Moog DS2100 User Manual
P
RELIMINARY
I
NSTALLATION
&
U
SER'S
M
ANUAL
DS2100
Digital Controller
Section 3 - Wiring and Installation
C7750-001 Rev. A 04/04
SECTION 3: WIRING AND INSTALLATION DS2100 User's Manual (Preliminary)
SECTION 3: WIRING AND INSTALLATION
PAGE 3-1
Errata Sheet DS2100 User's Manual (Preliminary)
ERRATA E:
PAGE 1
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DS2100 User's Manual (Preliminary) Errata
E.1 Introduction
This Errata sheet details changes to the preliminary release of the DS2100 Manual. The corrected information for the
manual is detailed below.
E.2 Changes
Page Description Change
1-5 Update to DS2100 Boxcar Reference to Form 757 added to Boxcar for valid
ordering numbers.
3-54, 3-74 Error in Encoder connector wiring
diagram
2-7 Line fuses specified in manual for Size
C drives incorrect.
3-64 Figure 3.46 Incorrect. Lines labelled
incorrectly
3-54, 3-74 Error in Encoder connector wiring
diagram
Clock + & Data + Lines swapped in wiring information
Clock - & Data - Lines swapped in wiring information
Changed line fuse requirements for Size C drives from
160 FEE 690V to 100 FE 690V Bussmann Fuses.
Receive and Transmit lines re-labelled to show Receive
on DS2100 side is connected to Transmit in PC side &
Transmit on DS2100 side is connected to Receive on
PC Side.
For Heidenheim endat encoder, necessary to swap
channel A and channel B signals. Required as
Heidenheim define positive direction phasing between
A & B channels in reverse to Stegmann.
PAGE 2
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DS2100 User's Manual (Preliminary) Errata
3.11.5 Motor Encoder Connection
The DS2100 encoder input supports a variety of encoders. These include Analogue, SSI, Hiperface and Endat. The
connections to the drive for each of these encoder types are given in Table 3.25.
Encoder
Connector
Figure 3.38 Motor Encoder Connector Location
- Fixed connector: 15 pin, female Sub-D connector
- Mating connector, 15pin male Sub-D
- Wiring: cable. 28-18AWG (0.14-0.82mm2)
Encoder Type
Pos Analogue SSI Hiperface Endat
J4.1 Shield Shield Shield Shield
J4.2 - Sine - - Sine - Channel B
J4.3 - Cosine - - Cosine - Channel A
J4.4 Gnd Supply Gnd Supply Gnd Supply Gnd Supply
J4.5 - - Clock - - Clock
J4.6 - Channel Z (Zero) - Data RS485 - - Data
J4.7 - - - J4.8 NTC/PTC NTC/PTC NTC/PTC NTC/PTC
J4.9 + Sine - + Sine + Channel B
J4.10 + Cosine - + Cosine + Channel A
J4.11 +5 V .. +12V
Supply (150 mA
max.)
J4.12 - Fault + Clock - + Clock
J4.13 + Channel Z (Zero)
J4.14 Gnd Supply Gnd Supply Gnd Supply Gnd Supply
J4.15 NTC/PTC NTC/PTC NTC/PTC NTC/PTC
Table 3.25 Encoder Cable Input Connections
+5 V .. +12V
Supply (150 mA
max.)
+ Data RS485 + + Data
+5 V .. +12V
Supply (150 mA
max.)
Supply (150 mA
+5 V .. +12V
max.)
PAGE 4
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Errata Sheet DS2100 User's Manual (Preliminary)
3.14.5.7 Encoder
- Fixed connector: 15 pin, female Sub-D connector
- Mating connector, 15pin male Sub-D
- Wiring: cable. 28-18AWG (0.14-0.82mm2)
Encoder Type
Pos Analogue SSI Hiperface Endat
15-Pin Sub-D Connector
Plug (male) on cable
DS2100 Cable End
J4
J4.1 Shield Shield Shield Shield
J4.2 - Sine - - Sine - Channel B
J4.3 - Cosine - - Cosine - Channel A
J4.4 Gnd Supply Gnd Supply Gnd Supply Gnd Supply
J4.5 - - Clock - - Clock
J4.6 - Channel Z (Zero) - Data RS485 - - Data
J4.7 - - - J4.8 NTC/PTC NTC/PTC NTC/PTC NTC/PTC
J4.9 + Sine - + Sine + Channel B
J4.10 + Cosine - + Cosine + Channel A
J4.11 +5 V .. +12V
Supply (150 mA
max.)
