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Moog DM2020 Series

Moog DM2020 Series
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THISDOCUMENTDESCRIBESTHE INSTALLATION
ANDSTARTUP FOR THE DM2020 SYSTEM
PN: L-MAM2-E-201
INSTALLATIONANDSTARTUP
MULTI AXIS DIGITAL
SERVO SYSTEM
DM2020 TECHNOLOGY
www.moog.com

Table of Contents

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Moog DM2020 Series Specifications

General IconGeneral
CategoryDC Drives
SeriesDM2020
Output Current20 A
Cooling MethodConvection
Protection FeaturesOvercurrent, Overtemperature, Undervoltage

Summary

Foreword

About Moog

Reader Instructions

1 Introduction

1.1 Contents

Details the manual's scope and purpose for DM2020 system installation.

1.2 Related Documents

Lists other essential documents for DM2020 system installation and operation.

1.3 Package Contents

Lists the components included in a complete DM2020 system package.

1.4 Required Qualifications of Personnel

1.5 Applicable Laws

1.6 Getting Started

2 Safety Information

2.1 Safety and Usage Guidelines

Crucial instructions for safe installation, operation, and maintenance of the DM2020 system.

2.2 Qualified Personnel

Defines the qualifications and training required for personnel working with the DM2020 system.

2.3 Electrical Hazards

2.3.1 Voltage Arcs and High Voltage

Explains the dangers of voltage arcs and high voltages, including capacitor discharge times.

2.3.2 General Hazards and Safeguards

Outlines general safety precautions and safeguards for the DM2020 system and its components.

2.4 Thermal Hazards

2.5 Mechanical Hazards

2.6 STO Safety Feature

2.6.1 Description

Explains the STO function's purpose as an interlock against accidental motor rotations.

2.6.2 Directives on Safety

Details safety directives, including electrical and mechanical hazards related to STO.

2.7 Safe Use of the DM2020 System

2.7.1 Risk Assessment

Emphasizes the need for risk assessment for safe operation of the DM2020 system in industrial applications.

2.7.2 Electrical Connections

Specifies requirements for electrical connections, including the use of enclosed control cabinets.

2.7.3 Motor Selection

Discusses criteria for selecting suitable motors to be controlled by the DM2020 drives.

2.7.4 Power Supply

Details the power supply requirements and characteristics for the DM2020 series drives.

2.7.5 Prohibited Use

2.8 Risk Assessment

2.8.1 Installation Risk Assessment

Details the safety functional requirements and the relationship between PL and SIL for DM2020 installations.

2.8.2 General MachineSystem Safeguards Information

Provides general requirements for machine and system safeguards to ensure personnel safety.

2.8.3 Safeguards Related to SCRF (Safety-Related Control Function)

Outlines safeguards for Safety-Related Control Functions (SCRF) and required specifications.

3 System Overview

3.1 Product Structure

Details the physical structure and main components of the DM2020 drive system.

3.1.1 Product description

Describes the DM2020 drive as a digital servo drive with a multi-axis rack configuration.

3.1.2 Storage and Working Conditions

3.1.3 Standard power supply models

3.1.4 DM2020 Standard Models

3.1.4.1 Models and coding auxiliary bus capacitor (ABC) modules

3.1.4.2 Mechanical Dimensions

3.1.5 Axis Module coding

3.1.6 Power supply units coding

3.2 PSU Features and Details

3.2.1 Electrical and Mechanical Data

Lists the electrical and mechanical specifications for the DM2020 power supply unit (PSU).

3.2.2 Mechanical Data

Presents the mechanical dimensions for the PSU modules L50 and L150.

3.2.2 Module Side Plate Types

Illustrates and describes the types of side plates found on axis, power supply, and capacitor modules.

3.2.3 Transducers

3.2.4 Connectors

3.2.4.1 Connector layout

3.2.5 Filters

3.2.6 Brake resistor

3.2.7 Line inductors

3.2.7.1 Position transducers

3.2.7.2 Interfaces with field and other modules

3.2.7.3 Connector view

3.2.4.1 Connector Layout

3.3 Axis Module Connectors and Interfaces

X1 (X11) Connector Details

Details the pinout and function of the X1 (X11) connector for encoders.

X2, X3, X4 Connector Details

Details the pinout and function for X2, X3, and X4 connectors.

X5 Programmable Interface Connector

Details the pinout and function of the X5 programmable interface connector.

