIVE OK acquisition by the control

• t

Time to allow the Drive to reach the torque and to check the proper operation of power

stages.

The respect of the times indicated in Fig. 2.15 is important to avoid wrong FAULT indications by the drive.

NOTE: The internal soft-start resistors are sized for a start-up occurring every 60 s. Lower times cause an excessive stress and can cause the breakdown of such resistors.

DS2000 USER’S MANUAL (rev.C)

2.36

SECTION TWO – WIRING AND INSTALLATION

2.13 STARTING SEQUENCE TIMES

≥ 3 s, t2 ≥ 100 ms., t3 ≥ 1 s, t4 = 3 s, t5 ≥ 100 ms., t6 ≥ 100 ms.

24Vdc

RESET (restart) pulse

230/460 V

Three-phase

DRIVE OK

DRIVE ENABLE

REFERENCE ENABLE

Fig. 2.15 – Starting sequence times

NOTES:

• Reset pulse generates a complete initialization of the card with all the voltages already stabilized; this allows a more careful reading of the voltages and a better compensation of internal offsets.

• In case the auxiliary voltage (24V

) is missing, give the RESET pulse (for a time greater

than 100 ms) after at least 3 seconds from the moment in which the drive is supplied by three-phase voltage.

• RESET is necessary only after the first drive start-up or, in case of FAULT, to restore the proper operation of drive.

• DRIVE OK signal depends upon the three-phase voltage presence, in order to allow a quick and immediate enabling of motor torque.

DS2000 USER’S MANUAL (rev.C)

SECTION TWO – WIRING AND INSTALLATION

2.37

2.14 DYNAMIC BRAKING

It is possible to execute a dynamic braking with the help of the motor torque, even in emergency condition, if the drive is not in FAULT conditions: it is necessary to follow the sequence times. At braking request, the REFERENCE ENABLE is removed and the motor brakes with all the available torque.

• t

after 100 ms (this time can be increased in case load inertia is much bigger than motor

inertia) the DRIVE ENABLE can be removed

= 100 ms

Fig. 2.16 – Dynamic braking sequence times

DS2000 USER’S MANUAL (rev.C)

2.38

SECTION TWO – WIRING AND INSTALLATION

2.15 POWER OFF

It is necessary to follow the power-off sequence times.

• t

after 100 ms (this time can be increased in case load inertia is much bigger than motor

inertia) the DRIVE ENABLE can be removed

• t

Three-phase input voltage release delayed time in order to avoid the undervoltage

FAULT.

• t

DC BUS discharge time

= 100 ms, t2 = 15 ms, t3 = 6 min. (to access the drive).

Fig. 2.17 – Power-off sequence times

REFERENCE ENABLE

DRIVE ENABLE

230/460 V

Three-phase

DS2000 USER’S MANUAL (rev.C)

SECTION TWO – WIRING AND INSTALLATION

2.39

2.16 MECHANICAL BRAKING

The FASTACT series motors have an optional electromagnetic brake with pressure springs to be supplied with 24 V

CAUTION: the brake must be used only for standing (with motor at standstill). The use of this brake for dynamic braking seriously damages the brake and reduces the braking torque.

Note 1: t

≥ 300 ms, t2 = application depending, t3 = 100 ms, t4 ≥ 200 ms

Note 2: For FASTACT motors, size 3 and size 4, t

nominal voltage (24 to 26 Vdc) at the motor terminal.

≥ 1000 ms

OFF

RELEASE

CLAMP

0 rpm

DRIVE ENABLE

24V BRAKE POWER SUPPLY

BRAKE

REFERENCE ENABLE

MOTOR SPEED

Fig. 2.18 – Mechanical braking sequence times

DS2000 USER’S MANUAL (rev.C)

2.40

SECTION TWO – WIRING AND INSTALLATION

THIS PAGE INTENTIONALLY BLANK

DS2000 USER’S MANUAL (rev.C)

SECTION THREE – ELECTROMAGNETIC COMPATIBILITY (EMC)

3.1

3. ELECTROMAGNETIC COMPATIBILITY (EMC)

3.1 INTRODUCTION

In this section are described the recommended drive installation procedure following EMC standards. EMC filters are described in the 3.3 par. and the grounding and screening in the

3.4 par. and following. The installer of the drive is responsible for ensuring compliance with the EMC regulations that apply where the drive is to be used.

3.2 EUROPEAN DIRECTIVE (89/336/EEC)

Compliance with the European Directive 89/336/EEC is required for all electric and electronic products brought onto the European market after December 31st, 1995. DS2000 drives meet the following EMC product standard related to the Directive:

EN 61800-3:1996 and EN 61800-3/A11:2000: "Adjustable speed electrical power drive systems. Part 3: EMC product standard including specific test methods". Second environment (industrial) compatibility levels.

Tests have been made in an independent test house.

3.3 FILTERS

3.3.1 FILTER TYPES

Trade-mark

Schaffner FN2070-3-06

Schaffner FN 258-7/07

Schaffner FN 258-16/07

Schaffner FN 258-30/07

Schaffner FN 258-42/07 Schaffner FN 258-55/07 Schaffner FN 258-100/35

Rated current [A] at 50°C (40°C)

(3) 250 24Vdc input

7 (8.4) 3x480

16 (19.2) 3x480 DS2000 14/42

30 (36) 3x480

42 (50.4) 3x480 DS2000 50/140

55 (66) 3x480 DS2000 60/180

100 (113) 3x480 DS2000 100/300

Max Voltage [Vac] at 50°C

Drive type / input

DS2000 3/9 DS2000 4/12 DS2000 6/15 DS2000 8/22

DS2000 20/45 DS2000 25/70 DS2000 30/90

Tab. 3.1 – Filter types

DS2000 USER’S MANUAL (rev.C)

3.2

SECTION THREE – ELECTROMAGNETIC COMPATIBILITY (EMC)

3.3.2 FILTER SIZING

The filter/drive coupling in the previous table is a standard application coupling. The filter can be undersized according to the rms input current of the actual application. This should be done not only because, as a mat-ter of fact, undersizing the filter means less money, but because the undersized filter provides better performance to EMC.