J4.12 - Fault + Clock - + Clock
J4.13 + Channel Z (Zero)
J4.14 Gnd Supply Gnd Supply Gnd Supply Gnd Supply
J4.15 NTC/PTC NTC/PTC NTC/PTC NTC/PTC
+5 V .. +12V
Supply (150 mA
max.)
+ Data RS485 + + Data
+5 V .. +12V
Supply (150 mA
max.)
Supply (150 mA
+5 V .. +12V
max.)
PAGE 5
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Errata Sheet DS2100 User's Manual (Preliminary)
3.13.1 RS232 Serial Communications Interface
The pin assignment enables use of a 9-pin Sub-D cable with all signals connected straight through.
Serial Communications
Connector (RS232)
Figure 3.45 RS232 Connector Location
- Fixed connector: 9 pin, female Sub-D connector
- Mating connector, 9 pin male Sub-D
- Wiring: cable. 28-18AWG (0.14-0.82mm2)
Pos. DS2100 Signal Function PC Signal
J1.1 - connected to pin 4 DCD input
J1.2 TxD Transmit Data RxD input
J1.3 RxD Receive Data TxD output
J1.4 - connected to pin 1 and 6 DTR output
J1.5 Gnd Gnd Gnd
J1.6 - connected to pin 4 DSR input
J1.7 - connected to pin 8 RTS output
J1.8 - connected to pin 7 CTS input
J1.9 - unused RI input
Table 3.29 J1, DS2100 RS232 Serial Interface Connector
Tx
2
Rx
3
5
Gnd
Rx
Tx
PCDS2100
2
3
5
Figure 3.46 DS2100's J1 RS232 Wire Pin-out
The RS232 Cable shield should be connected to the metal body of the D-Type connector.
PAGE 7
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DS2100 User's Manual (Preliminary) SECTION 3: WIRING AND INSTALLATION
TABLE OF CONTENTS
SECTION 3: WIRING AND INSTALLATION ........................................................................................................ 3-1
3.1 System Components .........................................................................................................................................3-4
3.1.1 A.C. Mains Power Interface......................................................................................................................3-4
3.1.2 A.C. Input Line Protection........................................................................................................................ 3-5
3.1.3 Line Filter Requirements ..........................................................................................................................3-5
3.1.4 Serial Set-up Terminal (User-Supplied) ...................................................................................................3-7
3.1.5 Control-Backup Power Input (User Supplied).......................................................................................... 3-7
3.1.6 Brushless Servo motors ............................................................................................................................3-8
3.1.7 Heatsinks and Climatic Control................................................................................................................ 3-8
3.2 Equipment Mounting ........................................................................................................................................ 3-9
3.2.1 CE Items for Mechanical Installation ..................................................................................................... 3-16
3.3 Power Dissipation........................................................................................................................................... 3-17
3.4 DS2100 Connector Terminals.........................................................................................................................3-18
3.5 General System Wiring Guidelines ................................................................................................................3-22
3.5.1 Drive Contactor (User Supplied) ............................................................................................................3-23
3.5.2 Wiring notes for J6, J7, J9 connectors (Size C)...................................................................................... 3-24
3.6 Sequence of Component Wiring Recommendations ...................................................................................... 3-25
3.7 Three-Phase A.C. Mains Power Source Configuration...................................................................................3-26
3.7.1 AC Mains Power Source Connection .....................................................................................................3-28
3.7.2 Softstart & Power Cycling Frequency Limits......................................................................................... 3-31
3.8 24V Backup Connection................................................................................................................................. 3-32
3.8.1 Size mA 24V Input Connection............................................................................................................... 3-32
3.8.2 Size A,B,C & D 24V Input Connection.................................................................................................. 3-33
3.9 Paralleling DS2100 Units through the D.C. Bus............................................................................................. 3-34
3.9.1 mA Size DC Bus Inter-connection ..........................................................................................................3-34
3.9.2 A & B Size DC Bus Inter-connection..................................................................................................... 3-35
3.9.3 C Size DC Bus Inter-connection............................................................................................................. 3-36
3.9.4 D Size DC Bus Inter-connection.............................................................................................................3-37
3.10 Internal/External Regeneration (Regen) Resistors – Configurations .............................................................. 3-38
3.10.1 mA Size Regeneration Resistor Connection............................................................................................ 3-39
3.10.2 A, B Size Regeneration Resistor connection ..........................................................................................3-39
3.10.3 C Size Regeneration Resistor connection ...............................................................................................3-40
