CDS38231 - L081-602 Igv Moog

PARTLY COMPLETED
MACHINERY
Electro Mechanical
Actuator for IGV
Assembly Instructions
Rev. 0, April 2013

THIS DOCUMENT DESCRIBES THE INSTALLATION, OPERATION AND MAINTENANCE OF THE MOOG PARTLY COMPLETED
MACHINERY Electro Mechanical Actuator for IGV.
DOCUMENT NR. CDS38231
FOREWORD
This manual "PARTLY COMPLETED MACHINERY Electro Mechanical Actuator for IGV – Assembly Instructions" has been
prepared in accordance with CEI EN 62079, "Preparation for instructions - Structuring, content and presentation."
The manual was written and checked at the best experience of Moog.
Moog written this technical documentation complied with the requirements of the Machinery Directive 2006/42/EC.
IMPORTANT: No part of this document may be copied, duplicated, reproduced, stored in a data
storage system, translated into different language, or transmitted by data communication system,
without the consent of Moog
ABOUT MOOG
Moog’s Industrial Group designs and manufactures high performance motion control solutions combining electric,
hydraulic, and hybrid technologies with expert consultative support in a range of applications including test,
simulation, plastics, metal forming, and power generation.
Moog customers include leading automotive manufacturers, aerospace manufacturers, testing labs and global
automotive racing teams.
We help performance-driven companies design and develop their next-generation machines.
Moog’s Industrial Group is part of Moog Inc.
For more information please visit www.moog.com/industrial.
Info Description
Moog Company Moog Italiana S.r.l. (Malnate)
Via G. Pastore, 4
Address
Malnate (VA) 21046 - Italy
Tel +39 0332 421 111
Fax +39 0332 429 233
e-Mail info.italy@moog.com
Web Site www.moog.com

DOCUMENT VERSION
The following table shows the version of this document and all other possible versions:
ES DA DE EL EN FR IT NL PT FL SV CS ET LV HU MT PL SK SL BG RO GA
The language of documents and drawings are subject to contractual negotiations with the Customer.
IN case of “Translation of the Original Instructions”, the manufacturer of the machinery supplies also the “Original
Instructions”.
REVISION RECORD
The following table shows the revision record:
Revision Description Prepared Checked Approved Date
0 First issue BEB CAR, FAP LOF April 2013

GLOSSARY
The following table shows the abbreviations adopted in Moog documents:
Abbreviation Explanation
EMA Electro Mechanical Actuator
EH Electro Hydraulic Actuator
EHA Electro Hydrostatic Actuator
MSD Moog Servo Drive
The following table shows the symbols adopted in Moog documents:
Symbol Explanation
IMPORTANT: Warning and notes about important operations and useful information
ATTENTION: Danger to persons, including death

CONTENTS
Foreword ........................................................................................................................................................... 2
About Moog ....................................................................................................................................................... 2
Document version ............................................................................................................................................. 3
Revision record .................................................................................................................................................. 3
Glossary ............................................................................................................................................................. 4
Contents ............................................................................................................................................................ 5
1. Identification ............................................................................................................................................. 8
1.1. Nameplate and type designation ...................................................................................................... 8
1.2. Manufacturer name and address .................................................................................................... 10
1.3. Warranty and Liability ..................................................................................................................... 10
1.4. Declaration of Incorporation ........................................................................................................... 11
1.5. Applicable standards ....................................................................................................................... 11
2. General description ................................................................................................................................. 13
Servo Actuator ............................................................................................................................................. 14
Driver ........................................................................................................................................................... 14
Cables .......................................................................................................................................................... 14
2.1. Intended use .................................................................................................................................... 14
2.2. Dimensions and weight ................................................................................................................... 15
2.3. Connections ..................................................................................................................................... 15
2.4. Energy consumption and conditions ............................................................................................... 15
2.5. Emissions ......................................................................................................................................... 15
2.5.1. Noise, gases, water .................................................................................................................. 15
2.5.2. Radiations ................................................................................................................................ 15
2.6. IP code ............................................................................................................................................. 15
2.7. Electromagnetic compatibility......................................................................................................... 15
2.8. PPE ................................................................................................................................................... 16
2.9. Reasonably foreseeable misuse ...................................................................................................... 16
3. Safety ....................................................................................................................................................... 17
3.1. General warnings ............................................................................................................................. 17
3.2. Recommendations for safe application........................................................................................... 17
3.3. Environmental conditions and limits ............................................................................................... 19
3.4. Disposal............................................................................................................................................ 19
3.5. Risks ................................................................................................................................................. 20
3.5.1. Hazards arising from incorrect use .......................................................................................... 20
3.5.2. Residual risks ........................................................................................................................... 20
3.5.3. Particular risks due to certain applications ............................................................................. 20
3.6. Protections ...................................................................................................................................... 20
3.6.1. Safe design measures .............................................................................................................. 20
3.6.2. Safeguarding measures ........................................................................................................... 20
3.6.3. Protective measures ................................................................................................................ 20
3.6.4. Complementary protective measures ..................................................................................... 21
3.7. Special Labels................................................................................................................................... 21
4. Preparing the product for use ................................................................................................................. 23
4.1. Transport ......................................................................................................................................... 23
4.2. Storage............................................................................................................................................. 23
4.3. Installation and assembly ................................................................................................................ 23
4.3.1. Procedures for unpacking ........................................................................................................ 23
4.3.2. Inventory checklist................................................................................................................... 23
4.3.3. Fixing/anchoring and vibration damping requirements.......................................................... 23
4.3.4. Foundation block or similar base ............................................................................................ 23
4.3.5. Provisions against emissions ................................................................................................... 23
4.3.6. Minimum space needed for use, maintenance and repair ..................................................... 23
4.3.7. Layout plan .............................................................................................................................. 24
4.3.8. Installation plan ....................................................................................................................... 24
4.3.9. Interconnection diagrams ....................................................................................................... 24
4.3.10. Methods of connection ........................................................................................................... 24
4.3.11. Permissible environmental conditions .................................................................................... 24
4.3.12. Waste removal/disposal .......................................................................................................... 24
4.4. Commissioning ................................................................................................................................ 24
5. Operating instructions ............................................................................................................................. 25
5.1. Safe functioning ............................................................................................................................... 25
5.2. Normal function............................................................................................................................... 25
5.3. Secondary functions ........................................................................................................................ 25
5.4. Exceptional functions ...................................................................................................................... 25
5.5. Signal to be observed ...................................................................................................................... 25
6. Maintenance and cleaning ...................................................................................................................... 26
6.1. Safety precautions ........................................................................................................................... 26
6.2. By users............................................................................................................................................ 26
6.2.1. Nature and frequency of maintenance operations ................................................................. 26
6.2.2. Preventive maintenance .......................................................................................................... 26
6.2.3. Maintenance schedules ........................................................................................................... 26
6.2.4. Inspection for safety ................................................................................................................ 27
6.2.5. Safety warnings for running or live equipment ....................................................................... 27
6.2.6. Drawings and diagrams ........................................................................................................... 27
6.2.7. Cleaning ................................................................................................................................... 27
6.3. Trouble-shooting, fault diagnosis, and repair ................................................................................. 27
6.3.1. Fault diagnosis and identification............................................................................................ 27
6.3.2. Repair and adjustments........................................................................................................... 27
6.3.3. Built-in diagnostic systems ...................................................................................................... 27
6.3.4. Checking of warning devices ................................................................................................... 27
7. Spare parts and consumables.................................................................................................................. 28
7.1. Identification ................................................................................................................................... 28
7.2. Bill of material ................................................................................................................................. 28
7.3. Source of supply .............................................................................................................................. 28
8. Workstations ........................................................................................................................................... 29
9. Tool characteristics .................................................................................................................................. 30
9.1. Standards tools ................................................................................................................................ 30
9.2. Special tools ..................................................................................................................................... 30
9.3. Source of supply .............................................................................................................................. 30
10. Decommissioning ................................................................................................................................ 31
10.1. Destruction .................................................................................................................................. 31
10.2. Recycling ...................................................................................................................................... 31
10.3. Disposal........................................................................................................................................ 31
11. Attachments ........................................................................................................................................ 32
1. IDENTIFICATION
1.1. Nameplate and type designation

