Moog DS2110 User Manual

DS2110 DIGITAL CONTROLLER

INSTALLATION & USER’S MANUAL

Document No.: CDS7324 (formerly LSF-0819) Revision: A Date: May 2011

INDUSTRIAL CONTROLS DIVISION

TABLE OF CONTENTS T/C -1

CHAPTER 1.0 OVERVIEW............................................................................................................. 1-1

1.1 Introduction...................................................................................................................... 1-1

1.2 DS2110 Models................................................................................................................. 1-2

1.3 Environmental Specifications......................................................................................... 1-4

1.4 Design Standards............................................................................................................. 1-5

1.5 Power Ratings Specifications.......................................................................................... 1-6

1.6 General functional specifications................................................................................... 1-9

CHAPTER 2.0 SAFETY & EMC INSTRUCTIONS.......................................................................... 2-1

2.1 General.............................................................................................................................. 2-1

2.2 Safety Regulations............................................................................................................ 2-2

2.3 Electromagnetic Compatibility........................................................................................ 2-12

2.4 UL Requirements ............................................................................................................. 2-22

CHAPTER 3.0 WIRING AND INSTALLATION............................................................................... 3-1

3.1 System Components........................................................................................................ 3-1

3.2 Equipment Mounting........................................................................................................ 3-5

3.3 Pow er Di ssipation ............................................................................................................ 3-15

3.4 DS2110 Connector Terminals ......................................................................................... 3-16

3.5 General System Wiring Guidelines................................................................................. 3-20

3.6 Sequence of Component Wiring Recommendations.................................................... 3-22

3.7 Three Phase AC Mains Power Source Configuration ................................................... 3-23

3.8 24V Backup Connection .................................................................................................. 3-29

3.9 Internal/External Regeneration (Regen) Resistors – Configurations .......................... 3-32

3.10 Motors – Installation ...................................................................................................... 3-36

3.11 DS2110 Control Inputs and Outputs............................................................................. 3-49

3.12 Communication Interface Wiring and Configuration .................................................. 3-54

3.13 Wiring Summary............................................................................................................. 3-55

CHAPTER 4.0 GETTING STARTED.............................................................................................. 4-1

4.1 Introduction...................................................................................................................... 4-1

4.2 Initial Preparation............................................................................................................. 4-1

4.3 Power Supply ................................................................................................................... 4-1

4.4 Installing Windrive ........................................................................................................... 4-2

4.5 Controller Access ............................................................................................................ 4-3

4.6 Motor Selection ................................................................................................................ 4-4

4.7 Regen Resistor Configuration ........................................................................................ 4-6

4.8 Acceleration Limits.......................................................................................................... 4-8

4.9 Parameter Utilities............................................................................................................ 4-9

4.10 Status and Faults ........................................................................................................... 4-10

4.11 High Power Application................................................................................................. 4-11

4.12 Autophasing.................................................................................................................... 4-12

4.13 Torque Mode Enable...................................................................................................... 4-13

4.14 Velocity Mode Enable .................................................................................................... 4-14

4.15 Oscilloscope................................................................................................................... 4-15

4.16 Pow er Down Sequence.................................................................................................. 4-20

TABLE OF CONTENTS

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

TABLE OF CONTENTS

CHAPTER 5.0 FUNCTIONAL OVERVIEW..................................................................................... 5-1

5.1 Introduction ...................................................................................................................... 5-1

5.2 DS2110 Conventions........................................................................................................ 5-1

5.3 Power Interface Section................................................................................................... 5-2

5.4 Motor Configuration......................................................................................................... 5-8

5.5 Resolver Input .................................................................................................................. 5-13

5.6 Encoder Input................................................................................................................... 5-16

5.7 Commutation Module....................................................................................................... 5-21

5.8 Position Feedback............................................................................................................ 5-24

5.9 Velocity Feedback............................................................................................................ 5-25

5.10 Input and Output Functional Description..................................................................... 5-26

5.11 Control Loops ................................................................................................................. 5-34

5.12 Dri ve Monitoring & Fault Detection .............................................................................. 5-52

5.13 Self Protection................................................................................................................ 5-66

5.14 Parameter Storage ......................................................................................................... 5-67

APPENDIX A – DATA LOGGER.................................................................................................... A-1

APPENDIX B – GUI........................................................................................................................ B-1

B.1 Introduction...................................................................................................................... B-1

B.2 Getting Started/Common Features ................................................................................ B-2

APPENDIX C – RESTART INTERLOCK CIRCUITS...................................................................... C-1

C.1 Intended Application....................................................................................................... C-1

C.2 Restart Interlock Function .............................................................................................. C-2

C.3 Safety Requirements....................................................................................................... C-4

C.4 Restart Interlock Circuit.................................................................................................. C-5

C.5 Restart Interlock Connections........................................................................................ C-7

C.6 Safety Relays – Technical Data...................................................................................... C-9

C.7 Application Example....................................................................................................... C-10

C.8 Checking the Restart Interlock....................................................................................... C-13

C.9 External Consistency Checks ........................................................................................ C-14

C.10 Installation and Routine Test........................................................................................ C-15

APPENDIX D – MEZZANINE CARD INSTALLATION................................................................... D-1

APPENDIX E – ANALOG I/O MEZZANINE CARD........................................................................ E-1

E.1 Introduction...................................................................................................................... E-1

E.2 Overview........................................................................................................................... E-1

E.3 Configurations ................................................................................................................. E-1

E.4 Analog I/O......................................................................................................................... E-2

E.5 SSI Interface..................................................................................................................... E-4

E.6 Simulated Encoder/Resolver .......................................................................................... E-5

E.7 PLC Master – DS2110 Slave Arrangement..................................................................... E-7

E.8 Noise Reduction .............................................................................................................. E-7

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TABLE OF CONTENTS

APPENDIX F – DEVICENET™ MEZZANINE CARD...................................................................... F-1

F.1 Connector......................................................................................................................... F-1

F.2 Network Status................................................................................................................. F-1

