Moog DS2000 User manual

DS2000
USER'S MANUAL (rev.C)
GB-4534

INDEX
DS2000 USER’S MANUAL (rev.C)
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,
Section 3-4-7,
Appendix
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
All
C Sep 06 G motor resolver connection, APHAPOS
parameter, update figures Size E, update section
8 – Restart Interlock Function, correct
miscellaneous errors
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

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DS2000 USER’S MANUAL (rev.C)
I.2
INDEX OF CONTENTS
Index 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
I.1
I.2
I.3
I.4
I.5
I.6
I.7
I.8
I.9
I.10
Section 1
Description Introduction
Product range
General features
Technical data
Standard versions codes
Special versions codes
Options
Serial number – Nameplate
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
Section 2
Wiring and installation Introduction
Dimensions and drilling jig
External fuses
Power dissipation
Soft-start
Recovery circuit
Fans
Reset
Connection cables
AWG/mm2conversion
Wiring and connectors
Drive starting sequence
Starting sequence times
Dynamic braking
Power off
Mechanical braking
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
Section 3
Electromagnetic
compatibility (EMC)
Introduction
European directive (89/336/EEC)
Filters
Wiring and grounding
Recovery resistor
Screening
Safety aspects
3.1
3.2
3.3
3.4
3.5
3.6
3.7

INDEX
DS2000 USER’S MANUAL (rev.C)
I.3
Section 4
Starting Introduction
Drive setting up information
First Start-up
Configuration for installation in electrical cabinet
4.1
4.2
4.3
4.4
Section 5
Component description Introduction
High power input section
High power output section
Control section
5.1
5.2
5.3
5.4
Section 6
Commands 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
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
Section 7
Troubleshooting Introduction
Faults on drive power supply circuit
Faults on drive output section
Faults on feedback section
Control loops troubles
Motor troubles
Recovery resistor troubles
7.1
7.2
7.3
7.4
7.5
7.6
7.7
Section 8
Restart interlock circuit
(Optional)
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
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.12
Appendix Appendix A - Motors technical data
Appendix B - FC series technical data
Appendix C - Active software release
Appendix D - Obsolete software release

INDEX
DS2000 USER’S MANUAL (rev.C)
I.4
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.

INDEX
DS2000 USER’S MANUAL (rev.C)
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.

INDEX
DS2000 USER’S MANUAL (rev.C)
I.6
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 ≥810Vdc even after switching off
(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).
Tightening torque
Screw thread [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

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DS2000 USER’S MANUAL (rev.C)
I.7
I.4 EC DECLARATION OF CONFORMITY

INDEX
DS2000 USER’S MANUAL (rev.C)
I.8
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).

INDEX
DS2000 USER’S MANUAL (rev.C)
I.9
I.6 UL AUTHORIZATION (page 1)

INDEX
DS2000 USER’S MANUAL (rev.C)
I.10
UL AUTHORIZATION (page 2)

INDEX
DS2000 USER’S MANUAL (rev.C)
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.

INDEX
DS2000 USER’S MANUAL (rev.C)
I.12
•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 Ref.
Code Manufacturer TVSS Mod. No. Operating
Voltage
(Vac)
Clamping
Voltage
(Vac)Maximum
Energy (J) Max
Op.
Temp
Qty
Littelfuse Inc V-575-LA-40-
A
575 Vrms
max 1500 120
(10x1000µs) 85°C
S14-K-550 550 Vrms
max 1500 120 (2ms) 85°C
Epcos Ohg
S20-K-550 550 Vrms
max 1500 210
(2ms) 85°C
A and B
size AS5046
S A BC
Components NV 2322 595.551 550 Vrms
max 1500 160
(10x1000µs) 85°C
3

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DS2000 USER’S MANUAL (rev.C)
I.13
I.8 ICEPI CERTIFICATE

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DS2000 USER’S MANUAL (rev.C)
I.14
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

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DS2000 USER’S MANUAL (rev.C)
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.

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DS2000 USER’S MANUAL (rev.C)
I.16
THIS PAGE INTENTIONALLY BLANK

SECTION ONE – DESCRIPTION
DS2000 USER’S MANUAL (rev.C)
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.

SECTION ONE – DESCRIPTION
DS2000 USER’S MANUAL (rev.C)
1.2
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 Arms nominal currents.
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.