The following image shows an example of the label of the servo actuator of the partly completed machinery
Electro Mechanical Actuator for IGV:
In this label there are three (3) fields to define the characteristics of the servo actuator. The following table shows
these three fields:
Characteristic Description Value
Mod: Model L875-603
S/N Serial Number See on the nameplate
Date Manufacturing date (month/year) See on the nameplate
NP Purchasing Code Nuovo Pignone Purchasing Code RAO21196
The following image shows an example of the label of the motor of the partly completed machinery Electro
Mechanical Actuator for IGV:
The following table lists the fields of the nameplate of the servo motor:
Model Motor Model G495L1007
Serial Serial Number See on the nameplate
Mfg.Date Manufacturing date (year/month) See on the nameplate

-1
nN [min ] Nominal Speed 2.000
PN [kW] Nominal Power 2,451
Ud [V] Voltage 565
Mo [Nm] Nominal Torque 18,39
Io [Arms] Current 10,43

2
J [kgcm ] Moment of Inertia 19,4080
Temp. class Temperature class T4
Am. Temp. Ambient temperature -40° C/ +80° C
Weight [kg] Weight 22
Brake [Nm] Brake torque 22
Type Motor Type G-5LV8-020-02-99-01-00-000

-1
nmax [min ] Maximum Speed 4.260
Mmax [Nm] Maximum Torque 61,26
Fsw [kHz] Switching Frequency 4
The following image shows an example of the labels of the driver of the partly completed machinery Electro
In this label there are eight (8) fields to define the characteristics of the servo actuator. The following table shows
these eight fields:
IECEx BKI 10.0001X

IECEx Certificate
- Ex nA IIB+H2 T5 Gc
IECEx Certification
Ex t IIIC T100°C Dc
Code Model code CZ140100
Vin Voltage 400 Vac +/-10%
Iin In current 6 Arms
Iout Out current 6 Arms 22 Apeak
- ATEX Certification II 3GD
IP66
- Environmental conditions
-20°C≤Ta≤+55°C
1.2. Manufacturer name and address

The following table shows all the information regarding the manufacturer:
Info Description
Via G. Pastore, 4
Address
Tel +39 0332 421 111
Fax +39 0332 429 233
1.3. Warranty and Liability

In principle, Moog general terms and conditions for delivery and payment apply. These shall be available to the
buyer at the latest at the time the sales contract is completes. See the document: “General Terms and Conditions
of Sale and Delivery of Moog Italiana S.r.l. (Malnate)”.
1.4. Declaration of Incorporation
The following image shows an example of the Declaration of Incorporation supplied with the partly completed
machinery Electro Mechanical Actuator for IGV:
A hard copy of the Declaration of Incorporation related to the partly completed machinery Electro Mechanical
Actuator for IGV is supplied to the Customer together with this Instructions manual and the partly completed
machinery itself (see Attachment 1).
1.5. Applicable standards

The following table shows the applicable European Directives:
Directive Description
2006/95/EC Low Voltage Directive
2004/108/EC EMC Directive
94/9/EC ATEX Directive

The following table shows the applicable standards:
Standard Description
Explosive atmospheres - Explosion prevention and protection - Part 1: Basic concepts and
EN 1127-1:2011
methodology
EN ISO 12100: 2010 Safety of machinery – General principles for design – risk assessment and risk reduction
Non-electrical equipment for use in potentially explosive atmospheres - Part 1: Basic method
EN 13463-1: 2009
and requirements
EN 13463-5:2011: Non-electrical equipment intended for use in potentially explosive atmospheres - Part 5:
2011 Protection by constructional safety ‘c’
EN 50178: 1997 Electronic equipment for use in power installations
EN 60034-1: 2010 Rotating electrical machines - Part 1: Rating and performance
Rotating electrical machines - Part 5: Degrees of protection provided by the integral design of
EN 60034-5:2006
rotating electrical machines (IP code) - Classification
EN 60079-0: 2009 Explosive atmospheres - Part 0: Equipment - General requirements
EN 60079-1: 2007 Explosive atmospheres - Part 1: Equipment protection by pressurized enclosure ‘p’
EN 60079-7: 2007 Explosive atmospheres - Part 7: Equipment protection by increased safety ‘e’
EN 60079-15: 2010 Explosive atmospheres - Part 15: Equipment protection by type of protection ‘n’
EN 60079-31: 2009 Explosive atmospheres - Part 31: Equipment dust ignition protection by enclosure ‘t’
IEC EN 60204-1:2006 Safety of machinery - Electrical equipment of machines - Part 1: General requirements
Low-voltage fuses - Part 3: Supplementary requirements for fuses for use by unskilled persons
EN 60269-3: 2007 (fuses mainly for household or similar applications) - Examples of standardized systems of
fuses A to F
EN 60529:1991 Degrees of protection provided by enclosures (IP Code)
Electromagnetic compatibility (EMC) - Part 4-2: Testing and measurement techniques -
EN 61000-4-2:2009
Electrostatic discharge immunity test
EN 61000-4-3:2006
Radiated, radio-frequency, electromagnetic field immunity test
Electromagnetic compatibility (EMC) – Part 4-4: Testing and measurement techniques –
EN 61000-4-4:2004
Electrical fast transient/burst immunity test
Electromagnetic compatibility (EMC) - Part 4-5: Testing and measurement techniques - Surge
EN 61000-4-5:2006
immunity test
EN 61000-4-6:2009
Immunity to conducted disturbances, induced by radio-frequency fields
Adjustable speed electrical power drive systems - Part 3: EMC requirements and specific test
EN 61800-3:2011
methods
Adjustable speed electrical power drive systems - Part 5-1: Safety requirements - Electrical,
EN 61800-5-1: 2007
thermal and energy
2. GENERAL DESCRIPTION
The product is made up of the following parts:
Parts Description
L875-603 Servo Actuator
CZ140100 Servo Driver
CB54994 Power cable
CB54995 Signal cable
The following image shows a general sketch of the partly completed machinery Electro Mechanical Actuator for
IGV:
EMA ACTUATOR
SERVO DRIVE
Servo Actuator
The mechanical converter performs motor torque amplification through a planetary gear train and converts rotary to
linear movement by a ball screw.
The motor is a synchronous DC motor with electronic commutation and permanent magnet field excitation.
Please, refer to the Attachment 2 for further information.
Driver
The drive is a full digital brushless servo drive which control the brushless DC motor; the drive permits a close loop in
position, using the feedback from the resolver.
Cables
The power and signal cables connect the servo actuator to the servo drive, which need to be connected to the power.
Please, refer to the Attachments 4 and 5 for further information.
2.1. Intended use