F.3 Available Objects............................................................................................................. F-1

F.4 MacID and Baud Rate ...................................................................................................... F-2

F.5 Initial Motion Setup.......................................................................................................... F-2

F.6 Fieldbus Scaling Factors................................................................................................. F-2

F.7 Units.................................................................................................................................. F-3

F.8 PARAM UPDATE in.......................................................................................................... F-3

F.9 Implicit I/O......................................................................................................................... F-3

F.10 Parameter List ................................................................................................................ F-4

APPENDIX G – ETHERNET MEZZANINE CARD.......................................................................... G-1

G.1 Introduction ..................................................................................................................... G-1

G.2 Modes of Operation......................................................................................................... G-1

G.3 Changing IP Address for Ethernet Device .................................................................... G-2

G.4 Changing Commands and Status Registers................................................................. G-4

G.5 Allen-Bradley RSLogix Configuration with DS2110 ..................................................... G-6

CDS7324 REV. A INSTALLATION & USER’S MANUAL

CHAPTER 1.0 Overview 1-1

1.1 Introduction

This section gives an overview of the available DS2110 models, ratings and general specifications. Detailed outlines of installation and wiring, functionality, user interfaces and other technical data are given in subsequent sections.

CAUTION: Repairs or modifications to the product by anyone other than a Moog authorized repair facility may create unsafe operating conditions and will invalidate the product warranty.

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CHAPTER 1.0 Overview 1-2

1.2 DS2110 Models

The DS2110 family is available in twelve base models, which cover a range of output current ratings.

DS2110 Base Model Amplifier Current Rating Code Size Continuous

Maximum (Arms) Peak (A)

(Arms) G362-x03 µA or A 3 6.4 9 G362-x04 A 4 8.5 12 G362-x06 µA or A 6 16 22 G362-x08 A 8 16 22 G362-010 B 10 29.7 42 G362-014 B 14 29.7 42 G362-020 C 20 31.8 45 G362-025 C 25 49.5 70 G362-030 C 30 63.6 90 G362-050 D 50 99.3 140 G362-060 D 60 127.6 180 G362-100 E 100 212.1 300

Table 1.1 DS2110 Family Models

The DS2110 family uses a 14 character coding system to identify the unique attributes of each model.

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CHAPTER 1.0 Overview 1-3

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CHAPTER 1.0 Overview 1-4

1.3 Environmental Specifications

DS2110 Electronics

Maximum temperature

Storage: -25 C to 55 C (Class 1K4) Transport: -25 C to 70 C (Class 2K3) Surrounding air 0 C to 40 C

Relative humidity: 5 % to 85 %, non-condensing, 1 g/m3 to 25 g/m3, in accordance with

EN50178 class 3k3

Elevation: 1000m (3,300 feet); derate output 2% per 300m (1000 ft) above 1000m

(3300 ft) Air pressure: 86 kPa to 106 kPa Type of protection: Components must be installed into an enclosure. The enclosure must

provide at least IP54 per standard EN60529 or equivalent. Pollution degree: Drive is suitable for installation in a Pollution Degree 2 environment. Installed position: Vertical only. Overvoltage protection class: Category 2 per standard VDE0110 / IEC664 Noise: Overall noise depends on the user installation and cabinet.

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1.4 Design Standards

The DS2110 is CE-Marked under the EU's Low Voltage Directive. It has been designed to allow easy compliance of customer's machines under the EU's EMC Directive (measures as directed in this manual have to be taken to ensure EMC compliance). It is designed to the UL508C standard. The A size DS2110 units are UL recognized. The DS2110 A-D sizes are UL listed.

The DS2110 has been designed to the following specific standards:-

IP Code EN 60529:1991 EMC EN 61800-3:1996 , EN 61800-3/A11:2000 (Second Environment) UL UL508C with reference to UL840

Table 1.2 DS2110 Design Standards

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CHAPTER 1.0 Overview 1-6

1.5 Power Ratings Specifications

Model : G362-x

A.C. Mains Input Range

Minimum

Maximum

Frequency Range

Internal Regeneration Power

Continuous Dissipation Peak Dissipation @ 230Vac Peak Dissipation @ 400Vac

External Regeneration Power

Continuous Dissipation Peak Dissipation @ 230Vac Peak Dissipation @ 400Vac

Softstart Peak Inrush

Current/Phase

Power Supply Fault Detection

3Amp 6Amp 8Amp 10Amp 14Amp 20Amp 25Amp 30Amp 50Amp 60Amp 100Amp

65Vac (110Vac -40%)

506Vac (440Vac +10%)

50 - 60Hz

150W

50W

1.3Kw

4.8kW

50W

1.2Kw

4.8kW

100W

1.3kW

4.8kW

100W

1.2kW

4.8kW

2.6kW

10.3kW N/A N/A N/A N/A N/A N/A N/A N/A

200W

2.8kW

11.3kW

240W

6.6kW

26.3kW

250W

4.4kW

17.5kW

370W

12.0kW

48.1kW

370W

12.0kW

48.1kW

370W

12.0kW

48.1kW

750W

14.4kW

57.8kW

750W

14.4kW

57.8kW

1kW

37kW

148kW

30Apk

D.C. Bus Overvoltage

D.C. Bus Undervoltage

Bridge Temperature Fault

Amplifier Short Circuit Protection

24V Logic Backup Monitoring

Voltage Discharge after A.C

Mains Removal

Bleed Resistors across high voltage section.

Table 1.3 DS2110 Power Ratings

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CHAPTER 1.0 Overview 1-7

1.5.1 Optional Control Logic Backup Power

D.C. Bus Minimum Voltage (below which 24Vd.c. Control Logic Backup supply is needed) 24V Input

Table 1.4 DS2110 Control Logic Backup Power Ratings

An auxiliary 24V d.c. control logic backup supply is MANDATORY for the –x003 & -x006 variants of the DS2110 product family.

The 24V Backup supply input is intended for use in the secondary of a Class 2 supply. Alternatively, it should be additionally fitted with a Listed Current limiting type fuse, rated 3A on the supply input to the device.