X6, X16 IO Connectors

Details the pinout and function of the X6, X16 connectors for I/O signals.

X7 Connector and Fieldbus Interfaces

Details the X7 connector and fieldbus interfaces (EtherCAT, CANopen).

Power and Brake Connectors

Details the X18, X19, X20, X21 connectors for power and brake connections.

3.3 Selecting a Non-Moog Motor

3.3.3 Connector X20 and X21

3.3.4 Motor Brake Management

3.4 Cables

4 Certifications

4.1 CE Certificate

Details the DM2020 system's compliance with European Community Directives (EMC, LVD).

4.2 Safe Torque Off (STO)

4.3 UL

4.3.1 REQUIREMENTS

Details UL requirements for modular servo-drive systems and short-circuit protection.

4.3.2 Overvoltage control

Describes the transient overvoltage control mechanisms for the DM2020 series servo drives.

4.3.3 Primary Circuit Overvoltage Protection

Lists external overvoltage protection devices and environmental conditions for the DM2020.

4.3.3 Dynamic Brake Unit Ratings

Provides ratings for the dynamic brake unit, including max current and duty cycle.

5 Electrical and Mechanical Installation

5.1 Tools and Equipment

Lists the necessary tools and electronic equipment for installing the DM2020 system.

5.1.1 Tools

Specifies the required tools for the installation of the DM2020 system.

5.1.2 Electronic Equipment

Lists the essential electronic equipment needed for DM2020 system installation.

5.2 Mechanical Installation

Provides instructions for the mechanical installation of DM2020 system components.

5.2.1 Assembly of System Components

Details the process for assembling the power supply and axis modules.

5.2.1.3 Braking Resistor Positioning

Explains the correct positioning and guarding of the external braking resistor.

5.3 Electrical Installation and Thermal Rating

Covers electrical installation procedures and thermal rating considerations for the DM2020 system.

5.3.1 Safety and General Instructions

Provides safety and general instructions for electrical installation and thermal rating.

5.3.2 Electrical Installation

Details the electrical installation of the DM2020 system, focusing on grounding, shielding, and filters.

5.3.3 Thermal Rating of the Electrical Panel

Explains how to determine the thermal rating of the electrical panel based on power dissipation.

5.3.3.1 Drive Axis Power Dissipation

Presents data on power dissipation for drive axes at different current levels.

5.3.3.2 Power Supply Unit (PSU) Dissipation

Shows power dissipation data for PSU modules at different current percentages.

5.3.3.3 Thermal Dissipation of Accessories

Lists thermal dissipation values for accessories like network filters and brake resistors.

5.3.4 Control Power Requirements

Details the required control power supply voltage and current consumption for DM2020 components.

5.3.5 AC Mains PowerGround Connection

Explains the AC mains power and ground connection requirements for the DM2020 system.

5.3.5.1 Types of Earthing (Grounding) Systems

Describes TN-C and TN-S earthing systems used for grounding the DM2020 system.

5.3.5.2 Protection Components

Recommends semiconductor fuses for short circuit protection and discusses fuse sizing.

5.3.5.3 Ground Connection

Details EMC Ground and Safety Ground connections within electrical panels.

5.3.6 Drive Wiring

Outlines the steps for wiring the DM2020 drive.

5.3.6.1 Grounding

Explains the grounding procedure for mounting the DM2020 drive to the control cabinet.

5.3.6.2 Power Cord and Braking resistor Connection

Details the connection points for power cords and braking resistors.

5.3.6.3 BUSBAR Connection

Describes how to connect the DC bus terminals of the power supply and axis modules using BUSBARs.

5.3.6.4 Auxiliary voltage and signal connection

Explains the connection of the 24 V DC auxiliary voltage and CAN connector.

5.3.6.5 Signal Connection

Refers to other sections for details on signal connectors X5, X15, X6, X16.

5.3.6.6 Motor Cable Connection Details

Shows connection points for motor cables and related warnings about voltage drop.

5.3.6.7 Brake Cable Connection

Details the brake cable connection, timing diagrams, and safety considerations.

5.3.6.8 IO Signal Connection

Explains the I/O signal connections for connectors X5, X15, X6, X16, including analogue and digital inputs/outputs.

5.3.6.9 STO signals connection

Describes how to connect STO signals using the X4-X14 connector for safety functions.

5.3.6.10 Transducer Connection

Lists common position motor transducers and their corresponding connector assignments.