3.3.3 FILTER DIMENSIONS

Top View

Side View

Trade-mark

Schaffner FN2070-3-06* Schaffner FN 250-6/07* Schaffner FN 250-12/07* Schaffner FN 258-7/07 Schaffner FN 258-16/07 Schaffner FN 258-30/07 Schaffner FN 258-42/07 Schaffner FN 258-55/07 Schaffner FN 258-75/34 Schaffner FN 258-100/35

L1 L2 L3 L4 L5 L6 L7

85 75 54 0 65 40.3 faston 0.25 85 75 54 0 65 30 300 0.24

85 75 54 0 65 40 300 0.31 255 240 50 25 305 290 55 30 335 320 60 35 305 150 400 1.8 329 314 70 45 300 185 500 2.8 329 314 80 55 300 185 500 3.1 329 314 80 55 300 220

379

±1.5

364

Dimensions [mm]

±0.8

225

±0.8

275

±0.8

350

±1.2

126

±0.8

142

±0.8

220

±1.5

300 1.1 300 1.7

Terminal

block

Terminal

block

* = the FN2070-3-06 filter have faston at both sides * = the FN250-6/07 filter have wiring leads (length=300mm) at both sides * = the FN250-12/07 filter have wiring leads (length=300mm) at both sides

Weight

[kg]

5.5

Tab. 3.2 – Filter dimensions

DS2000 USER’S MANUAL (rev.C)

SECTION THREE – ELECTROMAGNETIC COMPATIBILITY (EMC)

3.3.4 FILTER INSTALLATION

The filter must be mounted on the same drive panel. CAUTION: leave a clear space at least 60mm around the filter for air circulation when the

cabinet does not have forced ventilation. The filter must be connected as close as possible to the cabinet input. If the separation

between filter and drive exceeds around 30 cm (1 ft.) then a shielded cable should be used for the RF connection between filter and drive.

NOTE: when mounting the drive and the filter to the panel, it is essential that any paint or other covering material be removed before mounting the drive and the filter.

The maximum torque of mounting screws at terminal block is as follows:

FILTER Max torque

FN 258 - 7/07 0.8 Nm FN 258 - 16/07 0.8 Nm FN 258 - 30/07 1.8 Nm FN 258 - 42/07 1.8 Nm FN 258 - 55/07 3.0 Nm FN 258 - 75/34 3.0 Nm FN 258 - 100/35 4.0 Nm

3.3

Tab. 3.3 – Maximum torque of mounting screws at terminal block

WARNING: the filter can produce high leakage currents (see Filter Data Sheets) WARNING: the filter must be connected to ground before connecting the supply WARNING: High Voltage - Discharge time approx. 10 seconds

DS2000 USER’S MANUAL (rev.C)

3.4

SECTION THREE – ELECTROMAGNETIC COMPATIBILITY (EMC)

3.4 WIRING AND GROUNDING

All the following cables must be shielded, with 85% minimum shielding coverage: Power - Power motor cable

- External recovery resistor cable

- DC-BUS cable

Signal - Encoder cable (see Fig. 3.1)

- Resolver cable (see Fig. 3.1)

- RS485 / CAN BUS cable

- J2A, J2B, J2C cable

- 24V power supply cable

- Restart Interlock cable

- 24V fans cable (only size E)

Fig. 3.1 – Grounding of shield to connectors at motor side

NOTES:

 If a power terminal board is used at motor side, the shield must be RF connected to a metallic PG gland.  The shields of the cables must be connected at both ends to the proper housing via full circumferential bond to metallic connectors or hose clamps.

 In case of Sub-D connector, cable shield must be grounded to the metallic hood.  When there is not metallic connector at drive side, a kit with stand-off, screws and

metallic hose clamps is provided. The shield of the cable must be uncovered from insulation coating and RF connected to the stand-off through the metallic hose clamp, as in Fig.3.2.

Fig. 3.2 – Grounding of shield without metallic connector

DS2000 USER’S MANUAL (rev.C)

SECTION THREE – ELECTROMAGNETIC COMPATIBILITY (EMC)

3.5

Fig. 3.3 – A and B size connections drive side

Cable 1 = J2A, J2B, J2C Cable 2 = Motor power Cable 3 = Recovery resistor and –AT Cable 4 = Safety - Restart Interlock (optional)

NOTE:Unshielded (three-phase power supply) and Sub-D cables are not shown in the figure.

DS2000 USER’S MANUAL (rev.C)

3.6

SECTION THREE – ELECTROMAGNETIC COMPATIBILITY (EMC)

Fig. 3.4 – C size connections drive side

Cable 1 = J2A, J2B, J2C Cable 2 = Motor power Cable 3 = Recovery resistor and +/-AT Cable 4 = Safety - Restart Interlock (optional)

NOTE:Unshielded (three-phase power supply) and Sub-D cables are not shown in the figure.

DS2000 USER’S MANUAL (rev.C)

SECTION THREE – ELECTROMAGNETIC COMPATIBILITY (EMC)

3.7

Fig. 3.5 – D size connections drive side

Cable 1 = J2A, J2B, J2C Cable 2 = Motor power and +/-AT Cable 3 = Recovery resistor Cable 4 = Safety - Restart Interlock (optional)

NOTE:Unshielded (three-phase power supply) and Sub-D cables are not shown in the figure.

DS2000 USER’S MANUAL (rev.C)

3.8

SECTION THREE – ELECTROMAGNETIC COMPATIBILITY (EMC)

Fig. 3.5.1 – E size connections drive side

Cable 1 = J2A, J2B, J2C Cable 2 = Motor power and +/-AT Cable 3 = Recovery resistor Cable 4 = Safety - Restart Interlock (optional)

NOTE:Unshielded (three-phase power supply) and Sub-D cables are not shown in the figure.

