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Application Note:
Wiring Diagrams to
replace
DS2000
with
DS2020

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Foreword
Moog has identified the DS2020 as the ideal replacement for the DS2000 drive in all applications. In the
following pages the main characteristics of the two drives are listed and the necessary operations to make
the replacement while maintaining the functionality of the system, are detailed.

Index
DS2000 pg 2
Dimensions
Standard sizes
Connection and Connectors
DS2020 pg 7
Dimensions
Standard sizes
Connection and Connectors
Size comparison pg 12
Preliminary operations details pg 12
DS2000 Interface towards DS2020 pg 13
DS2020 settings pg 16

Operational Addendum pg 17

DS2000

The DS2000 is a fully digital drive, powered by 220 to 460 Vac three-phase, equipped with soft start and braking
units on all sizes; Is equipped with a on-board programming keypad and an RS485 / 422 interface for interfacing with
a computer or PLC.
Available sizes cover currents from 3 to 140 Arms, with peak values from 9 to 500 Asin and drives are ventilated
independently.
The DS2000 drives allow you to use any type of brushless motor and any type of resolver.

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Dimensioni

Size A

Size B

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Size C

Size D

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Available Sizes

Note:
The first number of the size indicates the RMS output current of the drive; The second number is the peak sinusoidal
output current; The RMS peak value is obtained by dividing this value by 0.7. A verification of the codes and models
must be made at the time of order in order to have the exact compatibility between the drives.

Attention
The DS2020 currently only covers the DS2000 sizes up to 50/140

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Connections
Input References Connector J2A

Pos. N
Pos. Function
Differential, non-inverted input of speed or torque reference signal (0÷
1■ VRef+ ±10V, corresponding to 0÷ ±Max input reference). The end of scale is ad-
justable via software from ±3.2 to ±10V in steps of 0.1V
2 VRef- Differential, inverted input of speed or torque reference signal
Differential, non-inverted input of analog current limit (0÷ ±10V, corre-
3 Ilimit+ sponding to 0÷ 100%Max set current). The end of scale is adjust-able via
software from ±3.2 to ±10V in steps of 0.1V
4 Ilimit- Differential, inverted input of analog current limit
Drive Enable Connector J2B
Pos. N Function
1■ +15V OUT +15Vdc output, max 100 mA
2 0V Logic Zero
3 ANL OUT Configurable output (see Analog out configuration)
Tachometric signal output
4 TCH OUT (0 ÷ ±10V, corresponding to 0 ÷ ± Max speed rpm). The end of scale
is adjustable via software from ±5 to ±10V in steps of 0.1V
5 ESTART+ Opto-insulated Reset input (15 ÷24 Vdc/12mA)
By means of a > 20 ms duration pulse the re-initialization of the digi-
6 ESTART- tal control card and the protections reset are carried out
7 DRV EN+ Opto-insulated Drive Enable input (15 ÷ 24 Vdc/12mA)
8 DRV EN- When signal is missing the drive does not supply current
9 EF EN+ Opto-insulated Reference Enable input (15 ÷ 24 Vdc/12mA)
When signal is missing the motor is in standstill position, at zero
10 EF EN- speed if in speed control mode, it has zero torque if in torque control
mode. This input can be used for emergency braking
11 RV OK Drive OK outputs. Contact closed (24Vdc relays, max 100 mA) indi-
cates that Drive is OK.
It is recommended to logically connect the DRIVE OK isolated output
12 RV OK presence to the power contactor, so that the power supply is disabled
in case of fault

Connector Simulated Encoder J2C

Pos. Name
N ame Function
1■ A+ Encoder output: A channel
2 A- Encoder output: A channel denied
3 B+ Encoder output: B channel
4 B- Encoder output: B channel denied
5 C+ Encoder output: C channel
6 C- Encoder output: C channel denied

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DS2020

The DS2020 is a series of digital drives that can simply replace the corresponding DS2000 family models.
The available sizes cover currents from 2 to 48 Arms, with peak values from 4 to 96 Arms and the drives are
ventilated independently.

The DS2020 drives have the same customizations as DS2000 drives, using any type of motor and any type of
resolver; Replacement is always possible as all the same features are available.

Whilst changing the connectors it is possible to control both the drives in the same way and have the same
enabling and command sequences.

The auxiliary power is 24 Volt DC.

Note:
If DS2000 is used with the simulated external encoder in "single ended" mode, contact Moog Casella to check
the compatibility between the signal levels.