5.3.6.11 Connecting the Fieldbus - X8, X9, X10 Connectors

Explains how to connect EtherCAT (X8, X9) and CANopen (X10) fieldbus interfaces.

6 Commissioning with Dx2020 Software

6.1 Safety

Highlights essential safety precautions before attempting to commission the DM2020 system.

6.2 Dx2020 GUI

Introduces the Dx2020 GUI software for configuring and controlling DM2020 drives.

6.2.1 Overview

Provides an overview of the Dx2020 GUI features and capabilities for DM2020 system management.

6.2.2 Minimum PC Requirements

Lists the minimum hardware and software requirements for the PC used with the Dx2020 GUI.

6.2.3 Dx2020 GUI Installation

Explains the procedure for installing the Dx2020 GUI software on a PC.

6.2.4 GUI Drive Connection

Guides the user on how to connect the Dx2020 GUI to the DM2020 system via serial, EtherCAT, or CAN bus.

6.2.5 Layout

Describes the layout and main areas of the Dx2020 GUI interface after establishing a connection.

6.2.6 Firmware Update (BootLoader)

Details the procedure for updating the firmware of the DM2020 system using the BootLoader.

6.2.7 Accessing the Dx2020 GUI help on-line

Explains how to access the online help documentation for the Dx2020 GUI.

6.3 Activate Power

Guides on activating power to the DM2020 system, including checking DC bus voltage.

6.4 System Configuration

Outlines the steps involved in configuring the DM2020 system, including axis, motor, and I/O settings.

6.4.1 Axis Identification

Explains how to identify and configure axes within the DM2020 system using the Dx2020 GUI.

6.4.2 Motor Parameter Configuration

Details how to configure motor parameters, including selecting motor types and enabling algorithms.

6.4.3 Transducer Configuration

Explains how to configure feedback transducers for the DM2020 system.

6.4.3.1 Sensorless

Describes how to enable and configure the sensorless mode for the DM2020 drive.

6.4.4 IO Configuration

Details how to configure the digital and analog I/O settings for the DM2020 system.

6.4.4.1 Details of Possible Configurations

Explains the various configuration options for digital inputs and outputs on the DM2020.

6.4.4.2 Programming Analog and Digital IO Connector X5

Details the programming of analog and digital I/O for the X5 connector.

6.4.5 Control Loops Configuration

Explains the configuration of control loops (torque, speed, position) in the DM2020 system.

6.4.5.1 Control mode configuration

Describes the nested control loop structure (torque, speed, position) in the DM2020.

6.4.5.2 Torque loop parameter configuration

Details how to configure torque loop parameters, including bandwidth settings.

6.4.5.3 Speed loop parameter configuration

Explains speed control loop parameterization, including PI control and feedforward.

Filter configuration

Describes the structure and types of filters available for configuring control loops.

6.4.5.4 Configuration of the position loop parameters

Explains how to configure position loop parameters, including PID control.

6.4.6 Fault Configuration

Guides on configuring fault reactions for various alarms in the DM2020 system.

6.4.7 Application Parameters Configuration

Explains how to configure drive reactions to specific events and parameters.

6.4.8 Commands and Modes Configuration

Details how to set drive command sources and operating modes.

DM2020 State Machine

Provides an overview of the DM2020 drive state machine and its functions.

6.5 STO Activation

Details the procedure for activating the Safe Torque Off (STO) circuit for axis enabling.

6.6 Auto-Phase Procedure

Guides on performing the auto-phasing procedure to find the correct motor phasing angle.

6.7 Drive (Axis) Enable and Limit Switch EnableDisable

Explains how to enable and disable the drive axis and limit switches using commands.

6.8 Oscilloscope Function and Log File (.UCX)

Describes the oscilloscope function for recording and displaying drive internal variables.

6.8.1 Log Configuration

Details how to configure logging parameters, including channels, recording time, and sampling frequency.

6.8.2 Start Logging

Explains how to start and stop data logging from the drive.

6.8.3 View Logs

Guides on viewing the logged data using the GUI's view tab.

6.8.4 UCX File Management

Explains how to manage UCX files, which store recorded data.

6.9 Using the GUI in Offline Mode

Describes how to use the Dx2020 GUI in offline mode for configuration file creation and editing.

6.10 Contextual Help For Parameter Management

Details the context menu options for parameter management within the Dx2020 GUI.

6.11 Decommissioning Procedure

Provides step-by-step instructions for safely decommissioning the DM2020 system.