3.10.4 D Size Regeneration Resistor connection............................................................................................... 3-41
3.11 Motors - Installation........................................................................................................................................3-42
3.11.1 Assembling Motor Resolver and Power Cables......................................................................................3-42
3.11.2 Motor Power Cable................................................................................................................................. 3-43
3.11.3 Motor Brake Connection.........................................................................................................................3-48
3.11.4 Motor Resolver Connection.................................................................................................................... 3-51
3.11.5 Motor Encoder Connection..................................................................................................................... 3-54
3.11.6 Motor Rotation Direction........................................................................................................................ 3-56
3.12 DS2100 Control Input and Outputs ................................................................................................................3-57
3.12.1 General Purpose Description of the Digital Inputs .................................................................................3-58
3.12.2 General Purpose Description of the Digital Outputs...............................................................................3-60
3.12.3 Power Sequencing on Startup .................................................................................................................3-62
3.13 Communications Interface Wiring and Configuration....................................................................................3-63
3.13.1 RS232 Serial Communications Interface................................................................................................3-63
3.13.2 CAN Cable Wiring .................................................................................................................................3-64
3.14 Wiring Summary ............................................................................................................................................3-67
3.14.1 mA Size Power Stage ..............................................................................................................................3-67
3.14.2 A & B Size Power Stage......................................................................................................................... 3-68
PAGE 3-2
SECTION 3: WIRING AND INSTALLATION DS2100 User's Manual (Preliminary)
3.14.3 C Size Power Stage ................................................................................................................................ 3-69
3.14.4 D Size Power Stage ................................................................................................................................ 3-70
3.14.5 Control Card........................................................................................................................................... 3-71
PAGE 3-3
DS2100 User's Manual (Preliminary) SECTION 3: WIRING AND INSTALLATION
This section covers the installation, wiring and cabling of the Moog DS2100 Servo-drive series. A pictorial diagram of a
single-axis system, with typical components included, is shown in Figure 3.1. Users are directed to read Section 2,
Safety Instructions, before proceeding with wiring and installation.
WARNING - This equipment must be permanently and reliably connected to Earth and
all conductive parts in the IP54 rated enclosure in which the DS2100 Series Servo-drive
is installed must be reliably connected to Protective Earth. A Protective Earth connection
must come directly from an approved AC mains network. Stranded copper-wire is
recommended to carry the earth.
FAILURE TO PROVIDE AN ADEQUATE EARTH MAY CAUSE SERIOUS
PERSONAL INJURY AND EQUIPMENT MALFUNCTION.
3.1 System Components
The following components are required to build a Moog brushless motor digital control system (refer to Figure 3.1). The
user supplies all components besides the DS2100, EMC-Brackets, motor and other accessory cabling.
3.1.1 A.C. Mains Power Interface
The DS2100 should be connected to a three-phase AC supply. Operation with a single-phase supply is only allowed with
the G361-x003 and G361-x006 variants of the drive. For single-phase operation, the phase supply voltage must be
limited to 230V and the input power to the drive limited to 1.1kW.
PAGE 3-4
SECTION 3: WIRING AND INSTALLATION DS2100 User's Manual (Preliminary)
3.1.2 A.C. Input Line Protection
Details of the recommended Line fuses are given in Section 2 of this manual. Alternatively an AC mains Circuit Breaker
(Instantaneous Trip Type) can be used as a protective device provide its ratings are equivalent to the recommended
fuses.
After a power loss to the servo-drive, the motor will continue running until its stored energy is dissipated through
friction alone, or will be stopped by a motor-equipped brake if a brake is available.
It is also recommended to install a contactor rated for the DS2100 input between the line fuses and the EMC filter at the
input of the DS2100 (refer to Figure 3.1). This contactor should be controlled directly by user supplied Emergency Stop
Buttons and other series connected safety switches to remove AC input power in any situation affecting personnel
safety.
WARNING - The supply-disconnecting device (circuit breaker) must be switched to
the OFF position before any service or maintenance activity is commenced.
3.1.3 Line Filter Requirements
Details of the recommended line filters for each of the DS2100 variants are given in Section 2 of this manual.
PAGE 3-5
DS2100 User's Manual (Preliminary) SECTION 3: WIRING AND INSTALLATION
PAGE 3-6
Figure 3.1 Typical DS2100 System Components (mA Size)
SECTION 3: WIRING AND INSTALLATION DS2100 User's Manual (Preliminary)
3.1.4 Serial Set-up Terminal (User-Supplied)
An RS-232 interface should be established for individual servo-drive communications, using a PC. The PC can run
Moog's WinDrive Windows-based user-interface program.