DS2000 USER’S MANUAL (rev.C)

SECTION THREE – ELECTROMAGNETIC COMPATIBILITY (EMC)

3.9

It is not necessary to shield the input power wires. A shielded cable should be used between filter and drive if the separation exceeds 30 cm.

The shields of cables inside the cabinet must be 360° clamped to the cabinet wall (see Fig. 3.6).

Fig. 3.6 – Backpanel connection

The power cables must be kept away from signal cables by at least 30 cm. When the power cables cross the signal cables, this intersection must be done with angles as near to 90° as possible.

The crossing of the cabinet should be accomplished with a low impedance (RF) connection between cable shield and enclosure. If a connector is not involved, the shortest practical lengths of connecting strap should be used (see Fig.3.7).

Fig. 3.7 – Partition penetration

DS2000 USER’S MANUAL (rev.C)

3.10

SECTION THREE – ELECTROMAGNETIC COMPATIBILITY (EMC)

3.5 RECOVERY RESISTOR

To meet the EMC Directive the enclosures containing the recovery resistors must be conductive. The recovery resistor cable must be shielded and the shield must be 360° clamped at both sides.

NOTE: before mounting the enclosure of recovery resistor to the panel make sure that any paint or other covering material be removed.

3.6 SCREENING

To effectively screening the system all the single screens (CNC, electronic cabinet, machine, motor housing, cables) must be connected together to effectively form one screen.

3.7 SAFETY ASPECTS

Noise suppression of motor and drive systems involves consideration of the grounding system, and its effective-ness at high frequencies. It should not be forgotten the safety aspect and that the safety must take priority over EMC.

To reduce the radiated emissions, the use of capacitance to ground is very effective. In fact, Schaffner filters have Y-type capacitors near the input power supply connector. These capacitors leak current from phase to ground; this can be in the order of hundreds of milliamperes.

WARNING: appropriate safety measures should be taken to ensure that this potentially dangerous current flows to ground.

CAUTION: it is recommended to disconnect the drive and the EMC filters to carry out the AC Voltage Tests of EN 60204-1:1997, par.19.4, in order to not damage the Y-type capacitors between phases and ground. Moreover the DC voltage dielectric test required by EN 50178:1997, product family standard, has been carried out in factory as a routine test. The DC Insulation Resistance Tests of EN 60204-1:1997, par.19.3, may be carried out without disconnecting the drive and the EMC filters.

DS2000 USER’S MANUAL (rev.C)

SECTION FOUR – STARTING

4.1

4. STARTING

4.1 INTRODUCTION

The purpose of this section is to provide a series of suggestions to make the first start-up of a DS2000 drive, connected to a Moog motor, easier. All the information hereinafter are easy and descriptive, in order to be clearly understood even by personnel not skilled in servosystems installation. Please, refer to the previous sections to search for any eventual missing information on cable connections. Please, refer to Section 6 for a detailed description of motor and drive parameters.

DS2000 USER’S MANUAL (rev.C)

4.2

SECTION FOUR – STARTING

4.2 DRIVE SETTING UP INFORMATION

To set a drive it is necessary to search for some information, unless Moog already set them upon customer’s request. It is necessary to know:

a) Motor settings

1) Number of motor poles

2) Motor max current

3) Motor voltage rating

4) Motor nominal speed

5) Motor BEFM (at 1000 rpm)

6) Motor resistance

7) Motor inductance

8) ID magnetization current (only for vectorial control asynchronous motors)

9) SG slip (only for vectorial control asynchronous motors)

10) Motor thermal feedback (PTC or NTC)

11) Resolver or Encoder feedback

12) Starting Speed for FASG algorithm (required only for G motor at high speed)

13) Max phase angle for FASG algorithm (required only for G motor at high speed)

14) Number of encoder pulses or number of resolver poles

15) Number of pulses per electrical revolution needed by the CNC (for resolver interface only)

16) Zero marker width (for resolver interface only)

NOTE: It is not possible to modify the number of output pulses and the zero marker width using the Encoder feedback. Such function is available only using resolver feedback.

b) Drive settings

1) Remote control for drive enable

2) Max speed requested to motor

3) Max current supplied by the drive

4) Speed or torque control; set speed control mode when drive is used for tests

5) ACC/DEC value (only in speed control mode; function is disabled when set to 0)

6) Reference analog control

7) Digital (managed by drive) or analog (managed by control) current (torque) limit

8) VKI and VKP (integral and proportional gain) according to the applied load

9) LPF filter on error and reference, and Notch

10) Anti Free wheeling function if required (perform a velocity stop if motor is in OVT, drive is in OVT, mains is lost)

11) Protection on RR parameters if required

12) Drive I2T protection parameters if required

13) Dead band amplitude on analog references if required

CAUTION: The installation can be carried out also without some of the above information because it is possible to enter them later using the built-in keypad or the WinDrive GUI program.

DS2000 USER’S MANUAL (rev.C)

SECTION FOUR – STARTING

4.3

NOTE:

The display shows immediate information about motor and drive status by means of lighting:

• The display is lit with full light if no FAULTS are detected

• The display is lit with reduced intensity in case of FAULTS (refer to Section 6)

4.3 FIRST START-UP (ON TEST BENCH, FOR TESTING PURPOSES)

First, connect the power supply (both in case of 24 Volt and alternating voltage option). Connect the feedback (resolver or encoder) and motor power cable, to also control the motion. Power the drive without giving the DRIVE ENABLE and the REFERENCE ENABLE. The display must be lit, it is to say not in alarm condition; otherwise, check alarms in the appropriate menu. Hand-rotate the motor shaft in order to check the proper reading of feedback information by the drive and eventually check the motor speed reading following the instructions contained in the Display menu described in Section 6. To control also motor motion, supply the three-phase alternating voltage and give the DRIVE ENABLE and the REFERENCE ENABLE. It will be possible to move the motor with the given settings if connections are not wrong. If movements are missing, refer to Section 7 (Troubleshooting).