Partly completed machinery Electro Mechanical Actuator for IGV is a work machine use to control the IGV of the
Nuovo Pignone FRAME 5-2E gas turbine.
The partly completed machinery Electro Mechanical Actuator for IGV is designed for industrial applications.
For its intended use, the following applies:
 Observance of the “Assembly Instructions” manual
 Handling the partly completed machinery safety
 Adhering to the inspection and maintenance instructions from the customer for the plant of installation
 Following all of the corresponding relevant supplemental documentation in accordance with the
application
 Observance of the relevant regulations applicable nationally and internationally, as well as applicable
standards and directives (such as e.g. the EU Machinery Directive and the applicable regulations by the
Employer’s Liability Insurance Association, TUEV or VDE) as amended
 Modification to the design or repairs and maintenance work or improperly performances are
unauthorised
 Adhering to all technical data during storage, transport, assembly, disassembly, connecting, start-up,
configuring, operating, cleaning, repairing or resolving any possible failures, especially to the ambient
conditions
 Avoiding improper storage, transport, assembly, disassembly, connection, start-up, configuration,
operation, cleaning, repairing, resolving any possible failures or disposal
 Avoiding the use of unsuitable or defective accessories or rather unsuitable or defective spare parts
 Catastrophic events beyond our control or acts of Gods are not under Moog responsibility
2.2. Dimensions and weight
For the main dimensions and weight of the partly completed machinery Electro Mechanical Actuator for IGV,
please refer to the following attachments 2, 3, 4 and 5.
For the mechanical characteristics of the partly completed machinery Electro Mechanical Actuator for IGV, please
refer to the Attachment 2.
For the electrical characteristics of the partly completed machinery Electro Mechanical Actuator for IGV, please
refer to Attachments 2, 3, 4 and 5.
2.3. Connections
For the installation drawings in which it is possible to find all the indications for mechanical connections of the
partly completed machinery Electro Mechanical Actuator for IGV, please refer to the Attachments 2 and 3.
For the electrical connection drawings of the partly completed machinery Electro Mechanical Actuator for IGV,
please refer to the Attachment 2 and 3.
2.4. Energy consumption and conditions

For consumption data of the motors of the partly completed machinery Electro Mechanical Actuator for IGV,
please refer to the Attachment 2.
2.5. Emissions
2.5.1. Noise, gases, water

Not applicable.
2.5.2. Radiations
Not applicable.
2.6. IP code
For the IP code of the partly completed machinery Electro Mechanical Actuator for IGV, please refer to the
Attachments 2 and 3.
2.7. Electromagnetic compatibility

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 provided by the EMC filter mounted inside the drive enclosure and by the cable shielding.
The shields of the cables must be connected at both ends to the proper housing via full circumferential bond to
the metallic cable glands or connectors.
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).
It is not intended to be used on a low-voltage public network which supplies domestic premises (first
environment). Radio frequency interference is expected if used on such a network.
Please, refer to the Attachments 2 and 3.
2.8. PPE
Personal Protective Equipment could be required to move, to mount, to dismount, to perform any activities with
the partly completed machinery. The general and also the local regulations on the prevention of accidents and on
environmental protection should be observed.
2.9. Reasonably foreseeable misuse
IMPORTANT: Use of the product in any other way than as described under “Intended use” is
considered to be misuse and is therefore not permitted
Misuse is connected to operating the partly completed machinery outside the specifically defined application and
environmental conditions in relation to:
 Force, speed and stroke
 Temperature
 Shock/vibration
 Protection class
 Electrical and electromagnetic connections
 Operation in explosion hazardous areas if permitted for use in Zone 2, according to EN 60079 standards
resp. in Zone 22 according to EN 61241 standards, where the explosion risk is due to the mixture of IIA,
IIB+H2 gas+air mixture, resp. the mixture of flammable dusts and air. The permissible maximum surface
temperature is 200°C for the motor, 150°C for the actuator and 100°C for the drive. In environments
where combustible dusts may be present, the user must assure a regular cleaning of the apparatus so as
to prevent build-up of dust on the surface.
3. SAFETY
3.1. General warnings

The product has been manufactured according to generally accepted standards of good engineering practice.
Nevertheless, if these safety instructions are not adhered to, there is a risk of personal injury and damage to
property when using the product.
IMPORTANT: Before commencing any work with the product, be sure to read the product
documentation carefully and completely
IMPORTANT: Make sure these safety instructions and the product documentation are
always accessible to all users
IMPORTANT: When passing the product on to third parties, always include these safety
instructions and all the required documentation
IMPORTANT: The product may only be mounted, started up and maintained in accordance
with these safety instructions and the information given in the product documentation
3.2. Recommendations for safe application
IMPORTANT: Do not apply impacts and shocks; do not use a hammer during installation
IMPORTANT: High Voltage. Device can have 140Vdc voltage even after switching off
(capacitive voltage). Discharge Time approx. 6 Minutes
IMPORTANT: do not open the door of the drive enclosure when an explosive atmosphere
may be present
IMPORTANT: do not open the door of the drive enclosure when energized
IMPORTANT: do not open or disassemble the terminal box of the motor when energized
IMPORTANT: do not remove or replace fuse inside the drive enclosure when energized
ATTENTION: Never change wiring while power is active; make sure of power non-active
before servicing the product, otherwise it may result in electric shock or personal injury
ATTENTION: replace fuse inside the drive enclosure only with Mod. No.1320050 (marking
code: 2212004-01) by Italweber or with an equivalent model compliant with IEC 60269-3
ATTENTION: make sure that the correct input voltage, 110Vdc nominal, has been connected
3.3. Environmental conditions and limits
The following table shows the environmental conditions and limits:
Environmental
Servo Actuator Limit Driver Limit Cables Limit
condition
Operating
-20° C/+80° C -40° C/+55° C -55° C/+155° C
Temperature
Degree of
IP65 IP66 IP66
protection
Electrical parts
II 2G Ex d IIC T3 – T6 Gb
II 2D Ex tb IIIC T200°C – T85°C
ATEX Db IP65/67 II 3GD N/A
Mechanical parts
II 3G c IIB+H2 135°C
II 3D c 135°C
MIL-STD-810C, Method 514.2,

Procedure I, Fig.514.2-2, curve AR
Vibration (2 g, 5 - 2000 Hz) N/A N/A
Procedure I (Half-sine, 10 g, 11ms)
3.4. Disposal
Proceed as follows at the end of the partly completed machinery's working life:
 Remove the nameplate and keep it with this manual and documentation provided by the manufacturer
 Remove and separate electrical parts
 Remove and separate plastic parts
 Separate metallic parts according to their type (aluminium, steel, etc.)
ATTENTION: do not dismantle the motor. Permanent motor magnets generate high forces
that could severely injure the operator
Operators assigned to this activity do not require special training. When removing and dismantling metallic parts,
wear protective gloves to avoid potential abrasions with sharp parts.
Observe the locally valid regulation to recycle the previous mentioned parts.
3.5. Risks
3.5.1. Hazards arising from incorrect use

The partly completed machinery Electro Mechanical Actuator for IGV has been constructed according to current
technological standards and accepted safety regulations.
To avoid danger to the operator or damage the product, it may be put to use only for its intended use (see
chapter 2.1 “Intended use”) and in a technically flawless and safe state.
3.5.2. Residual risks
ATTENTION: Hot surfaces can cause serious burns. Touch the servo motor and the gearbox
housing only when wearing protective gloves or after they have been at standstill for some
time
ATTENTION: Solvents and lubricants can pollute soil and water. Use and dispose of cleaning
solvents as well as lubricants appropriately
3.5.3. Particular risks due to certain applications