170Vd.c. (Generated from rectified 120Va.c.) 24Vd.c.± 10%

2.0A steady state

1.5.2 Power Amplifier

All current ratings are specified in ampere r.m.s. unless otherwise stated.

Power Amplifier Ratings: G362-x03 3A continuous/9A peak G362-x04 4A continuous/12A peak G362-x06 6A continuous/15A peak G362-x08 8A continuous/22A peak G362-010 10A continuous/42A peak G362-014 14A continuous/42A peak G362-020 20A continuous/45A peak G362-025 25A continuous/70A peak G362-030 30A continuous/90A peak G362-050 50A continuous/ 140A peak G362-060 60A continuous/ 180A peak G362-100 100A continuous/ 300A peak

Table 1.5 DS2110 Power Amplifier Ratings

Two levels of thermal protection which limit the peak current and the time for which it is available protect the DS2110 drives. These are:

• RMS Protection,

• Thermal Foldback.

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CHAPTER 1.0 Overview 1-8

1.5.4.1 RMS Protection The RMS protection acts to limit the current provided to the rated continuous current of the drive. Thus,

a G362-x006 cannot supply, on average, greater than 6Acontinuous RMS to the motor. The current to the motor is averaged and if it exceeds the RMS rating, the drive limits the current command. If the controller continuously demands current greater than the drive capability, the RMS protection will limit the actual current supplied to the drive rating. The time for which peak current can be supplied is dependent on whether the motor is stalled or running.

1.5.4.2 Thermal Foldback Thermal foldback is implemented in the DS2110 drives to prevent the junction temperatures of the

amplifier bridge IGBT’s exceeding their maximum rated temperature. The thermal foldback is based on a measure of the heatsink temperature and the mode in which the drive is operating (motor running or stalled). As the heatsink temperature increases, the peak current capability of the drive is reduced to ensure the IGBT die temperature cannot increase above the device maximum rating.

For the DS2110 D size, a simple thermal shutdown is implemented. These drives will report an overtemperature fault once the measured heatsink temperature exceeds the maximum rating of the drive.

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CHAPTER 1.0 Overview 1-9

1.6 General Functional Specifications

1.6.1 Digital Inputs (J2A)

• 8 Digital Inputs, user configurable

• Digital Input 1 Dedicated to High Power Enable

• All Optically Isolated, 12…36V Input Range.

• 5k input impedance.

STANDARD FUNCTION

High Power Enable Input High Power Enable Input Auto / Manual Mode See Section 5.9 Torque / Velocity Mode Switch See Section 5.9 Brake Control See Section 5.9 CW Limit Switch See Section 5.9 CCW limit Switch See Section 5.9 Quick Stop See Section 5.9 Controlled Disable See Section 5.9

FIELDBUS OR INTERFACE SPECIFIC

Table 1.6 DS2110 Digital Inputs Overview : Standard Configuration

1.6.2 Digital Outputs (J2B)

• 3 Digital outputs, user configurable

• All outputs are Optically Isolated.

• Nominal ratings of 6V to 32V, 250mA

• Protected for supply range of –40V to 40V

• Short-circuit & reverse polarity protected

• Off-state leakage current <100μA at 0V

Standard Function

Limiting Function

Table 1.7 DS2110 Digital Outputs Overview

Drive Enabled

User defined

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CHAPTER 1.0 Overview 1-10

1.6.3 Standard I/O

Drive Ready (J2C)

Brake Control (J2D)

Motor Position Feedback Type (J3/J4)

Communications Interfaces (J1)

Relay output, contact ratings: 36V, 100mA max. Closed when drive is ready and has no faults. 2A, 24Vd.c. solid-state high-side drive for motor brake control. Switched under user control or DS2110 software control Resolver Encoder Types

• SSI

• Hiperface

• Analogue encoders

• Endat

• NRZ serial

RS232 Interface at 19200Baud

Table 1.8 DS2110 Standard I/O Summary

1.6.4 Variant Specific I/O

Refer to the appendix for details on a specific fieldbus variant.

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CHAPTER 2.0 Safety & EMC Instructions 2-1

2.1 General

This user’s manual is intended to provide sufficient information on how to install Moog DS2110 electric motor systems. Section 2.2 covers Safety and System Safeguards. Section 2.3 covers Electromagnetic Compatibility (EMC). This user’s guide must be read and understood before applying power and operating the equipment described.

This equipment must be installed and serviced only by duly qualified service personnel. All information in this manual is directed towards such persons only. Individuals responsible for the installation of the equipment described in this user’s guide must ensure;

1) only technically qualified individuals are employed to work on the installation,

2) these qualified individuals must have the accompanying documentation available at all times when working on the installation and are obliged to use this documentation in a consistent manner, and

3) work on, or close to, the installation is prohibited for non-technically qualified individuals

Throughout this user’s guide may be found NOTES, CAUTIONS, and WARNINGS and CECompliance-Required. They are defined as follows:

Required for

CE-Compliance

NOTES are general in nature and are intended to em

hasise information.

CAUTIONS are to alert personnel to actions that could cause equipment damage, resulting in the equipment becoming unsafe.

WARNINGS serve to make personnel aware of potentially hazardous actions that may result in personal injury or death.

CE-Compliance indicates where a particular application-related safety or EMC requirement is driven by the need for CECompliance of the DS2110 when installed in the system. Customers who do not need CE-Compliance on their machinery ma

choose not to implement these features.

The DS2110 controller contains potentially lethal voltages. Extreme caution shall be observed whenever the equipment is in operation. Incorrect installation of the motor or the controller may cause damage to the equipment, serious personal injury or death. Consequently, the instructions in this user’s manual, as well as national and local rules and safety regulations must be complied with.

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CHAPTER 2.0 Safety & EMC Instructions 2-2

2.2 Safety Regulations

1. The DS2110 controller must be disconnected from all power if repair work is to be carried out. Check that the mains supply has been disconnected and that at least 5 minutes has passed for the A size (6 minutes for AE sizes), to allow for D.C. bus capacitors to discharge, before removing motor and mains connections.