The personal computer using Windrive is a service engineering tool
only and must be installed so that use of the key sequences which allow
control of the machine functions is accessible to authorised qualified
Requ i red for
CE-Compliance
service personnel only. All such service set-up computers must be CE marked as compliant with the EU EMC Directive.
3.1.5 Control-Backup Power Input (User Supplied)
The DS2100 requires a control power source to supply backup-power for the control electronics. This control-backup
power is useful where the user requires that the DS2100 does not loose absolute position data or status information when
AC mains power is removed from the DS2100.
The user is directed to the local Moog sales office or authorised distributor for a recommended list of these control
power source devices.
The G361-x003 &-x006 MUST have a 24Vdc logic backup supply
connected for the drive to operate. No internal high voltage backup is
provided on these smaller models.
The 24V
control power option allows high voltage motor power to be removed from a DS2100 Series Servo-drive
dc
without losing control power.
The acceptable voltage range for this supply is 24V
±10% with a minimum current rating of 2Adc per DS2100 Series
dc
Servo-drive connected. A low cost unregulated DC supply is adequate.
NOTE - The 24Vdc power supply must be compliant with the
requirements of the EU EMC Directive. The 24V
output from the
dc
power supply must be Safety Extra Low Voltage (SELV - as defined
Requ i red for
CE-Compliance
by European standard EN 60950).
PAGE 3-7
DS2100 User's Manual (Preliminary) SECTION 3: WIRING AND INSTALLATION
3.1.6 Brushless Servo motors
The DS2100 series Servo-drive is compatible with Moog brushless servomotors.
Normal connection to the motor requires two cables - a power and a signal cable. The power cable provides three-phase
stator power, protective earth and brake connections. The signal cable carries position transducer feedback signals and
motor temperature detection connections.
3.1.6.1 Brushless Motor Brake 24V Power Supply
The motor brake requires a 24V
currents of all brakes connected.
supply for release. This should be rated to cover at least twice the sums of the rated
dc
3.1.7 Heatsinks and Climatic Control
The need for air conditioning will depend on the duty cycle of the system and the surrounding ambient temperature. The
maximum allowable ambient temperature is 40°C (104°F). The humidity range is 5-95% non-condensing.
All DS2100 Servo-drives incorporate internal cooling fans and integral heat sinks. Other than controlling ambient
conditions, additional heat sinking is not required.
PAGE 3-8
SECTION 3: WIRING AND INSTALLATION DS2100 User's Manual (Preliminary)
3.2 Equipment Mounting
This section details the mechanical dimensions of the DS2100 chassis, as well as required clearances for cabling etc. The
DS2100 is designed to be panel or cabinet mounted. The DS2100 must be mounted in a vertical orientation. The DS2100
must be panel mounted within an enclosure or cabinet that provides a degree of ingress protection against liquids and
objects of at least IP54. Such enclosures or cabinets must be accessible to technically qualified service or maintenance
persons only. It is recommended that the cabinet be ventilated using filtered or conditioned air, free of corrosive or
electrically conductive contaminants. The accumulation of dust, dirt, etc. on the equipment must be avoided. A
minimum clearance above and below each of the DS2100 drive sizes is required. These distances are detailed in Table
3.1.
DS2100 Size Minimum Clearance Top
(mm)
mA & A
B 60 100
C 80 160
D 100 200
Table 3.1 Minimum Clearance around DS2100 Drives
If any of the DS2100 units are mounted in a closed cabinet, allow 80mm clearance at the front for cable bends.
60 100
Minimum Clearance Bottom
(mm)
PAGE 3-9
DS2100 User's Manual (Preliminary) SECTION 3: WIRING AND INSTALLATION
Figure 3.2 Typical DS2100 Cable Bend Radius Requirements
The DS2100 must be permanently and reliably connected to Earth and all conductive parts in the IP54 rated enclosure or
cabinet must be permanently connected to Earth. The impedance between the earth terminal and any accessible part of
the enclosure or cabinet should be less than or equal to 0.1 W.
NOTE - The DS2100 Series Servo-drives are system components that must
be installed in the correct manner to ensure that all electromagnetic
compatibility (EMC) requirements are met. (Refer to Section 2 of this User’s
Guide).
The DS2100 must be mounted on a panel with a flat solid surface in a manner
that ensures that EMC earthing requirements are met.
Requ i red for
CE-Compliance
There must be a clean flat conductive surface at all of the mounting points.
Remove paint or other insulating materials and provide conductive corrosion
protection at the mounting points. It is important that there is good high-
frequency bonding between the panel and the DS2100 Servo-drive.
Conductive hex socket head bolts with conductive locking washers should be
used.