The only possible application of the partly completed machinery Electro Mechanical Actuator for IGV is related
with the control of the IGV in the Nuovo Pignone FRAME 5-2E gas turbine.
3.6. Protections
3.6.1. Safe design measures

Not applicable.
The final application of the partly completed machinery Electro Mechanical Actuator for IGV is strictly connected
with the integration in the final machine, made by the Customer (Nuovo Pignone). The Customer has to consider
any possible type of protections and any possible risks related to the use of the partly completed machinery
Electro Mechanical Actuator for IGV in its machine.
3.6.2. Safeguarding measures

Not applicable.
The final application of the partly completed machinery Electro Mechanical Actuator for IGVis strictly connected
Electro Mechanical Actuator for IGVin its machine.
3.6.3. Protective measures

Not applicable.
3.6.4. Complementary protective measures
Not applicable.
3.7. Special Labels

The Electro Mechanical Actuator for IGV has the following special and safety labels for the Brazilian market
(Actuator side):
Refer to the Attachment 6 for the position of the labels themselves on the servoactuator.
The Electro Mechanical Actuator for IGV has the following special and safety labels for the Brazilian market (Driver
side):
4. PREPARING THE PRODUCT FOR USE
4.1. Transport
IMPORTANT: Don’t overturn the package during transport. Check the anchor points
Please, refer to Chapter 2.2 for the product’s main dimensions.

For further information, please refer to the Attachments 2, 3, 4 and 5.
4.2. Storage
For the environmental conditions of the storage of the partly completed machinery Electro Mechanical Actuator
for IGV, please refer to the Attachments 2 and 3.
4.3. Installation and assembly
4.3.1. Procedures for unpacking

The following table shows the steps necessary for unpacking the product:
Step Description
1 Check the package list and all documents attached
2 Open the package following the indications of the external labels
3 Check if the contents of the package correspond to the package list
4 Check for damage, paying particular attention to the external lead wires
Retain the actuator’s original shipping container. In the event of future transportation requirements, this
container will minimize damage during shipment.
4.3.2. Inventory checklist

Please, refer to the BOM for the packaging checklist.
4.3.3. Fixing/anchoring and vibration damping requirements

Not applicable.
4.3.4. Foundation block or similar base

Not applicable.
4.3.5. Provisions against emissions

Not applicable.
4.3.6. Minimum space needed for use, maintenance and repair

4.3.7. Layout plan
Not applicable.
4.3.8. Installation plan

Not applicable.
4.3.9. Interconnection diagrams

Please, see the installation drawings (ref. to chapter 2.3).
4.3.10. Methods of connection

Please, see the Attachments 2, 3, 4 and 5.
4.3.11. Permissible environmental conditions

Please, refer to Chapter 3.3 for the environmental conditions and limits.
4.3.12. Waste removal/disposal

Please, observe the locally valid regulation for disposals.
4.4. Commissioning
Please, see the Order Confirmation to check the applicability and all the details.
5. OPERATING INSTRUCTIONS
5.1. Safe functioning

Please, see the Attachment 3.
5.2. Normal function

5.3. Secondary functions

5.4. Exceptional functions

5.5. Signal to be observed

6. MAINTENANCE AND CLEANING
6.1. Safety precautions

Please, see the chapter 3, Safety.
6.2. By users
6.2.1. Nature and frequency of maintenance operations

Frequency of maintenance operations depends from the working cycle of the partly completed machinery Electro
Mechanical Actuator for IGV and from the installation plant.
6.2.2. Preventive maintenance

The following table shows the preventive maintenance operations to be operated on the partly completed
Every
Every
8.000
Every 6 27.000 When
Preventive maintenance operation working
months working blow
hours/12
hours
months
Check for the lubrication X

Mechanical converter
Major inspection X
Motor Return to the factory X
Drive Replace fuse X
6.2.3. Maintenance schedules

The following table shows the maintenance schedules to be operated on the partly completed machinery Electro
Every
Every
8.000
Every 6 27.000 When
Maintenance operation working
months working blow
hours/12
hours
months

Major inspection X

6.2.4. Inspection for safety
Not applicable.
6.2.5. Safety warnings for running or live equipment

Not applicable.
6.2.6. Drawings and diagrams

Not applicable.
6.2.7. Cleaning
Not applicable.
6.3. Trouble-shooting, fault diagnosis, and repair
6.3.1. Fault diagnosis and identification

Please, see the Attachments 2 and 3.
6.3.2. Repair and adjustments

6.3.3. Built-in diagnostic systems

6.3.4. Checking of warning devices

7. SPARE PARTS AND CONSUMABLES
7.1. Identification
Not applicable.
7.2. Bill of material

Please, see the BOM.
7.3. Source of supply

Not applicable.
8. WORKSTATIONS
Not applicable.
9. TOOL CHARACTERISTICS
9.1. Standards tools

Not applicable.
9.2. Special tools

Not applicable.

Not applicable.
10.DECOMMISSIONING
10.1. Destruction
Please, observe the locally valid regulation for destruction, or contact Moog Italiana S.r.l. (Malnate).
10.2. Recycling
Please, observe the locally valid regulation for recycling, or contact Moog Italiana S.r.l. (Malnate).
10.3. Disposal
Please, observe the locally valid regulation for disposal, or contact Moog Italiana S.r.l. (Malnate).
11.ATTACHMENTS
The following table shows the attachments:
Attachment Nr. Attachment Name Attachment Description
MRQ38237_L081-602_DoI.pdf
Declaration of Incorporation
1 MRQ38238_L081-
EC ATEX Declaration of Conformity
602_ATEX_DoC.pdf
2 Servo Actuator - Maintenance & Instructions Manual CDS37897_L875-603_MIM.pdf
CZ140100 Model Operations Manual

Rev0.pdf
3-4-269-01_1.pdf
3 Servo Drive - Maintenance & Instructions Manual
MRE37113_L081-601-2_ECS.pdf
MRE37114_L081-601-2_TBDCD.pdf
MRE37118_L081-601-2_WD.pdf
CB54994.pdf
4 Power cable Data Sheet
DOC-0000413342 power.pdf
CB54995.pdf
5 Signal cable Data Sheet
DOC-0000413459 signal.pdf
6 Servo Actuator - Label Installation drawing CB63036(-).pdf

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PARTLY COMPELTED MACHINERY

Rev. , 20 Document nr.
ELECTRO MECHANICAL
ACTUATOR FOR IGV
L081-602
ATTACHMENT 1 – Declaration of Incorporation
EC ATEX Declaration of Conformity
Rev. 0, April2013
DOCUMENT NR. CDS38231 – Att. 1

ELECTRO MECHANICAL
ACTUATOR FOR IGV
L081-602
ATTACHMENT 2 – Servo Actuator - Maintenance &
Instructions Manual
Rev. 0, April 2013

IDENTIFICAZIONE ATTUATORE EM Error! Reference source not found. | ISTRUZIONI
ATTUATORE EM
L875-603
Manuale di Installazione & Manutenzione
Originale
Rev. 0, Gennaio 2013
QUESTO DOCUMENTO DESCRIVE L’INSTALLAZIONE, IL FUNZIONAMENTO E LA