4.3.1 FEEDBACK CONNECTION (ENCODER OR RESOLVER)

Feedback connection must always be made according to the specification in section 2 even if drive power supply is made only for testing purposes. Inadequate connections (i.e.: unshielded cables) cause feedback and motor control errors.

4.3.2 “TEMPORARY” OR TEST POWER WIRING

In order to carry out a drive test, it is possible to supply the DS2000 with power in two ways:

• By a 24 VOLT, 1.5 A source

• By an alternating v oltage (both s ingle-phas e and three-phase) between 120 and 510 V

(if the drive is supplied with a voltage lower than 120V

it is necessary to supply a 24

Vdc auxiliary voltage, as the internal power supplier cannot properly work). The 24 Volt solution allows a safe setting and testing the signal connections without dangerous voltages.

NOTE: it is not possible to enable the output stages when DC BUS is not supplied with power giving a DRIVE ENABLE signal, otherwise the drive will signal a DC BUS UNDERVOLTAGE FAULT condition.

When drive is connected for test purposes only, it is possible to use a common, unshielded cable, both for power input and to connect the motor power.

DS2000 USER’S MANUAL (rev.C)

4.4

SECTION FOUR – STARTING

4.3.3 TEMPORARY CONNECTIONS

The cross section of the cable connecting the drive to power line and to motor can be lower than the one recommended for drive size if drive peak current will not be supplied and the connection is made only for setting and checking purposes, and the motor is used at low speed and reduced torque. Even if a soft-start circuit is always present and active on each drive, it is recommended to protect the power input line with fuses or a circuit breaker; anyway, the current absorbed by the drive during the soft-start is limited by a resistor.

NOTE: Remember to wait at least 60 s between two power switches in order to allow the internal soft-start resistor to properly dissipate the accumulated energy.

4.4 CONFIGURATION FOR INSTALLATION IN ELECTRICAL CABINET

Additional settings for installation in the electrical cabinet concern the torque remote enable setting in order to allow the CNC to control torque supply, when requested, giving the DRIVE ENABLE hardware signal. Remember to eliminate the settings used on test bench that eventually limit performances.

DS2000 USER’S MANUAL (rev.C)

SECTION FIVE – COMPONENT DESCRIPTION

5. COMPONENT DESCRIPTION

5.1 INTRODUCTION

This section provides descriptions for the DS2000 Series Drives.

5.1

DS2000 USER’S MANUAL (rev.C)

5.2

SECTION FIVE – COMPONENT DESCRIPTION

5.2 HIGH POWER INPUT SECTION

The high power supply section has the following features:

• Three Phase AC Operation

• Direct Off-Line 230 V

• Soft-start (AC Inrush Current Limiting)

• Input Varistor Transient Protection

• Drive Ready Relay (DROK)

• Provision for External Recovery Resistor

• Integral Heat Sink and Cooling Fans

• Input 24V Logic Backup

• Internal inductance only for size E

These features are described in the next sections.

WARNING: High Voltage. Bus Bar’s can have voltage ≥810V

(capacitive voltage). Discharge Time approx. 6 Minutes.

WARNING: High Voltage. The recovery resistor is connected to the Bus Bar’s and can have

voltage ≥810Vdc.

WARNING: do not touch recovery resistor during operation to avoid scalds.

5.2.1 CIRCUIT DESCRIPTION

The high power supply consists of four functional blocks:

• High voltage rectification and filtering

• Soft-start of AC mains power-on

• Low voltage control power supply

• Recovery circuit

to 460V

rms

±10% Operation

rms

even after switching off

DS2000 USER’S MANUAL (rev.C)

SECTION FIVE – COMPONENT DESCRIPTION

5.2.1.1 HIGH VOLTAGE RECTIFICATION AND FILTERING

The AC mains input is rectified by a three-phase diode bridge and filtered by a bank of electrolytic capacitors to generate the internal DC BUS. This high power DC supply is unregulated and will vary in direct proportion with the AC mains input voltage magnitude.

Inductance only for size E

5.3

Fig. 5.1 – Power input section

5.2.1.2 SOFT START

Soft start is used to limit the inrush current to the DC BUS capacitor bank on application of AC mains power. This is intended to prevent blowing of line fuses on power-up. The switch is a relay on DS2000 Series up to size B. It is an SCR on the other sizes. The soft start switch will close when the monitoring circuit and associated control software determines that the high-voltage DC BUS has charged up and the DC BUS is at steady state. If the DC BUS voltage suddenly changes at drive enable, it is possible that troubles are present on the three-phase power line (interrupted fuse, missing connection, or inadequate power supply) and the drive gives an error signal.

5.2.1.3 LOW VOLTAGE CONTROL POWER SUPPLY

Control power for the logic circuits is generated by a DC/DC converter, which provides control-circuitry power that is isolated from the mains input. This control voltage also powers the cooling fans.

DS2000 USER’S MANUAL (rev.C)

5.4

SECTION FIVE – COMPONENT DESCRIPTION

5.2.1.4 RECOVERY CIRCUIT

Rapid motor deceleration or an overhauling load creates a situation in which energy is returned back into the DC BUS. This recovery energy will charge up the power supply DC BUS capacitors. To prevent capacitor overvoltage, a shunt regulator circuit senses when the DC BUS voltage exceeds the recovery cut-in voltage and via a recovery IGBT, switches a recovery resistor across the DC BUS to dissipate the recovery energy. Hysteresis in the circuit keeps the recovery circuit active until the DC BUS voltage is reduced below the recovery cutout voltage. The drive controls the braking circuit thresholds according to the different power supply voltages with no need for hardware calibration or setting.