PAGE 3-10
SECTION 3: WIRING AND INSTALLATION DS2100 User's Manual (Preliminary)
Figure 3.3 DS2100 mA Mechanical & Mounting Dimensions
PAGE 3-11
DS2100 User's Manual (Preliminary) SECTION 3: WIRING AND INSTALLATION
PAGE 3-12
Figure 3.4 DS2100 A Mechanical & Mounting Dimensions
SECTION 3: WIRING AND INSTALLATION DS2100 User's Manual (Preliminary)
Figure 3.5 DS2100 B Mechanical & Mounting Dimensions
PAGE 3-13
DS2100 User's Manual (Preliminary) SECTION 3: WIRING AND INSTALLATION
PAGE 3-14
Figure 3.6 DS2100 C Mechanical & Mounting Dimensions
SECTION 3: WIRING AND INSTALLATION DS2100 User's Manual (Preliminary)
Figure 3.7 DS2100 D Mechanical & Mounting Dimensions
PAGE 3-15
DS2100 User's Manual (Preliminary) SECTION 3: WIRING AND INSTALLATION
3.2.1 CE Items for Mechanical Installation
Additional electromagnetic compatibility (EMC) measures must be installed
on equipment associated with the DS2100 Servo-drive. The following
measures must be implemented:
· All external Regen (Regenerative circuit) resistors used with the DS2100
must be installed in enclosures which provide a degree of ingress
protection against liquids and objects of at least IP22 and which are
accessible to technically qualified service or maintenance persons only.
Protection against electric shock must be maintained when installing
these resistors.
· Use shielded cable to connect the external regen resistor (if installed) to
the DS2100 power supply. The length of this cable should be as short as
possible. The shields of these cables should be earthed to Chassis Earth
using the optional EMC Bracket kit or the panel earth bar. Alternatively,
if the cable is required to pass through an enclosure panel earthed to
Chassis Earth, the shield may be earthed to the panel by use of a 360
degree metal cable gland.
Requ i red for
CE-Compliance
· Cables supplying external d.c. supply voltages to the DS2100 Series
Servo-drives (for example, the 24 Vd.c. supply) must be as short as
possible. The supply wires should be twisted together or alternatively
shielded cable should be used.
· Cables connecting the D.C. Bus from the DS2100 Power Supply to other
DS2100 Servo-drives must be as short as possible. The supply cables
should be shielded.
· Motor power cables must be shielded with the cable shield securely
connected to Chassis Earth at both ends of the cable. At the DS2100
Servo-drive end of the cable, the shield should be earthed using the EMC
Bracket.
· Motor feedback & signal cables must be shielded with the cable shield
securely connected to Chassis Earth at both ends of the cable.
· Signal cables must be shielded with the cable shield securely connected
to make a good HF earth bond to Chassis Earth at both ends of the cable.
Further details for the correct installation and shielding of cables and
conductors are given in Section 2.
PAGE 3-16
CAUTION - Enclosure or cabinet temperature control is critical for
performance, reliability and life of electrical components. Maintaining a
uniform temperature (check for hot spots) within the specified values for the
equipment will prevent premature failure due to temperature stress.
SECTION 3: WIRING AND INSTALLATION DS2100 User's Manual (Preliminary)
3.3 Power Dissipation
To calculate cabinet cooling requirements, Table 3.2 provides approximate equipment power dissipation values. If the
application employs regeneration, be sure to add the regen resistor power dissipation to the numbers quoted in Table 3.2
below, (use the continuous wattage rating of the regen resistor if the actual application regen dissipation is unknown).
Power Dissipation (Watts)
DS2100
-003 -006 -008 -014 -025 -030 -050 -060
53 100 110 180 300 400 650 800
Table 3.2 Estimated Power Dissipation for the DS2100 Servo-drives
PAGE 3-17
DS2100 User's Manual (Preliminary) SECTION 3: WIRING AND INSTALLATION
3.4 DS2100 Connector Terminals
Figure 3.8 to Figure 3.12 below detail the connectors on the DS2100 (all sizes).
Serial Communications
Connector (RS232)
Motor Resolver
Connector
Digital Input
Connector
Motor Encoder
Connector
CAN Field Bus
Interface
Digital Output
Connector
Drive Ready Relay
Connector
Motor Brake
Connector
Figure 3.8 DS2100 Control Card Connector Terminals
PAGE 3-18
SECTION 3: WIRING AND INSTALLATION DS2100 User's Manual (Preliminary)
Figure 3.9 DS2100 Size mA Power Connector Terminals
Figure 3.10 DS2100 Size A & B Power Connector Terminals
PAGE 3-19
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