MANUTENZIONE DELL’ATTUATORE MOOG EM L875-603.
DOCUMENTO N. CDS37003
PREFAZIONE
Il presente manuale “ATTUATORE EM L875-603 - Istruzioni di Installazione & Manutenzione - Originale” è stato
redatto in conformità alla CEI EN 62079, “Preparazione di istruzioni – Struttura, contenuto e presentazione”. Il
manuale è stato scritto e controllato al meglio dell’esperienza di Moog
Moog non è responsabile per il suo utilizzo e si riserva il diritto di modificare il prodotto e le informazioni di seguito
riportate, senza necessariamente darne informazione.
IMPORTANTE: Nessuna parte di questo documento può essere copiata, duplicate,

riprodotta, memorizzata con qualunque sistema di archiviazione dati, tradotta in qualunque
lingua o trasmessa con qualunque sistema di comunicazione dati senza il consenso da parte
di Moog
VERSIONE DEL DOCUMENTO
La version originale di questo manuale è stata redatta in: Italiano (IT).
La lingua utilizzata per documentazione e disegni è stata concordata con il Cliente, come da specifica d’Ordine.
In caso di traduzione del presente manuale, Moog fornisce anche la versione originale “Istruzioni di Installazione &
Manutenzione – Originale”.
INDICE DI REVISIONE
La seguente tabella riporta l’indice di revisione del manuale:
Rev Descrizione Preparato Controllato Approvato Data
0 Versione iniziale BEB CAR LOF Gennaio 2013

INDICE
PREFAZIONE ............................................................................................................................................................. 2
VERSIONE DEL DOCUMENTO .................................................................................................................................... 3
INDICE DI REVISIONE ................................................................................................................................................ 3
1. IDENTIFICAZIONE ......................................................................................................................................... 6
1.1 Targa e Designazione ....................................................................................................................................................................................6
1.2 Il Costruttore .................................................................................................................................................................................................7
1.3 Garanzia ........................................................................................................................................................................................................7
1.3.1 Predisposizioni a carico del Cliente ...............................................................................................................................................................7
1.4 Dichiarazione di Conformità ..........................................................................................................................................................................7
1.5 Dichiarazione di Incorporazione ....................................................................................................................................................................7
1.6 Standard applicati .........................................................................................................................................................................................8
2. DESCRIZIONE GENERALE .............................................................................................................................. 9

2.1 Motore brushless ........................................................................................................................................................................................10
2.2 Riduttore .....................................................................................................................................................................................................10
2.3 Limitatore di coppia ....................................................................................................................................................................................10
2.4 Convertitore meccanico ..............................................................................................................................................................................10
2.5 Sistema di fissaggio del corpo .....................................................................................................................................................................10
2.6 Stelo ............................................................................................................................................................................................................10
2.7 Sistema di fissaggio delle estremità ............................................................................................................................................................11
2.8 Uso previsto ................................................................................................................................................................................................11
2.9 Connessioni .................................................................................................................................................................................................12
2.10 Consumo energetico ...................................................................................................................................................................................12
2.11 Emissioni .....................................................................................................................................................................................................12
2.12 Codice IP .....................................................................................................................................................................................................12
2.13 Compatibilità elettromagnetica ..................................................................................................................................................................12
2.14 Dispositivi di Protezione Individuale (DPI) ...................................................................................................................................................13
2.15 Uso improprio .............................................................................................................................................................................................13
3. SICUREZZA ................................................................................................................................................. 14
3.1 Valutazione dei rischi ..................................................................................................................................................................................14
4. PREPARAZIONE DEL PRODOTTO PER L’UTILIZZO ........................................................................................ 15

4.1 Montaggio ...................................................................................................................................................................................................15
4.2 Installazione ................................................................................................................................................................................................15
4.3 Connessioni elettriche.................................................................................................................................................................................15
4.4 Messa in servizio .........................................................................................................................................................................................16
5. ISTRUZIONI DI FUNZIONAMENTO .............................................................................................................. 17

6. MANUTENZIONE E PULIZIA ........................................................................................................................ 18
6.1 Rilubrificazione............................................................................................................................................................................................18
6.2 Risoluzione dei problemi .............................................................................................................................................................................18
7. PARTI DI RICAMBIO E MATERIALI DI CONSUMO ........................................................................................ 19

8. ASSISTENZA E RIPARAZIONE ...................................................................................................................... 20
9. DEMOLIZIONE ............................................................................................................................................ 21
10. ALLEGATI ................................................................................................................................................... 22
GLOSSARIO ............................................................................................................................................................. 23
A PROPOSITO DI MOOG ......................................................................................................................................... 24
1. IDENTIFICAZIONE
1.1 Targa e Designazione

L’Attuare EM L875-603 presenta una targa metallica con i dati sensibili da comunicare in caso di richiesta
informazioni o simili a Moog.
La seguente immagine mostra il layout della targa:
La seguente tabella riporta i dati presenti in targa:
Identificazione Descrizione
Mod Modello del prodotto
S/N Numero di serie
Date Data di produzione (AAAA-MM)
NP Purchasing Code Codice di acquisto del cliente
Intervallo di temperatura ambiente di utilizzo consensito
Dati certificazione ATEX
La seguente tabella riassume i dati identificativi dell’attuatore:
Model/Description L875-603
Serial Nr. (if applicable) Tutti
Schemes/Drawings CB53763
Customer (if applicable) NUOVO PIGNONE
Customer plant (if applicable) IGV FOR FRAME 5-2E TURBINE
ATEX certification for the electrical
II 2D Ex tb IIIC T200°C – T85°C Db IP65/67
parts of the actuator
(vedi Allegato 4, Brushless servomotor - Declaration of Conformity)
Explosion classification for the II 3G c IIB+H2 135°C

mechanical parts of the actuator II 3D c 135°C
1.2 Il Costruttore
La seguente tabella riporta i dati di contatto del costruttore:
Nome Moog Italiana S.r.l.
Indirizzo Via G. Pastore 4, 21046 Malnate (VA)
Paese Italy
Telefono +39 0332 421 111
Fax + 39 0332 429 233
World Wide Web www.moog.com/industrial
1.3 Garanzia
L’attuatore è coperto da garanzia secondo le prescrizioni di legge, fatto salvo eventuali accordi contrattuali diversi.
Per i dettagli della copertura riferirsi al contratto d’acquisto.
Il decorso di tale garanzia è da intendersi a partire dalla data di consegna, salvo diverso accordo riportato nel
contratto d’acquisto.
1.3.1 Predisposizioni a carico del Cliente

È responsabilità del Cliente assicurarsi che il prodotto sia installato e utilizzato seguendo le direttive e le linee guida
locali e internazionali in materia di sicurezza. Il Cliente deve analizzare i rischi residui e predisporre:
 Interfacce elettriche e meccaniche adeguatamente dimensionate
 Opportune barriere e dispositivi di sicurezza
 Attrezzature per una corretta movimentazione/manipolazione del prodotto
1.4 Dichiarazione di Conformità

L’Attuatore EM L875-603 è un componente, per tanto non viene emessa Dichiarazione di Conformità CE ai sensi
della Direttiva Macchine. Tuttavia, l’Attuatore è soggetto alla Direttiva ATEX, per la quale è emessa Dichiarazione di
Conformità (vedi Allegato 7).
1.5 Dichiarazione di Incorporazione

L’Attuatore EM L875-603 è un componente, per tanto non viene emessa Dichiarazione di Incorporazione ai sensi
della Direttiva Macchine.
1.6 Standard applicati
L’attuatore è stato progettato e realizzato secondo la corretta prassi in uso.
La seguente tabella riporta le Direttive Europee applicate:
Direttiva Descrizione
2006/95/CE Direttiva Bassa Tensione
94/9/CE Direttiva ATEX
2004/108/CE Direttiva EMC
La seguente tabella riporta gli standard applicati:
Standard Descrizione
EN 60034-1:2010 Macchine elettriche rotanti – Parte 1: Caratteristiche nominali e di funzionamento