WARNING: High Voltage. The recovery resistor is connected to the Bus Bar’s and can

have voltage ≥810Vdc.

WARNING: do not touch recovery resistor during operation to avoid scalds. CAUTION: In applications where the working cycle implies decelerations with high inertial

loads, from high velocity in very short deceleration time, it is necessary to properly size the recovery resistor. In these cases, please contact Moog Service Centers.

DS2000 USER’S MANUAL (rev.C)

SECTION FIVE – COMPONENT DESCRIPTION

5.2.1.4.1 RECOVERY RESISTOR PROTECTION

In order to thermally protect the recovery resistor a set of parameters has been provided in the menu. These parameters are:

• Resistor (RECOVERY RESIST. RESREC)

• Power (RECOVERY RESIST. POWER)

• And recovery coefficient (RECOVERY RESIST. COEFF)

The parameters to be set with the standard recovery resistors are shown in tab 5.1.

Drive Size

Max

peak

Current [A]

Resistor

Value [Ω]

Resistor

Power [W]

Coeff.

Value

3/9 10.0 75 (ext.) 100 71 4/12 10.0 75 (ext.) 100 71 6/15 14.7 51 (ext.) 200 53 8/22 14.7 51 (ext.) 200 53 14/42 22.7 33 (ext.) 250 43 20/45 62.5 12 (ext.) 370 74 25/70 62.5 12 (ext.) 370 74 30/90 62.5 12 (ext.) 370 74 50/140 75.0 10 (ext.) 750 21 60/180 75.0 10 (ext.) 750 21 100/300 192.3 3.9 (ext.) 1000 17 3/9 9.1 82 (int.) 150 84 4/12 9.1 82 (int.) 150 84 6/15 13.4 56 (int.) 150 78

5.5

Tab. 5.1 – Setting protection coefficient of recovery resistor

With 230 Vac mains power supply a more efficient series of recovery resistors can be used. These optional resistors with the appropriate parameters are shown in tab 5.2.

Drive Size

Max

peak

Current [A]

Resistor

Value [Ω]

Resistor

Power [W]

Coeff.

Value

3/9 10.0 47 (ext.) 100 69 4/12 10.0 47 (ext.) 100 69 6/15 14.7 33 (ext.) 250 45 8/22 14.7 33 (ext.) 250 45 14/42 22.7 22 (ext.) 240 69 20/45 62.5 6.8 (ext.) 370 63 25/70 62.5 6.8 (ext.) 370 63 30/90 62.5 6.8 (ext.) 370 63 50/140 75.0 5.6 (ext.) 750 19 60/180 75.0 5.6 (ext.) 750 19 100/300 192.3 2.2 (ext.) 1000 17 3/9 9.1 47 (int.) 150 87 4/12 9.1 47 (int.) 150 87 6/15 13.4 33 (int.) 150 80

Tab. 5.2 – Setting protection coefficient of recovery resistor

DS2000 USER’S MANUAL (rev.C)

5.6

SECTION FIVE – COMPONENT DESCRIPTION

In applications where high or continuous recovery energy is anticipated, consult your Moog sales representative, requesting an application review. In case of different resistors, different parameters must be set.

5.3 HIGH POWER OUTPUT SECTION

The high power supply section has the following features:

• Three-phase output bridge

• PWM technology

• 10kHz switching frequency

5.3.1 CIRCUIT DESCRIPTION

5.3.1.1 HIGH POWER OUTPUT SECTION

The direct current energy available on the DC BUS is converted into current supplied to the motor by an output three-phase bridge formed by IGBT. By means of PWM technology the output currents are generated with a high energy efficiency ratio. The word PWM (Pulse Width Modulation) identifies a way of controlling the power devices in order to avoid any linear conduction status, and have only conduction and cut off status, to reduce the power dissipation. This way allows a high efficiency in energy conversion and, as a consequence, reduced energy losses. The 10kHz switching frequency allows to limit the heating effects per current ripple inside the motor.

Each IGBT is individually protected from short circuit and overload and its protection is directly managed by the control card.

Fig. 5.2 – Power output section

DS2000 USER’S MANUAL (rev.C)

SECTION FIVE – COMPONENT DESCRIPTION

5.4 CONTROL SECTION

The Control section has the following features:

• Speed loop

• Current loop

• Low-pass filters (LPF)

• Notch Filter

5.4.1 CIRCUIT DESCRIPTION

The Control Circuit consist of several functional blocks:

• Motor Feedback (size, voltage, rpm)

• Speed Feedback

• Speed loop (VKP, VKI)

• LPF Filter (frequency)

• Notch Filter ( frequency, band, gain)

• Current Feedback

• Current Loop (Rw, Lw, E1000, ID, SG)

• PWM Amplifier (limit)

• Position Feedback (APHAPOS)

5.7

Fig. 5.3 – Servosystem block diagram

5.4.1.1 HIGH POWER OUTPUT SECTION

The drive checks the current angular position in order to always keep a 90° angle between the magnetic field generated by currents and the one generated by magnets on the motor rotor. The motor position is given by the feedback signals coming from the encoder or from the resolver through an appropriate processing. According to the information existing in the setting loop, the drive processes the information concerning current width, frequency and angular position, and properly commands the IGBT to supply the currents. The current feedback is obtained by means of Hall sensors placed on U and V motor phases. The position feedback can be both the resolver and the encoder; inside the drive the two signals are managed by two separate circuits in order to obtain the same final information for the speed loop.

DS2000 USER’S MANUAL (rev.C)

5.8

SECTION FIVE – COMPONENT DESCRIPTION

LPF filters on the reference and on the speed error allow to adapt the servosystem (drive + motor) pass band to the application characteristics. The Notch filter allows to eliminate or reduce any eventual oscillation on the machine mechanics be-cause of the limited rigidity of the motor transmission parts (mechanical transmissions, belts, etc.), specially in presence of high inertia ratios between motor and load (mismatching load condition).