2. Correct protective earthing of the equipment must be established, the user must be protected against supply voltage, and the motor must be protected against overload in accordance with applicable national and local regulations.

3. Do not remove the connections for the motor and mains supply while the DS2110 controller is connected to mains power. Check that the mains supply has been disconnected and that the necessary time has passed before removing motor and mains connections.

Warning against unintended start

The installation of safety interlocks, additional control and protection devices must be done in accordance with the relevant local safety requirements. Note that changes made through software can result in the motor starting suddenly.

This user’s manual assumes that the user has a basic working knowledge of servo-drive products and the system motion controller. The user should provide the necessary additional training for ALL personnel working within or around the workcell.

NOTE - These safety precautions are guidelines only and are not claimed to be comprehensive. The Moog Brushless Technology products described herein, in conjunction with the system controller, provide the capability for control of remote devices. Typically, these remote devices move at high speeds and exert considerable force. Like all mechanical systems and most industrial equipment, they must be treated with respect by both the machine integrator and user, and the operator.

NOTE - This user’s guide defines “user” as the responsible person or company and “operator” as a person who starts, stops or monitors workcell operation.

NOTE - This user’s guide should be read by all personnel who operate or who work within or near the workcell.

Individuals responsible for the installation of the equipment described in this user’s guide must ensure that only technically qualified service personnel are employed to work on the installation.

In the context of these safety instructions, skilled technical personnel means people who are familiar with the product, and have the necessary technical qualifications required for the performance of their functions.

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CHAPTER 2.0 Safety & EMC Instructions 2-3

2.2.1 System Safeguards

a) General Safety Requirements

Users are required to implement safety measures with all equipment, systems and installations into which the DS2110 Servo-drive are installed. In addition, safeguards must be an integral part of workcell design, installation, operator training and operator procedures where this equipment is used.

Users are directed to refer to the European Union (EU) Machine Safety Directive: 98/37/EC and EU Low Voltage Directive 73/23/EEC (as amended by EU Directive 93/68/EEC) for essential health and safety requirements to be

Required for

CE-Compliance

met. Furthermore the requirements of the EU EMC Directive: 89/336/EEC (as amended by EU Directive 92/31/EEC and 93/68/EEC) must be met by all equipment, systems and installations into which the DS2110 Controllers are installed.

Users are recommended to refer to the latest publications of the European Union (EU) Commission and to local regulations for further information on the requirements of these Directives of the EU.

Users are required to ensure that the drive is only connected to supply network configurations of the following types

• TN Systems including TN-C, TN-S, TN-C-S

• TT Systems.

Required for

CE-Compliance

Connection to IT systems or corner-earthed TN systems is not allowed. Users should ensure the nature of the supply system is appropriate before connecting and operating the drive.

b) Specific Safety Requirements

The specific safety measures described below are required to be installed by the user into all equipment, systems and installations into which the DS2110 Series Controllers are installed.

The user is required to provide safety interlocks to prevent unexpected restart during servicing of the DS2110 Controller and any equipment attached to or driven by these units.

The DS2110 Servo-drives themselves must be installed in enclosures or cabinets that provide a degree of ingress protection against liquids and objects of at least IP54. These enclosures or cabinets must be accessible to technically qualified service or maintenance persons only. All external Regen (Regenerative circuit) resistors used with the DS2110 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.

The equipment may have a continuous leakage current of more than 3.5 mA A.C. or 10 mA D.C. in normal use. The DS2110 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 0.1ohm.

A D.C component can occur in the fault current in the event of a fault connection to earth. Only a residual-currentoperated protective device (RCD) of Type B is allowed. When the protection in installations with regard to indirect contact is achieved by means of an RCD, their appropriate function/combination shall be verified.

All electrical supply wires and cables to this equipment must be installed in wireways (cable routings) which are smooth and free from sharp edges.

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CHAPTER 2.0 Safety & EMC Instructions 2-4

Required for

CE-Compl iance

As no fuses are provided inside the drive, the DS2110 must be provided with suitable fusing to protect the drive. The fuses required for each DS2110 model are detailed in the following table It is recommended to use UL certified fuses and fuse blocks

DS2110 Models

Size 3/9 6/22 Short Circuit Rating 5,000 Amps Power Line Fuse 25A, 660V FWP25-A1F Semiconductor (Cooper Bussmann) Recovery Resistor Fuse Contact Moog Application Engineering for Advice 24Vdc Aux. Pwr. Fuse 3A, 250V Delayed

DS2110 Models Size A Size B Notes

Size 8/22 10/42 14/42 Short Circuit Rating 5,000 Amps Power Line Fuse 50-FE 690V Semiconductor (Cooper Bussmann) Recovery Resistor Fuse Contact Moog Application Engineering for Advice 24Vdc Aux. Pwr. Fuse 3A, 250V Delayed

DS2110 Models Size C Size D Notes

Size 20/45 25/70 30/90 50/140 60/180 Short Circuit Rating 5,000 Amps Power Line Fuse 100-FE 690V 160-FEE 690V Semiconduct or (Cooper Bussmann) Recovery Resistor Fuse Contact Moog Application Engineering for Advice 24Vdc Aux. Pwr. Fuse 3A, 250V Delayed

DS2110 Models Size E Notes

Size 100/240 Short Circuit Rating 10,000 Amps Power Line Fuse 315-FM Semiconductor (Cooper Bussmann) Recovery Resistor Fuse Contact Moog Application Engineering for Advice 24Vdc Aux. Pwr. Fuse 3A, 250V Delayed

All external d.c. supply voltages used with the DS2110 Series Controllers must be derived from a Safety Extra Low Voltage (SELV) supply as defined by standard EN60950. Such SELV voltages do not exceed a value of 60 Vd.c. or 42.4 Va.c. peak under normal conditions and are supplied by circuits which are separated from all hazardous voltage conductors by permitted safety methods such as reinforced insulation.