Macchine elettriche rotanti – Parte 5: Gradi di protezione degli involucri delle macchine rotanti
EN 60034-5:2006
(progetto integrale) (Codice IP) - Classificazione
Azionamenti elettrici a velocità variabile - Parte 3: Requisiti di compatibilità elettromagnetica e
EN 61800-3:2012
metodi di prova specifici
IEC EN 60204-1:2006 Sicurezza del macchinario. Equipaggiamento elettrico delle macchine - Parte 1: Regole generali
Sicurezza del macchinario - Principi generali di progettazione - Valutazione del rischio e riduzione
EN 12100:2010
del rischio
EN 60079-0:2009 Atmosfere esplosive - Parte 0: Apparecchiature - Prescrizioni generali
Atmosfere esplosive - Parte 1: Apparecchiature protette mediante custodie a prova d'esplosione
EN 60079-1:2007
"d"
Atmosfere esplosive - Parte 31: Apparecchi con modo di protezione mediante custodie "t"
EN 60079-31:2009
destinati a essere utilizzati in presenza di polveri combustibili
Apparecchi non elettrici destinati a essere utilizzati in atmosfere potenzialmente esplosive - Parte
EN 13463-1:2009
1: Metodo e requisiti di base
Apparecchi non elettrici per atmosfere potenzialmente esplosive - Parte5: Protezione per
EN 13463-5:2011
sicurezza costruttiva “c”
Atmosfere esplosive - Prevenzione dell'esplosione e protezione ocntro l'esplosione - Parte 1:
EN 1127-1:2011
Concetti fondamentali e metodologia
Compatibilità elettromagnetica (EMC) - Parte 4-2: Tecniche di prova e di misura - Prove di
EN 61000-4-2:2009
immunità a scariche di elettricità statica
Compatibilità elettromagnetica (EMC) - Parte 4-3: Tecniche di prova e di misura - Prova
EN 61000-4-3:2006
d'immunità ai campi elettromagnetici a radiofrequenza irradiati
Compatibilità elettromagnetica (EMC) - Parte 4-4: Tecniche di prova e di misura - Prova di
EN 61000-4-4:2004
immunità a transitori/raffiche di impulsi elettrici veloci
EN 61000-4-5:2006
immunità ad impulso
Compatibilità elettromagnetica (EMC) - Parte 4-6:Tecniche di prova e di misura - Immunità ai
EN 61000-4-6:2009
disturbi condotti, indotti da campi a radiofrequenza
2. DESCRIZIONE GENERALE
La seguente tabella mostra le parti principali dell’attuatore EM L875-603:
Colore Componente Descrizione Presente (Yes)/Non presente (No)*
Motore brushless - Yes
Riduttore - Yes - Integrated
Limitatore di coppia - No
Convertitore meccanico - Yes
Sistema di fissaggio del corpo TRUNNION Yes
Stelo - Yes
Sistema di fissaggio estremità stelo GIUNTO SFERICO Yes

* Fare rifermento alla tabella per identificare i componenti presenti nell’attuatore oggetto di questo manuale; nei paragrafi
sottostanti sono riportate le descrizione delle singole parti, anche se non contenute nell’attuatore in oggetto Per ulteriori dettagli
fare riferimento al Disegno di Installazione in allegato.
La seguente figura mostra le parti dell’Attuatore:

2.1 Motore brushless
Il motore brushless è un Servomotore Moog Explosion Proof (ExD). Si tratta di un motore sincrono brushless, con
eccitazione permanente del campo magnetico.
Per ulteriori informazioni, consultate il manuale del motore (vedi Allegato 1).
2.2 Riduttore
Il riduttore agisce come amplificatore di coppia ed è del tipo a ingranaggi planetari, dimensionato per una lunga vita
in servizio senza richiesta di particolari interventi di manutenzione.
La seguente tabella riporta le caratteristiche principali del riduttore:
Caratteristica Informazioni
Grado di protezione N.A.
Durata cuscinetti N.A. ore, in condizioni di funzionamento nominale
2.3 Limitatore di coppia

Il imitatore di coppia disconnette l’albero del riduttore dall’albero della vite, quando la coppia supera il valore di
sicurezza.
La seguente tabella riporta la casistica di intervento del limitatore:
Evento Azione Risultato
Impatto tra stelo attuatore ed Intervento limitatore Energia cinetica accumulata da motore e riduttore
ostacolo (movimento in velocità) di coppia NON scaricata sulla vite
2.4 Convertitore meccanico

Il convertitore meccanico effettua la conversione del moto da rotatorio a lineare, attraverso una vite a ricircolo di
sfere, ad alta precisione. Il carico assiale è sostenuto da una doppia coppia di cuscinetti a sfere a contatto obliquo, ad
alta precisione e basso attrito.
I cuscinetti e la vite sono lubrificati con lubrificante idoneo a garantire una lunga durata a temperature medio alte.
2.5 Sistema di fissaggio del corpo

L’attuatore può essere fissato con una delle tre opzioni evidenziata in figura:
 Flangia posteriore con fori filettati o passanti

 Trunnion
 Flangia frontale con fori filettati o passanti
Vedere Disegno di installazione per ulteriori particolari
2.6 Stelo
Lo stelo ha la funzione di trasmettere la forza e la velocità richieste dall’applicazione.

2.7 Sistema di fissaggio delle estremità
Lo stelo può essere collegato con una delle seguenti opzioni:
 Terminale con filetto maschio

 Terminale con filetto femmina
 Snodo sferico
2.8 Uso previsto

L’attuatore EM L875-603 è progettato esclusivamente per utilizzo industriale e professionale, in applicazioni
Powergen.
In particolare, l’attuatore EM L875-603 è destinato al IGV di macchine Powergen.
La seguente figura mostra una visualizzazione grafica dell’applicazione dell’Attuatore:
IMPORTANTE: Le caratteristiche dell’attuatore riportate nel presente manuale si riferiscono

a un utilizzo in ambiente con temperature comprese tra 10° C e 40° C e a un tasso di umidità
 70%
Differenti condizioni ambientali possono alterare i parametri di funzionamento
I materiali utilizzati per la costruzione non sono specificatamente studiati per l’impiego del
componente in ambienti chimicamente aggressivi, compresa l’esposizione a nebbia salina o
in atmosfere potenzialmente esplosive (Direttiva ATEX)
L’attuatore è in grado operare fino a 40 °C, sviluppando forze continuative ridotte. L’attuatore può anche essere
utilizzato a basse temperature, non inferiori a -40 °C.
La seguente tabella riporta le prestazioni dell’attuatore a 40° C:
Caratteristica Prestazioni
Massa 52 kg ca.
Dimensioni di ingombro 225 x 140 x 990 mm
Forza nominale 20 kN
Forza di picco 20 kN
Velocità max 70 mm/s
Corsa 95(+4,0/0)mm
Gioco <0,03 mm
Orientamento Nessuna restrizione
2.9 Connessioni
Per le connessioni meccaniche ed elettriche, vedere il disegno di installazione (vedi Allegato 2).
2.10 Consumo energetico
Per il consumo energetico, vedere il manuale del motore (vedi Allegato 1).
2.11 Emissioni
Per le emissioni, vedere il manuale del motore (vedi Allegato 1).
2.12 Codice IP
La seguente tabella riporta le caratteristiche del grado di protezione IP disponibili:
Caratteristica Descrizione
IP55 standard
N.A. optional
2.13 Compatibilità elettromagnetica