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Dimensions

Axis Module 50 mm (1,97 inch)

50 (1.97) 199.40 (7.85)

7.5 (0.30) 180 (7.09)
203 (7.99)

215 (8.46)

170 (6.69)
4.5 (0.18) 21 (0.83)

Axis Module 75 mm (2,95 inch)

75 (2.95) 199.40 (7.85)

7.5 (0.30) 180 (7.09)
203 (7.99)

215 (8.46)

170 (6.69)

4.5 (0.18) 21 (0.83)

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Axis Module 85 mm (3,35 inch)

Axis Module 125 mm (4,92inch)

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Available sizes

Mechanical hardware configuration

value type / Rated peak
width current current
02 Single / 50mm
2 Arms 4 Arms
l50A
04 Single / 50mm
4 Arms 8 Arms
l50A
06 Single / 75mm
6 Arms 12 Arms
l75A
08 Single / 75mm
8 Arms 16 Arms
l75A
12 Single / 75mm
12 Arms 22 Arms
l75B
16 Single / 85mm
16 Arms 32 Arms
l85A
24 Single /85mm
24 Arms 48 Arms
l85A
32 Single / 125mm
32 Arms 64 Arms
l125A
48 Single / 125mm
48 Arms 96 Arms
l125B

Note:
A verification of the codes and models must be made at the time of order in order to have the exact compatibility
between the drives.

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Connections

Connector as I/O Line Driver X4 Connector STO X6

X6
X4 Power +24V
STO and 0 to manage
Digital i/ O 3 Digital interfaces Safe STO function
line drivers line drivers Torque
freely programmable Off
as INPUTS and OUTPUTS

Simulated Encoder Connector X4

Reference Connector X5 X4
X5
Analog IN Simulated To PLC Encoder
Encoder Interface
Analog IN
Analog OUT
Input/Output 0 Volt for Analog IN and OUT
References Resolver Connector X2
Digital OUT
X2
DRV contact OK

Digital IN Resolver Same connections

Connector as DS2000 and DBS
0 Volt for Digital IN

Connector as I/O and RS232 X4

X4

Serial
RS232

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Size comparison

DS2000 Width Height Depth Equivalent DS2020

A 95,5 mm 330 mm 208 mm Size L50 e L75
B 120 mm 330 mm 208 mm Size L85
C 165 mm 410 mm 208 mm Size L125
D 265 mm 410 mm 208 mm Size L125

DS2020 Width Height Depth Equivalent DS2000

L50 50 mm 203 mm 199,4 mm Size A
L75 75 mm 203 mm 199,4 mm Size A
L85 85 mm 343 mm 243,2 mm Size B
L125 125 mm 343 mm 243,2 mm Size C e D

Preliminary operations details

1. Check the configuration of the machine equipped with the DS2000

2. Check motor models and their electrical characteristics
3. Depending on the number and the axis currents, choose the DS2020 modules
4. Verify if the power of the standard braking resistor is sufficient
5. Check the electrical wiring and make the necessary changes (especially for the sections "SAFETY", DRV OK and
MOTOR OK to fit according to how it is managed by the machine)
6. Check the securing holes for the drives in the cabinets and if necessary prepare a bracket (Panel) to optimize
drive replacement times
7. If possible, "read" the DS2000 axis calibrations to allow DS2020 to be programmed quickly with the settings
required by the application; From the DS2000 manual you can make out any difference between the drive
settings and the default.
Contact the Moog operations of Casella for suggestions and possible verifications.

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DS2000 interface towards DM2020

Cross Reference

Simulated Encoder
DS2000 DS2020
Signal Pin on J2C Pin on X4 Signal
A+ 1 2 A+
A- 2 3 A-
B+ 3 4 B+
B- 4 5 B-
C+ 5 6 C+
C- 6 7 C-

Input reference
DS2000 DS2020
Signal Pin on J2A Pin on X5 Signal
Vref+ 1 1 IN AN 1+
Vref- 2 2 IN AN 1-
Ilimit+ 3 3 IN AN 2+
Ilimit- 4 4 IN AN 2-

Enabling connector
DS2000 DS2020
Signal Pin on J2B Pin on X5 Signal
+15V OUT 1
0V 2 8 e 16 0VOLT DIG/ANAL
ANAL OUT 3 6 OUT AN2
TACHO OUT 4 5 OUT AN1
RESTART+ 5 15 RESTART
RESTART- 6 8 0VOLT DIG.
DRV EN+ 7 13 IN DIG 1
DRV EN- 8 8 0VOLT DIG.
REF EN+ 9 14 IN DIG 2
REF EN- 10 8 0VOLT DIG.
DRV OK 11 11 DRIVE_OK
DRV OK 12 12 DRIVE_OK

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Auxiliary power connector

DS2000 DS2020
Signal Pin on J6 Pin on X1 Signal
+24V 11 1 +24V
0V 12 2 0V

X1 connector on DS2020

J6 connector on DS 2000

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Power connections

DS2000 DS2020
Connector Connector X11
J6
DCBUS- Not existing
DCBUS+ RR
Not existing RRi
RR RRe
*see Note
L1 U1
L2 V1
L3 W1
PE GND
W W2
V V2
U U2

Note: It is necessary to remove the jumper between RRi and RRe on the X11 connector to use
the external RR

X11 connector on DS2020

J6 connector on DS2000

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DS2020 Settings
1. Set the motor parameters
2. Set drive parameters after converting the various settings to have the same functionality and calibration
and leave the drive in "Local"
3. Perform the phasing of the motor without load if possible to control the motor and the cables
4. Set in "Remote", save and the drive is ready to go.