7 Shipment and Storage

7.1 Receiving and Checking the Shipment

Outlines the procedure for inspecting shipments for damage and discrepancies.

7.2 Storage

Provides recommendations for storing DM2020 system components.

8 Maintenance

8.1 Periodic Maintenance

Details periodic checks for the exterior case and signal/power cables of the DM2020 system.

8.2 What to Do If Repairs Are Required?

Explains the process for initiating repairs, including obtaining an RMA number.

9 Troubleshooting

9.1 Power Supply Section Anomalies

Lists common anomalies in the power supply section and suggested actions.

9.2 Drive Alarms (Faults)

Explains how to troubleshoot drive alarms using the Dx2020 GUI software.

9.2.1 Alarms on the Power Section

Identifies alarms related to IGBTs affected by phases U, V, or W in the power section.

9.2.2 Alarm for VBUS Voltage Out of Tolerance

Details alarms related to VBUS voltage deviations and their causes.

9.2.3 Drive or Motor Overtemperature

Lists alarms related to overtemperature conditions in the drive or motor.

9.2.4 Removal of STO Signal

Explains issues related to the STO signal and its protection intervention.

9.2.5 Errors on Memory Devices

Addresses faults related to damaged or inaccessible internal memory devices.

9.2.6 Data Corrupted Fault

Lists common data corruption faults related to initialization, user data, and calibration memory.

9.2.7 Brake Feedback Fault

Details faults in the motor braking circuit and their potential causes.

9.2.8 Errors on Feedback Devices

Discusses errors related to feedback signals and transducers, emphasizing cable and configuration checks.

9.2.9 Synchronization, Interrupt Time and Task Time Error

Covers errors related to synchronization, interrupt time, and task execution time.

9.2.10 EtherCAT Fault

Lists common communication faults associated with EtherCAT interface.

9.2.11 Alarms Related to the Control Loops

Details alarms related to control loop monitoring, such as speed and following errors.

9.2.12 CAN Bus Alarms

Lists common communication faults associated with CAN bus interface.

9.3 Alarm Display in Analog Operating Mode

Explains how alarms are displayed in analog operating mode, including error codes and descriptions.

9.4 Faults During the GUI - Drive Connection

Describes common faults that can occur during the GUI to drive connection process.

10 Safe Torque Off Safety Function

10.1 Application

Describes the application of the STO safety function and its integrated circuit design.

10.2 Installation Risk Assessment

Explains safety functional requirements, SIL, and PL levels for DM2020 drive installations.

10.3 Safe Torque Off Function

Discusses the validation of the STO safety function according to safety integrity levels.

10.3.1 Characteristic Values According to UNI EN ISO 13849-1

Lists characteristic values for hardware and software feedback according to UNI EN ISO 13849-1.

10.3.2 Characteristic Values According to CEI EN 62061

Lists characteristic values for hardware and software feedback according to CEI EN 62061.

10.4 Safety Requirements

Outlines the safety requirements for the Safe Torque Off (STO) function.

10.4.1 Full Stop

Describes the "Full Stop" capability of the STO function and its implications for machine safety.

10.5 Safe Torque Off Circuit

Explains the design and operation of the Safe Torque Off circuit with redundant blocking devices.

10.6 Safe Torque Off Connections

Details the connections for the Safe Torque Off circuit, including channel management.

10.6.1 Connector X4 (X14)

Describes the pinout and function of the X4 (X14) connector for STO signals.

10.6.2 Connector X1-X11 (Option)

Details the pinout and function of the optional X1-X11 connector for STO feedback.

10.6.2 Electrical InputOutput Specifications

Provides electrical specifications for the input and output channels of the STO circuit.

10.7 Example Application

Illustrates an example circuit for Safe Torque Off after a controlled stop.

10.7.1 Description

Describes the components and redundant channels used in the STO example circuit.

10.7.2 Example Requirements

Lists the requirements for the STO example application, including PL and SIL levels.

10.8 Safe Torque Off Installation and Maintenance Procedure

Outlines the installation and maintenance procedures for the STO function.

10.9 Assembly and Serial Tests

Mentions that the STO circuit is assembled and tested at Moog Casella.

10.10 Identification of the STO Function on the Drive Plate

Explains how to identify the STO function on the drive plate.

11 System Disposal

12 Appendix

12.1 Glossary

Defines technical terms used in the DM2020 manual.

12.2 MetricAWG Conversion Table

Provides a conversion table between metric wire sizes and AWG gauges.

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