All external electrical wiring connected to this equipment must be colour coded in accordance with European Standard EN 60204-1 requirements.

All wires and cables entering and leaving the IP54 rated enclosures or cabinets containing the DS2110 Controllers and Regen resistor(s) must be protected and anchored in accordance with the requirements of EN 60204-1.

Size μA

Notes

rms

10,000 Amps

rms

Table 1 - Recommended DS2110 Fusing

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CHAPTER 2.0 Safety & EMC Instructions 2-5

2.2.2 Equipment Safety

All persons must observe sound safety practices during the operation and testing of all electrically powered equipment.

Prior to first use, power should not be applied to the DS2110 Servo-drive until all instructions in the Wiring and Installation section of this User’s manual have been carried out.

WARNING – In the event of a fuse failure, remove all power, refrain from working on the unit for at least 5minutes for the A size (6 minutes for the A-E sizes) to allow all internal voltages to decay to a safe level. Remove all fuses from the system. Determine the source of the failure before re-commencing operation of the drive.

WARNING - DO NOT remove or replace any assemblies, subassemblies or components with primary power present.

WARNING - Lethal voltages remain present within this equipment when the mains power is removed. It is recommended to refrain from commencing any servicing, maintenance, repair or upgrading of this equipment until at least 5 minute for the A size (6 minutes for the A-E sizes) after power shutdown. It is further recommended to measure the voltage level at all high voltage terminals before commencing any such activities, to ensure that no lethal voltages are present.

WARNING – The removable plug-in connectors of the DS2110 Servo-Drives are for ease of wiring installation. These removable plug-in connectors are not suitable for connection or disconnection under power. All connections must be made with power removed.

WARNING - Repair or internal adjustments to the DS2110 Series Controllers must not be attempted. All faulty items must be returned to Moog Service Centers for maintenance and repair.

WARNING - Entering the workcell when HIGH POWER or PROGRAM RUNNING indicators are ON may result in severe injury.

WARNING - The equipment described in this user’s guide operates at voltage levels, which can exceed 800 volts D.C., and/or 460 volts A.C. These levels are a potential source of severe electrical shock. DO NOT remove or replace any assemblies, subassemblies or components with the primary power present. To avoid possible personal injury or equipment damage, always remove power BEFORE attempting repair or upgrade procedures. Wait at least 5 minutes for the A size (6 minutes for the A-E sizes) after power shutdown to ensure power supply capacitors have discharged. Then using a voltmeter, check for safe levels across all high voltage power terminals.

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CHAPTER 2.0 Safety & EMC Instructions 2-6

Safeguards should be an integral part of a work cell design, installation, operator training, and operator procedures. A computer-controlled system may activate remote devices under program control at times not anticipated by personnel. It is critical that safeguards be in place to prevent personnel from entering the work cell whenever equipment power is present. Moog highly recommends the use of work cell safety features such as light curtains, safety gates or safety floor mats to prevent access to the workcell while power is present. Computer controlled systems have various communication features which may aid the user in constructing system safeguards, including:

• emergency stop circuitry

• binary input and output lines

• spare system-controlled user lines

The emergency power-off circuitry of a computer-controlled system is generally capable of switching external power systems, as well as detecting intrusion signals from safety barriers.

All personnel must observe sound safety practices during the operation and testing of all electrically powered equipment. To avoid injury or damage to equipment, always remove power BEFORE attempting ANY repair or upgrade activity.

2.2.3 Safety Requirements for Cables

a) Requirements - Conductors and Cables

All cables and conductors used shall be specified as compliant with the requirements of European Standard EN 60204-1 and other known National and International Standards for the environment in which they are installed and for the voltage and current carried.

Conductors and cables shall be specified and selected so as to be suitable for the operating conditions (e.g. voltage, current, protection against electric shock, grouping of cables) and external influences (e.g. ambient temperature, presence of water or corrosive substances, mechanical stress) which can exist.

Required for

CE-Compliance

User's whose machine installations require CECompliance should read this Section.

CDS7324 (FORMERLY LSF-0819) Rev. A INSTALLATION & USER’S MANUAL

CHAPTER 2.0 Safety & EMC Instructions 2-7

The following table details the recommended cable dimensions for all DS2110 models

Cable 3/9

AWG

(mm

Line Power 3x14 (2.1) 3x12 (3.3) Protective Bonding Cable 1x 6 (13) Motor Power Cable 4x14 (2.1) 4x12 (3.31) Shielded Regen Resistor Cable 2x14 (2.1) Shielded DC Bus Cable 2x14 (2.1) Shielded Safety Interlock (If

applicable) 24V Power Cable 2x14 (2.1) Shielded

µA A B

6/22

)

AWG

(mm

DS2110 Models Notes

8/22

)

AWG

(mm

)

2x22 (0.3) Shielded

10/42

AWG (mm2)

14/42

AWG (mm2)

Note: 2x14 (2.08) = Number of conductors x conductor size (AWG = American wire gauge)

DS2110 Models Notes

Cable 20/45

AWG

(mm

)

Line Power 3x8 (8.4) 3x 6 (13) 3x 4 (21) Protective Bonding Cable 1x 6 (13) 1x6 (13) 1x4 (21) Motor Power Cable 4x8 (8.4) 4x6 (13) 4x4 (21) Shielded Regen Resistor Cable 2x8 (8.4) 2x 6 (13) 2x4 (21) Shielded DC Bus Cable 2x8 (8.4) 2x 6 (13) 2x4 (21) Shielded Safety Interlock (If

applicable) 24V Power Cable 2x14 (2.1) Shielded

C D

25/70

AWG

(mm

30/90

AWG

)

(mm

)

2x22 (0.3) Shielded

50/140

AWG (mm2)

60/180

AWG (mm2)

Cable 100/240

Line Power 3 x 1 (42) Protective Bonding Cable 1 x 1 (42) Motor Power Cable 4 x 1 (42) Shielded Regen Resistor Cable 2 x 2 (34) Shielded DC Bus Cable 2 x 1 (42) Shielded

Safety Interlock (If applicable) 2x22 (0.3) Shielded 24V Power Cable 2 x 14 (2.1) Shielded

DS2110 Models Notes

AWG (mm2)

Table 2 - DS2110 Cable Dimensions

CDS7324 (FORMERLY LSF-0819) Rev. A INSTALLATION & USER’S MANUAL

CHAPTER 2.0 Safety & EMC Instructions 2-8

Wherever possible, insulated conductors and cables that have flame-retardant properties shall be used. Where insulated conductors and cables can constitute a fire hazard due to the propagation of a fire or the

emission of toxic or corrosive fumes (e.g. PVC), guidance from the cable supplier should be sought. In particular it is important to maintain the integrity of circuits having a safety function (e.g. emergency stop) for as long as possible under these conditions.