Per la compatibilità elettromagnetica, vedere il manuale del motore (vedi Allegato 1).
2.14 Dispositivi di Protezione Individuale (DPI)
GUANTI: utilizzare sempre guanti protettivi per evitare possibili abrasioni o lacerazioni
SCARPE: utilizzare sempre scarpe protettive per evitare possibili schiacciamenti
2.15 Uso improprio

Moog declina ogni responsabilità per danni causati a cose e/o persone in caso di:
 Uso dell’attuatore improprio e/o diverso da quanto indicato nel presente manuale
 Errata installazione
 Mancata o errata osservanza delle istruzioni riportate nel presente manuale
 Operazioni condotte da personale non addestrato o non qualificato
 Impiego dell’attuatore oltre i limiti consenti
 Mancanza di idonei ripari atti a garantire la sicurezza
3. SICUREZZA
3.1 Valutazione dei rischi

Robustezza e affidabilità sono state considerate nel progetto dell’attuatore per garantire un utilizzo sicuro.
ATTENZIONE: Dotare il personale addetto all’utilizzo/manutenzione del prodotto dei

necessari dispositivi di protezione individuali previsti dalle vigenti normative
La seguente tabella riporta i rischi residui relativi all’Attuatore:
Fattore di rischio Condizione Periodo d’esposizione
Schiacciamento arti Spostamento dello stelo Durante il funzionamento
Alta tensione Perdita d’isolamento di cavi e connettori Durante l’alimentazione
Massa del prodotto Caduta del prodotto Durante il trasporto/manutenzione
Riscaldamento del prodotto (correnti Durante il funzionamento (in

Alta temperatura (fino a 80° C)
parassite) condizioni di alto carico)
È compito del Cliente analizzare tali rischi e predisporre gli opportuni equipaggiamenti di salvaguardia del personale.
4. PREPARAZIONE DEL PRODOTTO PER L’UTILIZZO
4.1 Montaggio
Non sono previste operazioni di montaggio da parte del Cliente: l’attuatore EM L875-603 viene fornito montato in
tutte le sue parti.
Per la connessione dei cavi di potenza del motore, fare riferimento al manuale del motore stesso (Allegato 1)
4.2 Installazione
L’attuatore deve essere sollevato mediante idonee imbracature o utilizzando gli appositi golfari eventualmente
presenti sull’attuatore. Prima del sollevamento assicurarsi che il centro di gravità sia posizionato tra e sotto le
imbracature.
La seguente tabella mostra le connessioni dell’attuatore:
Caratteristiche della
Parte in connessione Tipo di connessione Coppia si serraggio
connessione
Struttura fissa Snodo basculante TRUNNION N.A.
Parte mobile Stelo – terminale a snodo GIUNTO SFERICO N.A.
IMPORTANTE: evitare di sottoporre l’attuatore a carichi laterali in quanto essi riducono la

vita utile e le prestazioni dell’attuatore
I carichi laterali possono generarsi per disallineamento o carichi eccentrici
4.3 Connessioni elettriche

Le connessioni elettriche tra motore e relativo azionamento dovrebbero essere eseguite con i cavi standard
specificati dalla Moog. Qualora si utilizzino altri cavi devono essere soddisfatti i seguenti requisiti:

2
cavo di potenza 4 x 4 + 2 x 1 mm

2
cavo di segnale: 5 x 2 x 0,25 mm schermati e intrecciati a coppie
IMPORTANTE: La connessione e la sconnessione del cavo motore deve essere effettuata con
azionamento non alimentato
La semplice disabilitazione non è sufficiente ad intercettare la tensione
Il cavo di messa a terra (PE) deve essere di sezione adeguata (pari a quella del conduttore di potenza) come previsto
dalle vigenti norme di sicurezza.
ATTENZIONE: Conduttori di sezione ridotta provocano un inaccettabile surriscaldamento
dei cavi e perdita di potenza
Si raccomanda la schermatura dei cavi di potenza e di ogni singola coppia di conduttori del cavo di segnale.
4.4 Messa in servizio

Il funzionamento e le prestazioni dell’attuatore EM L875-603 dipendono dalla scelta dei parametri inseriti
nell’azionamento.
I valori di coppia e velocità del motore selezionati non devono essere maggiori di quelli riportati sul disegno specifica
dell’attuatore.
Si prega di consultare il manuale dell’azionamento del motore.
Occorre riporre molta cura:
 nell’impostare sull’azionamento la velocità, la corrente continuativa e quella di picco del motore
 nel collegare i conduttori dei cavi di potenza e di segnale; una connessione errata può provocare la
perdita di controllo del motore con possibili danneggiamenti dei componenti meccanici in caso di
impatto veloce contro ostacoli
Prima di comandare il movimento dell’attuatore verificare i seguenti:
 la lubrificazione della struttura scorrevole della macchina
 il corretto serraggio delle viti
 l’assenza di ostacoli lungo la corsa dello stelo
Si consiglia di eseguire la messa in servizio a coppia e velocità ridotte (1/10 del valore nominale).
IMPORTANTE: evitare accuratamente urti a piena coppia e velocità motore

5. ISTRUZIONI DI FUNZIONAMENTO
L’Attuatore EM L875-603 è progettato per il IGV in una macchina per (Powergen).
A seguito dell’installazione, deve essere regolata la movimentazione dell’Attuatore mediante l’azionamento del
motore, non incluso nella fornitura.
Consultare, quindi, il manuale dell’azionamento del motore per ogni informazione circa le istruzioni di
funzionamento.
6. MANUTENZIONE E PULIZIA
L’attuatore è progettato per richiedere una manutenzione assai ridotta. Si raccomanda una ri-lubrificazione e
un’ispezione semestrale dello stato di usura delle guarnizioni di tenuta sullo stelo ogni sei mesi.
ATTENZIONE: Prima di eseguire ogni azione manutentiva verificare che:

 L’attuatore è in posizione sicura
 È assente potenza elettrica o meccanica
 Le alimentazioni non possono essere inavvertitamente attivate
 Il personale adiacente è avvertito della manutenzione in corso
 Non ci sono condizioni di pericolo derivanti da altre fonti
6.1 Rilubrificazione
Lo stelo dell’attuatore, la vite a sfere e i cuscinetti vengono forniti con quantità di grasso ottimale, ove non
specificato diversamente. Moog raccomanda il seguente lubrificante:
KLUBER Klubersynth BH 72-422
Nel caso di ri-lubrificazione periodica come indicato nel capitolo 6 del presente manuale, le istruzioni sono
contenute nel seguente documento CDP37236 in allegato.
Al termine di queste operazioni effettuare almeno 2 corse complete dell’attuatore senza carico per distribuire il
grasso inserito.
6.2 Risoluzione dei problemi

Si riporta di seguito una lista per la risoluzione dei problemi più comuni.
Problema Possibile causa Soluzione Note
Consultare manuale
Funzionamento Parametrizzazione errata controllore
azionamento motore
rumoroso
Disallineamento o carichi laterali Controllare allineamento
Attuatore fermo con Improprio collegamento meccanico Controllare connessione

motore in rotazione motore-convertitore mediante chiavetta
Controllare scelta parametri