5.4.1.1.1 LOW AND HIGH SPEED OPERATION

Current control loop has two different working conditions: Low speed and High speed. The difference is determined by motor voltage with respect to the available output voltage on motor phases. At low speed, the voltage supplied by the drive is higher than the one generated by the motor, and the field generated by current is in phase with the field generated by magnets. At high speed, the motor voltage can be compared to the voltage available from the drive; the relevant phase between the magnetic fields is automatically changed in order to keep such a voltage margin as to allow an optimal current adjustment. This algorithm allows an optimal exploitation of motor characteristics, supplying the same peak torque both at low and high speed, with a higher peak power available for machinery motion. It is also possible to wind the motors with a higher torque constant; thanks to this feature, in many applications, it is possible to use a drive supplying a lower current to obtain the same peak torque at motor output. All the motors produced by Moog, are provided with this feature and give high performances at high rotation speed. An additional phase shift is given by the G motors Algorithm, suggested mainly for motors having high poles number (8 or 12) and running at speed over 3000 rpm.

Standard Drive Phase max V=1/2 Vbus

DS2000 Drive Phase max V>1/2 Vbus

DS2000 USER’S MANUAL (rev.C)

SECTION FIVE – COMPONENT DESCRIPTION

5.4.1.1.2 ENCODER/RESOLVER SIGNALS COHERENCE CONTROL

The drive carries out a control on the encoder high and low transition coherence and on the resolver phases sequence. By manually rotating the motor, with drive supplied only with 24 Vdc, it is possible to carry out a control of the connection between feedback and drive; any eventual fault signal in dicates feedback problems (see Section 7).

5.4.1.2 CONTROL LOOPS

5.4.1.2.1 CURRENT LOOP

• The current loop is based on a PI structure with motor electromotive force (B.E.M.F.) compensation on speed variation.

• The implemented algorithms allow to adjust integral and proportional gains by entering data via keyboard or Windrive GUI with no drive instruments or test bench calibration.

• Only data concerning Electric Resistor (Rw), Motor inductance (Lw), and Motor electromotive force (B.E.M.F.) are needed to adapt the current loop frequency response to the motor characteristics.

• The electromotive force compensation allows the increase the peak current that can be supplied at high speeds because the loop compensates the voltage associated to the supplied current and to the current generated by motor, dephasing the currents position.

• The loop structure also compensates the phase shift introduced by the current sensors and by the interface circuits, allowing a null phase shift and a “flat” phase response between 0 and approx. 800 Hz, independently of the controlled motor model.

• The loop closing, at a frequency of 10 kHz, allows to dynamically compensate the inductance, resistor, and electromotive force variation of the motor at load and motor rotor angular position variation.

5.4.1.2.2 CURRENT LOOP OPTIMIZATION

The current loop optimization is automatically carried out by entering the motor physical characteristics: Resistor, Inductance, and Electromotive Force. Such data must be entered in physical units: the Resistor in Ohm, the Inductance in mH (milliHenry) and the Electromotive Force in Volt at 1000 rpm. The drive automatically adjusts the current loop gains and carries out the angular correction as a function of the motor rotation speed and of the torque requested to motor. No other customer calibration is needed, except for entering the motor physical parameters.

Note: If the output current at high speed (max working speed) is too high, it is possible trying to reduce it, reducing the motor inductance value (-20 %) and reducing the motor BEMF value; the reason is linked to the motor reluctance, that change in the motor revolution

5.9

DS2000 USER’S MANUAL (rev.C)

5.10

SECTION FIVE – COMPONENT DESCRIPTION

5.4.1.2.3 SPEED LOOP

• The speed loop has a simple PI structure.

• Through the KI and KP gains the servosystem response can be adapted to the

applied load.

• The control loop is closed with a frequency of 5 kHz.

• The pass band is internally limited via software at 400 Hz; the phase shift is missing

for the usable pass band.

• The loop allows the setting of the “higher frequency” of the pass band because it is

proportional to VKI (axis rigidity at low speed).

• The VKP value allows to control the oversho ot when set speed is reached

(higher gain,higher control)

• A low-pass filter of the second order is placed on the speed error to limit the frequency response in case of device oscillation that cannot be compensated by changing CNC or drive gains.

• System excessive gains can cause a reduction of the supplied torque due to the excessive pass band and to the aliasing effect on the servo system main frequencies.

5.4.1.2.4 SPEED LOOP OPTIMIZATION

The speed loop optimization is carried out adjusting VKI and VKP parameters, which correspond, respectively, to the speed loop Integral and Proportional Gain, as well as properly adjusting the filters, if necessary. It is possible to minimize the error acting on VKI and VKP gains during the device operation thus obtaining the required response.

DS2000 USER’S MANUAL (rev.C)

SECTION SIX – COMMANDS

6.1

6. COMMANDS

6.1 INTRODUCTION

The six keys on the drive front panel allow the visualization of the whole menu as well as the relevant drive configuration. A further key allows the display contrast adjustment. The keys can be divided according to their function:

• ENTER. This key allows to enter a menu and browse it. The variables scanning inside a menu is recursive. In some cases, this key activates a routine function (i.e. inside the “Utility” menu).

• < >. These keys allow the menu horizontal scrolling from right to left and vice versa.

• + -. These keys allow to increase and decrease a variable. Holding the key down approx.

5 s the fast forward starts.

• ESC. This key allows to go back inside the menu or terminate a function.

• ☼. Holding down the yellow key, it is possible to adjust the display contrast by means of

the + / - keys. In order to keep the setting, it is necessary to save the parameters before switching off the drive.

Fig. 6.1 – DS2000 front panel

NOTES:

• First screen at drive start-up show you the DS2000 size. The DRIVE ENABLE and REFERENCE ENABLE signals are shown in the start-up screen on the display by two stylized letters: “D” and “R” respectively.