All these settings are described in the installation manual of the DS2020.

Note:
Through the GUI DX2020 you can duplicate all the customizations of the DS2000.
At the end of setup operations, save the configuration, turn it off and on again to make sure all settings work
properly and to reset any alarms present.
If possible perform the timing with the motor disconnected from the load in order to avoid an inaccurate result.

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Operational Addendum:

Correspondence between
Parameter References
DS2000/DS2020

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DS2000 Startup Display

DS2020 GUI Starting Window

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General Motor Parameters Menu DS2000

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References between DS2000 and DS2020

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Set the I / O as indicated for SW releases ending with 0 (3.000, 3.100, 3.200). If you do not need the Analog TORQUE
LIMIT, do not select anything in AUX IN 2.
If the DS2000 has a SW release ending with number 1 (3.101, 3.201 etc.) set REL OUT as follows:

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Menu Parametri Azionamento

Serial or USB communication is just point-to-point; the multidrop

connection is no longer supported.

The protocol is no longer available for accessing internal data and sending
commands via serial, but only via CANOpen or EtherCat fieldbus or via GUI.

The braking resistor is not available.

The tachometer output is scaled permanently at 10 volts at the set

Maximum Speed

The dead band is set via shell with the aux1deadband parameter in millivolt.

The Antifreewheeling function can be set as a reaction to the "fault"

The protection I2T IGBT is defined as "overcurrent" and is already

programmed to the maximum allowed value for the IGBT used on different
sizes

Notch filter on velocity ring is available

Increased torque see "field weakening"

Remote Enable becomes Analog

The reverse direction function via SW is no longer

available

Only one acceleration and deceleration ramp

(symmetric) is available

The digital reference is no longer salvable on the drive

Both the Reference and the ILIMT are fixed at 10 volts

and are no longer scalable unless you change the
maximum speed

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Drive Parameters Correspondence

The threshold for the NTC

probe is fixed in the drive to
6500 Ohm

The aux1_deadband parameter is in

internal units (1mV = 3 units ).

Program alarms for Undervoltage OVT Drive

OVT Motor as "Disable" and then program the
Fault Reaction as Ramp Quickstop and set the
corresponding deceleration to a value that the
machine is able to handle (3000 rpm/s stops
the machine in a second from 3000 rpm)

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In "Local" you can move the

axis after it is enabled in both
JOG and with different speed
profiles

The "Remote" command

corresponds to the "Analog"
command

Note: In the Maximum Current field of the GUI, always insert the highest value between the two present in
the DS2000 (Motor Size and Maximum Current)

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The current loop parameters are directly set

from the "Motor Parameters" menu and no
further setting is required.

The two parameters Speed REF and Current

REF are no longer available.

ATTENTION
The DS2000 uses a scale for gains in internal
units while the DS2020 employs physical units.
Use the "Auto Calibration" to indicate the
gains to be set, entering an inertia indicative of
the load and the torque constant of the motor
for the calculation.
Set the bandwidth to 75/100 Hz.

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Offset Calibration of Analog Input for DS2020

Go to the "Advanced" mode of the GUI

Go to the I / O page and click Show Offset Calibration Window. Press Start Calibration and wait for execution. When
done press Save.

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Display Variables Menu

More information can be obtained with the oscilloscope of the DS2020.

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Utility Menu

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Autophasing

The procedure is as follows:

Set the DS2020 Drive in Local, with three-phase current provided, Connected STOs, Configured Resolver,
Resolver Cable Compensation Executed, Motor Parameters Inserted; if possible free the motor from any
load. Put the drive first in the "Power Off" and then in the "Power On" position.

Go to the Feedback menu, set a phasing current equal to the nominal motor current then press Start
Autophasing for its execution.

Note
The DS2000 APHAPOS parameter corresponds to the THETA ANGLE parameter of the DS2020. However, it is not a direct match
because the two parameters apply different scales. As a result, you cannot simply transfer the APHAPOS value of the old drive to
the new one. To obtain the correct THETA ANGLE value you must perform the phasing procedure.

For any information or request for assistance please contact

Moog Casella
Via Avosso 94, 16015 Casella, (GE) - Tel +3901096711 - email: [email protected]

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