The mechanical strength and thickness of the insulation shall be such that the insulation cannot be damaged in operation or during laying, especially for cables pulled into ducts.

The voltage drops on cables and conductors shall not exceed 5% of the nominal voltage. The current carrying capacity of the conductors and cables is determined by both:

• the maximum allowable conductor temperature under the highest possible steady state current under normal conditions; and

• the ultimate allowable short-time conductor temperature under short circuit conditions.

b) Wiring Practices - Connections and routing All connections, especially those of the protective bonding circuit, shall be secured against accidental loosening.

c) Wiring Practices - Conductor and cable runs

Conductors and cables shall be run from terminal to terminal without splices or intervening j oints Where it is necessary to connect and disconnect cables and cable assemblies, sufficient extra length shall be

provided for this purpose. The terminations of multicore cables shall be adequately supported where undue strain can be exerted on the

terminations of the conductors. Wherever possible, the protective conductor shall be placed close to the associated live conductors in order to

decrease the impedance of the loop.

d) Wiring Practices - Conductors of different circuits

Subject to the constraints for EMC suppression given in this User’s manual, conductors of different circuits may be laid side by side. They may occupy the same duct (e.g. conduit, cable trunking system) and may be in the same multicore cable, provided that the arrangement does not impair the proper functioning of the respective circuits. Where these circuits operate at different voltages, the conductors shall be either separated by suitable barriers or insulated for the highest voltage to which any conductor within the same duct can be subjected.

Circuits which are not switched off by the supply disconnecting device (circuit breaker) shall be either physically separated from other wiring or distinguished by color (or both) so that they can be identified as being live when the supply disconnecting device is in the OFF or OPEN position.

e) Wiring Practices - Identification of conductors

For safety reasons, the color Green or the color Yellow shall not be used where there is a possibility of confusion with the bicolor combination GREEN-AND-YELLOW.

Color identification using combinations of colors may be used provided there can be no confusion and that GREEN or YELLOW is not used, except in the bicolor combination GREEN- AND-YELLOW.

CDS7324 (FORMERLY LSF-0819) Rev. A INSTALLATION & USER’S MANUAL

CHAPTER 2.0 Safety & EMC Instructions 2-9

f) Wiring Practices - Identification of the protective conductor

The protective conductor shall be readily distinguishable by shape, location, marking or color. When identification is by color alone, the bicolor combination GREEN-AND-YELLOW shall be used throughout the length of the conductor. This color identification is strictly reserved for the protective conductor.

For insulated conductors, the bicolor combination GREEN-AND-YELLOW shall be such that on any 15mm length, one of the colors covers at least 30% and not more than 70% of the surface of the conductor, the other color covering the remainder of the surface.

Where the protective conductor can be easily identified by its shape, position or construction (e.g. braided conductor), or where the insulated conductor is not readily accessible, color coding throughout its length is not necessary. However, the ends or accessible positions shall be clearly identified by the graphical symbol or by the bicolor combination GREEN-AND-YELLOW.

g) Wiring Practices - Identification of the neutral conductor

Where a circuit includes a neutral conductor identified by color, the color shall be LIGHT BLUE. LIGHT BLUE shall not be used for identifying any other conductor where confusion is possible.

In the absence of a neutral conductor, a LIGHT BLUE conductor may be used for other purposes except for use as a protective conductor.

Where identification by color is used, bare conductors used as neutral conductors shall be either colored by a LIGHT BLUE stripe, 15 mm to 100 mm wide, in each compartment or unit or at each accessible position, or colored LIGHT BLUE throughout their length.

h) Wiring Practices - Wiring inside enclosures

Panel conductors shall be supported where necessary to keep them in place. Non-metallic channels or conduits shall be permitted only when made with a flame-retardant insulating material. Where possible earthed shielded metal cable ducting should be used to minimise EMC noise coupling.

It is recommended that electrical equipment mounted inside the enclosures be designed and constructed in such a way as to permit modification of the wiring from the front of the enclosure. Where this is not possible and control devices are connected from the rear of the enclosure, access doors or swing-out panels shall be provid ed.

Connections to devices mounted on doors or to other movable parts shall be made using flexible conductors in accordance with European standard EN 60204-1, to allow for the frequent movement of the part. The conductors shall be anchored to the fixed part and the movable part independently of the electrical connections.

Conductors and cables that do not run in ducts shall be adequately supported. Terminal blocks or attachment plug/socket combinations shall be used for control wiring that extends beyond the

enclosure. Power cables and cables of measuring circuits may be directly connected to the terminals of the devices for which

the connections were intended.

i) Wiring Practices - Wiring outside enclosures

The means of introduction of cables or ducts with their individual glands, bushings, etc., into an enclosure shall ensure that the degree of protection is not reduced.

Conductors and their connections external to the electrical equipment IP54 enclosures shall be installed in suitable ducts (i.e. conduit or cable trunking systems) as described in Section 2.2.4, except for suitably protected cables, which may be installed without enclosing ducts and with or without the use of open cable trays or cable support means.

Fittings used with ducts or multi-conductor cable shall be suitable for the physical environ ment.