• The first menu level can be accessed pressing ENTER. The first level is characterized by the two <> arrows which indicate the possibility of scrolling the menu from right to left. To access the menu, press ENTER. To go to the following parameter, press ENTER or < and > keys. The parameter scanning is recursive.

• To exit the menu, press ESC. Keep on pressing if the displayed parameter is not the first item of the menu.

DS2000 USER’S MANUAL (rev.C)

6.2

SECTION SIX – COMMANDS

• When the parameter to be modified is reached, press +/- to increase or decrease the variables.

• At start-up, after a reset, or a saving of parameters, the drive is in “locked keyboard” status in order to avoid parameters and system settings accidental modifications. To modify parameters it is necessary to unlock the keyboard. To unlock the keyboard it is necessary to activate the function “unlocked keyboard” inside the “Keyboard locked” menu (see cap. 6.8).

• In order to save the modified parameters the function “Save Parameters” inside the “Utility menu” should be used; the saving occurs only when drive is not enabled.

• In case of FAULT, the display light intensity is reduced.

• The main menu is not “circular”; when the bottom is reached, press ESC or < to go back.

The Enter button can be used to go forward the menu.

6.2 MOTOR PARAMETERS MENU

Fig. 6.2 – Motor parameters menu

DS2000 USER’S MANUAL (rev.C)

SECTION SIX – COMMANDS

6.2.1 MOTOR PARAMETERS MENU DESCRIPTION

MOTOR PARAMETERS POLES= Allowed values:

from 2 to 24 in 2 unit steps

MOTOR PARAMETERS SIZE= Allowed values:

from 1.0 A to the peak current supplied by the drive in 100mA steps

MOTOR PARAMETERS VOLTAGE= Allowed values:

• 230 V (for 230 V motors)

• 400 V (for 400/460 V)

MOTOR PARAMETERS SPEED= Allowed values: from 100 rpm to 9999 rpm in 10 rpm steps

MOTOR PARAMETERS BEMF= Allowed values:

from 0 V to 750 V in 1 unit steps

MOTOR PARAMETERS Rw= Allowed values:

from 0 Ω to 100 Ω in 0.1 unit steps

MOTOR PARAMETERS Lw= Allowed values:

from 0 mH to 200 mH in 0.1 unit steps

Description: it indicates the number of motor poles Note: set the values indicated on the nameplate of

the motor or refer to the data indicated on the motor catalogue.

Description: it indicates the motor peak current value Note: If this value is not available, it is possible to

obtain the peak current by means of the following formula:

peak

where Tm is the max torque in Nm and Kt is the motor torque constant in Nm/A

Description: it indicates the motor winding voltage

rating value

Note: set the values indicated on the nameplate of

the motor or refer to the data indicated on the motor catalogue

Description: it indicates the nominal motor speed Note: set the values indicated on the nameplate of

the motor or refer to the data indicated on the motor

catalogue

Description: it indicates the motor generated backelectromotive force value at 1000 rpm. Note: the drive uses this information to optimize the

current loop as a function of the motor rotation velocity. If this value is not available, it is possible to obtain the BEMF by means of the following formula:

BEMF=K

where K

Description: it indicates the motor resistance value, measured between phase and phase Note: set the values indicated on the nameplate of

the motor or refer to the data indicated on the motor catalogue. If this value is not available, it is possible

to obtain it using a multi-meter (set as an ohm-meter)

Description: it indicates the motor inductance value, measured between phase and phase Note: set the values indicated on the nameplate of

the motor or refer to the data indicated on the motor catalogue. If this value is not available, it is possible to obtain it using a multi-meter (set as an inductancemeter).

Attention: for G motors use the L

=1.41*Tm/Kt

*60.4

is the motor torque constant in Nm/A

value instead of L

6.3

DS2000 USER’S MANUAL (rev.C)

6.4

APHAPOS=

Allowed values: from 0 to ±255 in 1 unit steps

MOTOR PARAMETERS ID=

Allowed values:

from 0 to the peak current supplied by the drive in

100mA steps

MOTOR PARAMETERS SG=

Allowed values: from 0 to 100 in 0.1 unit steps

INI PHASE SHIFT=

Allowed values: from 100 to max speed drive in 10 unit steps

MAX PHASE SHIFT= Allowed values:

from 0 to 50 in 1 unit steps

PTC/NTC SEL.= Allowed values:

• 0 (for PTC thermal feedback)

• 1 (for NTC thermal feedback)

ENCODER<>RESOLVER Allowed values:

• ENCODER (for ENCODER feedback)

• RESOLVER (for RESOLVER feedback)

SECTION SIX – COMMANDS

Description: It indicates the phasing value correction

between the position feedback (resolver or encoder)

and the motor phases Note: this value can be automatically modified by the

PHASING procedure.

Note: the APHAPOS value can be manually entered

by the keyboard without the PHASING procedure.

Note: the APHAPOS values follows:

• APHAPOS = 0 for FAS T, FAS N, FAS K motors

• APHAPOS = 125 only for FASK motor with 2

resolver poles

• APHAPOS = -209 for G 8 poles motor with 2

resolver poles

• APHAPOS = 45 for G 12 poles motor with 2 resolver poles

Description: it indicates the magnetization current

value when using an asynchronous motor in vector

control mode

Note: set the values indicated on the motor catalogue

Description: it indicates the slip frequency (gain)

value for asynchronous motors control working in

vector control mode Note: set the values indicated on the motor

catalogue. If this value is not available, it is possible

to obtain it analyzing the response to transients

Description: it indicates the starting speed for the G

motors algorithm, to improve phase shift at high speed mainly for motors having 8-12 poles and

rotating over 3000 rpm Note: see related application notes for additional details

Description: it indicates in electrical degrees the max phase angle of the above algorithm Note: see related application notes for additional details

Description: Allow the selection between PTC or NTC as thermal feedback Note: set the thermal feedback according to motor data

Description: it indicates the type of motor feedback Note:

DS2000 USER’S MANUAL (rev.C)

SECTION SIX – COMMANDS

6.2.2 RESOLVER PARAMETERS POLES

RESOLVER PARAM. POLES= Allowed values:

from 2 to 24 in 2 unit steps

ENC.OUT.PULSES CONFIGURATION= Allowed values:

from 64 to 1024 pulses for resolver polar couple in power of 2n

ZERO LENGTH= Allowed values:

• 90°

• 180°

• 360°

6.2.3 ENCODER PARAMETERS DESCRIPTION

MOTOR PARAMETERS ENCODER= Allowed values:

from 1024 to 8192 in 512 unit steps

6.5

Description: it indicates the resolver poles number Note: set the values indicated on the nameplate of

the motor or refer to the data indicated on the mo-tor catalogue

Attention: available only with resolver feedback

mode

Description: it indicates the number of encoder

pulses output on J2C connector

Note: drive generates output pulses dividing the input

pulses anyway used for motor control

Attention:

- available only with resolver feedback mode

- to set a new configuration it is necessary to save and reboot

Description: it indicates the marker width for drive

electric loop measurement output on J2C connector

Note: drive generates output pulses dividing the input

pulses anyway used for motor control

Attention:

- available only with resolver feedback mode

- to set a new configuration it is necessary to save and reboot

Description: it indicates the number of motor

encoder pulses

Note: set the values indicated on the nameplate of

the motor or refer to the data indicated on the motor catalogue.

Attention: available only with encoder feedback

mode

DS2000 USER’S MANUAL (rev.C)

6.6

SECTION SIX – COMMANDS

6.3 DRIVE PARAMETERS MENU

Fig. 6.3 – Drive parameters menu

DS2000 USER’S MANUAL (rev.C)

SECTION SIX – COMMANDS

6.3.1 DRIVE PARAMETERS MENU DESCRIPTION

DRIVE ADDRESS DRVADDR= Allowed values:

from 1 to 63

PTCNTC THRESHOLD= Allowed values:

from 100 Ω to 10000 Ω in 1 unit steps

RECOVERY RESIST. RESREC= Allowed values:

from 3 Ω to 100 Ω in 1 unit steps

RR PROTECTION

Allowed values:

• 0 (for protection disabled)

• 1 (for protection enabled)

RECOVERY RESIST. POWER= Allowed values:

from 10 W to 6400 W in 1 unit steps

RECOVERY RESIST. COEFF.= Allowed values:

from 1 to 32000 in 1 unit steps

TACHO SCALE= Allowed values:

from 5 V to 10 V in 100 mV unit steps

ANAL.REF. ZERO BAND=

Allowed values:

from 0 to 128 (128 units = 0.625 V) in 1 unit steps

Description: it indicates drive address for serial

communication

Note: set a progressive and different value per each

drive to obtain only one serial line to interrogate all the drives existing in the machine

Description: it indicates NTC/PTC threshold value

used to protect motor from overtemperature

Note: set following value for Moog motor:

• 1200 Ω for PTC thermal feedback

• 6500 Ω for NTC thermal feedback

Description: it indicates the recovery resistor value Note: set the value indicated on the drive label. If the

precise value is not available, set the higher one. If the value is too high the drive will not be able to dissipate the recovered energy

Description: protection against recovery resistor

thermal overload

Note: see section 7 for additional details on this

function setup

Description: nominal resistor power, used for

resistor thermal protection

Note: see section 7 for additional details on this

function setup

Description: special parameter, used for resistor

thermal protection

Note: see section 7 for additional details on this

function setup

Description: it indicates the max tacho signal value

obtained at max number of motor revolutions

Note: setting 10 V for the max speed value allows to

obtain a simple and direct ratio between read value and speed

Description: set a dead band on the speed/torque

analog reference. Under this value the input is not acquired

Note: it is useful to cut random or too big offset from

CNC. Set to 0 for normal operation

6.7

DS2000 USER’S MANUAL (rev.C)

6.8

SECTION SIX – COMMANDS

ANTIFREEWHEELING

Allowed values:

• 0 (for disabled)

• 1 (for enabled)

I2T IGBT PROTECT Allowed values:

• 0 (for disabled)

• 1 (for enabled)

TIME I2T IGBT= Allowed values: from 100 ms to 1000 ms in 10 ms unit steps

FAULT I2T IGBT Allowed values:

• 0 (for disabled)

• 1 (for enabled)

NOTCH FILTER Allowed values:

• 0 (for disabled)

• 1 (for enabled)

NOTCH FREQUENCY=

Allowed values: from 50 Hz to 1500 Hz in 1 unit steps

Description: enable ANTIFREEWHEELING function

in following conditions:

• motor overtemperature

• drive overtemperature

• power lost

The drive brakes until null velocity is reached. If recovered power is not enough the drive will shut down without reaching null velocity. DRIVE ENABLE signal has to be applied to activate this function

Note: ACCELERATION and DECELERATION ramps

are active for a proper operation and emergency stop

Description: enable I2T protection on IGBT if output frequency is lower than 5kHz Note: enabling I2T IGBT PROTECT, NOTCH FILTER

will be automatically disabled

Note: when this protection is active, the letters I2T

will appear on the main window (Moog DS2000)

Description: set a time for I2T trigger Note: default value is 500 ms for all DS2000 drives

Description: enable the fault reaction on I2T IGBT drive condition Note: select the “reaction” following the application

needs

• if disabled, reduce the max output current to the

rated drive current

• if enabled, fault condition (alarm and torque

disable)

Description: enable notch filter function to remove precise critical frequency Note: available only if I2T IGBT PROTECT is disabled

Description: it allows to insert in the speed

adjustment loop a Notch filter which can be

programmed in frequency Note: set directly in Hz the filter attenuation frequency

DS2000 USER’S MANUAL (rev.C)

MOOG DS2000 USER'S MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual

INDEX OF CONTENTS