CDS7324 (FORMERLY LSF-0819) Rev. A INSTALLATION & USER’S MANUAL

CHAPTER 2.0 Safety & EMC Instructions 2-10

Flexible conduit or flexible multi-conductor cable shall be used where it is necessary to employ flexible connections to pendant push-button stations. The weight of pendant stations shall be supported by means other than the flexible conduit or the flexible multi-conductor cable, except where the conduit or cable is specifically designed for that purpose.

Flexible conduit or flexible multi-conductor cable shall be used for connections involving small or infrequent movements. They shall also be permitted to complete the connection to normally stationary motors, to position switches, and to other externally mounted devices.

Connections to frequently moving parts shall be made with conductors suitable for flexing service in accordance with European standard EN 60204-1. Flexible cable and flexible conduit shall be so installed as to avoid excessive flexing and straining particularly at the fittings.

Cables subject to movement shall be supported in such a way that there is no mechanical strain on the connection points nor any sharp bending. The loop shall have sufficient length to provide for a bending radius of the cable of at least ten times its outside diameter.

Where cables subject to movement are close to moving parts, precautions shall be taken so that a space of at least 25mm shall be maintained between the moving parts and the cables. Where this distance is not practicable, fixed barriers shall be provided between the cables and the moving parts.

The cable sheath shall be resistant to the normal wear which can be expected from movement, and to the effects of atmospheric contaminants (e.g. oil, water, coolants, dust).

Where flexible conduit is adjacent to moving parts, the construction and supporting means shall prevent damage to the flexible conduit or cable under all conditions of operation.

Flexible metal conduit shall not be used for rapid or frequent movements, except when specifically designed for that purpose.

j) Wiring Practices - Ducts, connection and junction boxes

All sharp edges, flash, burrs, rough surfaces, or threads, with which the insulation of the conductors may come in contact, shall be removed from ducts and fittings. Where necessary, additional protection consisting of a flameretardant, oil-resistant insulating material shall be provided to protect conductor insulatio n.

Ducts and cable trays shall be rigidly supported and positioned at a sufficient distance from the moving parts and in such a manner so as to minimise the possibility of damage or wear.

Cable trunking systems external to enclosures shall be rigidly supported and clear of all moving or contaminating portions of the machine or equipment into which they are installed.

CDS7324 (FORMERLY LSF-0819) Rev. A INSTALLATION & USER’S MANUAL

CHAPTER 2.0 Safety & EMC Instructions 2-11

2.2.4 EMC requirements for cables

Avoid close parallel routing of signal cables and power cables. Always use the minimum length of cable necessary and install all cables in a fixed routing.

Data signal cables, motor power and resolver/signal cables, regen resistor cables and power input cables shall have segregated routings. Where cable routings must intersect, it is recommended that they intersect at an angle of 90 degrees, to minimise EMC noise coupling.

Required for

CE-Compliance

User's whose machine installations require for CE-Compliance should read this Section.

Where signal and power cables must run in parallel it is recommended that these cables are separated by at least 20 cm. Where possible cables shall be routed in earthed shielded cable ducting, to minimise electromagnetic noise coupling.

Use shielded cable to connect the external regen resistor (if installed) to the DS2110. The length of this cable shall be as short as possible. The shields of these voltage supply cables shall be earthed to Chassis Earth using the EMC 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.

Cables supplying external d.c. supply voltages to the DS2110 Servo-drive (For example, the 24 Vd.c. supply) must be as short as possible. The supply wires shall be twisted together or alternatively shielded cable shall be used.

Cables connecting the d.c. bus from the DS2110 Servo-drives must be as short as possible. Shielded cable shall be used.

Motor power cables must be shielded with the cable shield securely connected to Chassis Earth at both ends of the cable. At the DS2110 end of the cable the shield shall be earthed to Chassis Earth using the EMC kit or the panel earth bar.

Motor resolver/signal cables must be sh ielded 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.

CDS7324 (FORMERLY LSF-0819) Rev. A INSTALLATION & USER’S MANUAL

CHAPTER 2.0 Safety & EMC Instructions 2-12

2.3 Electromagnetic Compatibility (EMC)

The DS2110 Servo-drive are system components which must be installed in a correct manner to ensure that all electromagnetic compatibility (EMC) requirements are met. The requirements of European Union (EU) EMC Directive: 89/336/EEC (as amended by EU Directives 92/31/EEC and 93/68/EEC ) must be met by all equipment, systems and installations into which the DS2110 Servo-drive are installed.

Required for

CE-Compliance

User's whose machine installations are intended for CE-Compliance should read this Section.

For further information on the requirements of EU EMC Directive the user is recommended to refer to the latest publications of the EU Commission and to local regulations.

The DS2110 Servo-drive have been tested for compliance with the requirements of the EU EMC Directive in so far as they can be regarded as single functional units. The DS2110 have been tested in typical configurations and it has been found that these configurations meet the essential requirements of the EU EMC Directive. The EMC standards applied is EN61800-3:

This standard is published by CENELEC, the European Committee for Electrotechnical Standardisation, Brussels.

2.3.1 Specific Electromagnetic Compatibility (EMC) Requirements:

The EMC measures outlined below are required to be installed by the user into all equipment, systems and installations into which the DS2110 is installed. Further details are given throughout this User’s Guide.

The DS2110 Servo-drive must be installed by mounting on a panel in a manner that ensures that EMC earthing requirements are met. (Refer Section 3 of this User’s Guide).

EMC brackets are provided to facilitate earthing of cable shields prior to entering the DS2110. Cable shields must be bonded to either the panel earthing bar or the EMC brackets.

For safety reasons the DS2110 Servo-drive, and the panel on which they are mounted must be installed in enclosures or cabinets which provide a degree of ingress protection against liquids and objects of at least IP54. These enclosures or cabinets must be accessible to technically qualified service or maintenance persons only.

For Electrostatic Discharge (ESD) reasons all service or maintenance persons must ground themselves to the chassis of the equipment when performing service functions inside the IP54 rated enclosure or cabinet in which the DS2110 Servo-drive are installed.

All external d.c. supply voltages used with the DS2110 must be supplied from power supplies which are compliant with the requirements of the EU EMC Directive. All other equipment that is connected to the DS2110 must be compliant with the EU EMC Directive.

CDS7324 (FORMERLY LSF-0819) Rev. A INSTALLATION & USER’S MANUAL

CHAPTER 2.0 Safety & EMC Instructions 2-13

Shielded cable is required to be installed by the user for many external user cable connections to the DS2110. Details of areas where shielded cable must be installed and details of earthing arrangements which must be implemented for the shields of such cables are given throughout Section 3 of this User’s Guide.

This equipment intended to be connected to an industrial low-voltage power supply network, or public network, which does not supply buildings used for domestic purposes (second environment, according to EMC Standards). If connected to a low-voltage public network that supplies domestic premises (first environment), this product is expected to cause radio interference in which case supplementary measures may be required.

2.3.2 Recommended EMC Filters

No internal filtering is provided in the DS2110. To ensure EMC compliance an external line filter must be installed. The recommended filters for the DS2110 are detailed below.

DS2110 µA Size

Moog Order Code

- Schaffner Fairite Clamp.

Manufacturer Rated Current

Max Voltage Drive Input

(A)

@ 50

C (40oC)

- -

Part # 00443164151

Input

24V

(4 Turns in Common Mode)

AT6009 Schaffner FN 258-7/07 7 (8.4) 3x480V 3-phase AC Line Input

- Schaffner FN 350-12/29 12 (13.8) 1x250V

1-phase AC Line Input (µA 3/11 only)

DS2110 A,B,C,D, E Sizes

Moog Order Code

Manufacturer Rated Current

Max Voltage Drive Input\Size

(A)

@ 50

C (40oC) AT60171 Schaffner FN2070-3-06 (3) 250V 24Vdc Input AT6009 Schaffner FN258-7/07 7 (8.4) 3x480V

AT6010 Schaffner FN258-16/07 16 (19.2) 3x480V

3-phase AC Line Input (Size A)

3-phase AC Line Input (Size B)

AT6011 Schaffner FN258-30/07 30 (36) 3x480V 3-phase AC Line Input

(Size C)

AT6012 Schaffner FN258-42/07 42 (50.4) 3x480V

AT6013 Schaffner FN258-55/07 55 (66) 3x480V

AT6015 Schaffner FN258-100/35 100 (113) 3x480V

3-phase AC Line Input (Size D 50/140)

3-phase AC Line Input (Size D 60/180)

3-phase AC Line Input (Size D 100/300)

Table 3 - Recommended EMC Filters for DS2110

The 24Vdc filter can be used with two DS2110 drives. If more than two DS2110 drives are in use on a machine, a filter

from the same series can be used with a higher current rating.

CDS7324 (FORMERLY LSF-0819) Rev. A INSTALLATION & USER’S MANUAL

CHAPTER 2.0 Safety & EMC Instructions 2-14

The following table details the mechanical dimensions of the recommended filters.

Moog Order Code

AT6017 AT6009

AT6010 AT6011 AT6012 AT6013

AT6015

Manufacturer Dimensions

[mm]

Schaffner FN2070-3-06

Schaffner FN 258-7/07

Schaffner FN350-12/29

Schaffner FN258-16/07

Schaffner FN258-30/07 Schaffner FN258-42/07 Schaffner FN258-55/07

Schaffner FN258-100/35

L1 L2 L3 L4 L5 L6 L7 [kg] 85 75 54 0 65 40.3 Fast-on 0.25

255 240 50 25

225

±0.8

126

±0.8

99.5 51 105 95 99.5 57

3.5 290 55 30

275±0.8 142±0.

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

379 364 90 65 350 220

TOP VIEW SIDE VIEW

L1 L2

L4 L3

Weight

300 1.1

Terminal

blocks

only

0.9

300 1.7

Terminal

blocks

only

5.5

Table 4 - DS2110 Recommended Filters Mechanical Sizing

Caution: A space of at least 60mm (2.4”) must be left around the filter for air circulation when the cabinet does not have forced ventilation.

The filter must be located as close as possible to the drive input. If the separation between filter and drive exceeds 30 cm (1’) , then a flat cable (multi-thread copper flat cable) should be used for the RF connection between filter and drive.

Before mounting the drive and the filter to the cabinet, check that the panel surface is conductive. If not, remove any paint and/or other insulating

Required for

CE-Comp liance

material before mounting the drive and filter.

CDS7324 (FORMERLY LSF-0819) Rev. A INSTALLATION & USER’S MANUAL

CHAPTER 2.0 Safety & EMC Instructions 2-15

EMC filter can produce high leakage currents to ground (Protective Earth). The current levels associated with individual filters are detailed in the associated filter datasheet.

CAUTION: The filter must be connected to earth before connecting the supply.

2.3.3 EMC requirements for cables

Requi red for

CE-Compl i ance

User's whose machine installations require for CECompliance should read this Section .

Avoid close parallel routing of signal cables and power cables. Always use the minimum length of cable necessary and install all cables in a fixed routing.

Figure 1 Partition Crossing

All external Regen (Regenerative circuit) resistors used with the DS2110 must be installed in conductive enclosures which provide a degree of ingress protection against liquids and objects of at least IP22. Any paint on the panel or regen resistor enclosure must be removed before the regen resistor enclosure is mounted.

Cables supplying external d.c. supply voltages to the DS2110 Servo-drive (For example, the 24 V

supply) must

d.c.

be as short as possible. The supply wires shall be twisted together or alternatively shielded cable shall be used. The 24 V

supply should be routed as far from the motor power cable as possible to ensu re EMC compliance.

d.c.

Cables connecting the d.c. bus from the DS2110 Servo-drives must be as short as possible. Shielded cable shall be used.

CDS7324 (FORMERLY LSF-0819) Rev. A INSTALLATION & USER’S MANUAL

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Moog DS2110 User Manual

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User Manual