Parametrizzazione errata controllore
Attuatore in stallo azionamento
Carico o attrito eccessivo Verificare carico e allineamenti
Riscaldamento esterno Controllare schermo termico

Surriscaldamento Rivolgersi a
motore Grippaggio motore, convertitore o Smontare attuatore e
Moog Italiana
parte mobile collegata determinare elemento grippato
S.r.l.
7. PARTI DI RICAMBIO E MATERIALI DI CONSUMO
Non sono previste parti di ricambio, né materiali di consumo.
8. ASSISTENZA E RIPARAZIONE
Le operazioni non programmate necessarie a ripristinare la funzionalità del prodotto devono essere eseguite da
Moog o da personale qualificato da Moog.
Collegandosi al sito www.moog.com è possibile individuare il più vicino centro d’assistenza Moog.
Quando è necessaria una riparazione tutte le parti non facenti parte del prodotto devono essere rimosse in quanto
Moog non può garantirne il corretto montaggio/smontaggio.
Dovrebbero essere altresì rimossi grasso e polvere.
L’equipaggiamento deve essere adeguatamente imballato per evitare danneggiamenti durante il trasporto.
9. DEMOLIZIONE
Alla fine della vita operativa dell’attuatore procedere come segue:
 Rimuovere il cartellino di identificazione e tenerlo insieme al presente manuale e la documentazione
data dalla ditta fornitrice
 Rimuovere e separare le parti elettriche
 Rimuovere e separare le parti in plastica
 Separare le parti metalliche a seconda della loro tipologia (alluminio, acciaio, ecc.)
ATTENZIONE: non disassemblare il motore. I magneti permanenti del motore

sviluppano alte forze che possono ferire gravemente l’operatore
Gli operatori addetti alla sopracitata attività non necessitano di speciale addestramento.
Durante la rimozione e lo smontaggio delle parti metalliche, utilizzare dei guanti protettivi, in modo da evitare
possibili abrasioni con le parti taglienti.
Seguite le procedure di eliminazione conformi alle disposizioni locali per la raccolta differenziata delle parti citate nei
paragrafi precedenti.
10. ALLEGATI
La seguente tabella mostra gli allegati al presente manuale:
Allegato # Descrizione Revisione
1 Servomotore – Istruzioni di Installazione CB07398-001 Rev. G
2 Servomotore – Dichiarazione di Conformità CE Rev. B
3 Attuatore – Disegno di Installazione CB53763 Rev. A
4 Attuatore – Istruzione di Ri-Lubrificazione CDP37326 Rev. 0
Attuatore – Dichiarazione di Conformità ATEX

5 Rev. 0
MRQ37890
Servomotore – EC Type Examination Certificate 10 ATEX

6 Rev. B
0915070X
Servomotore – Product Quality Assessment Notification

7 Rev. 0
09 ATEX Q148848
GLOSSARIO
La seguente tabella riporta le abbreviazioni utilizzate:
Abbreviazione Descrizione
Attuatore EM Attuatore Elettro Meccanico
La seguente tabella riporta i simboli utilizzati:
Simbolo Descrizione
IMPORTANTE: Avvisi e note a proposito di funzionalità importanti o di informazioni utili
ATTENZIONE: Pericolo per le persone (anche mortale)
GUANTI: guanti protettivi per evitare possibili abrasioni o lacerazioni (DPI)
SCARPE: scarpe protettive per evitare possibili schiacciamenti (DPI)

A PROPOSITO DI MOOG
L’Industrial Group di Moog progetta e costruisce “motion control solution” ad alte performance, utilizzando
tecnologie elettriche, idrauliche ed ibride, con il supporto di esperti in una vasta gamma di applicazioni, tra cui test,
simulazione, industria plastica, industria dei metalli pesanti e powergen.
Tra i clienti Moog si annoverano importanti case automobilistiche, produttori aerospaziali, laboratori di prova e
scuderie automobilistiche.
Moog aiuta le aziende a progettare e sviluppare macchine di nuova generazione.
L’Industrial Group di Moog è parte di Moog Inc.
Per maggiori informazioni visitare il sito www.moog.com/industrial.
Moog Italiana S.r.l.

Via G. Pastore 4
21046 Malnate (VA) – Italy
Tel. +39 0332 421 111
Fax + 39 0332 429 233
info.italy@moog.com
TAKE A CLOSER LOOK

+54 11 4326 5916 +353 21 451 9000 +46 31 680 060

+61 3 9561 6044 +39 0332 421 111 +41 71 394 5010

+43 664 144 65 80 +81 436 55 3767 +31 252 462 000

+55 11 5523 8011 +82 31 764 6711 +44 1564 784 777

+86 21 5854 1411 +352 40 46 401 +1 734 887 4250
Finland Norway
+358 9 2517 2730 +47 224 32927
France Russia
+33 1 4560 7000 +7 831 713 1811
Germany Singapore
+49 7031 622 0 +65 677 36238

+852 2 635 3200 +27 11 655 7030
India Spain
+91 80 4120 8785 +34 902 133 240
2011 Moog Inc. All rights reserved. All changes are reserved
ATTUATORE EM L875-603
Rev. 0, , Documento N. CDS37003
.
ATTUATORE EM
L875-603
Manuale di Istruzioni & Manutenzione
CDS37003 - Allegato 1
Servomotore - Istruzioni di Installazione
DOCUMENTO Nr. CDS37003 - Allegato 1

OPERATING INSTRUCTIONS FOR
EXPLOSION PROOF DYNAMIC

BRUSHLESS SERVOMOTORS
ExD SERIES
Rev. G, July 2012
FULLY CERTIFIED SERVO MOTORS FOR USE IN

POTENTIALLY EXPLOSIVE ATMOSPHERE IN ACCORDANCE
WITH ATEX AND IECEx
WHAT MOVES YOUR WORLD
1
INTRODUCTION MOOG INSTALLATION INSTRUCTIONS - EXD SERIES
Whenever the highest levels of motion control

performance and design flexibility are required, you’ll find
Moog’s expertise at work. Through collaboration, creativity
and world-class technological solutions, we help you
overcome your toughest engineering obstacles. Enhance
your machine‘s performance. And help take your thinking
further than you ever thought possible.
TABLE OF CONTENT
INTRODUCTION ....................................................................................................................................................................................... 2
1 GENERAL DESCRIPTION
1.1 Principal of operation / description ........................................................................................................................ 3
1.2 Model strategy ..................................................................................................................................................................... 4
2 FIELD OF APPLICATION ........................................................................................................................................................ 4
2.1 Information on the protection type ........................................................................................................................ 4
2.2 Explosion-proof type code ........................................................................................................................................... 4
2.3 Motor name plate ............................................................................................................................................................... 5
3 TRANSPORT ................................................................................................................................................................................... 5
4 INSTALLATION INSTRUCTIONS ..................................................................................................................................... 6
4.1 Safety and commissioning instructions ............................................................................................................... 6
4.2 Installation dimensions ................................................................................................................................................... 6
4.3 Installation / deinstallation .......................................................................................................................................... 6
5 ELECTRICAL CONNECTION ............................................................................................................................................... 7
5.1 Installing the connection cable .................................................................................................................................. 8
6 OPERATING THE MOTOR ..................................................................................................................................................... 12
7 MAINTENANCE ........................................................................................................................................................................... 15
7.1 Repair processing ................................................................................................................................................................ 15
8 SPECIAL CONDITIONS FOR SAFE USE ................................................................................................. 15
ANNEX
Electrical data
Current installation drawing of the respective motor model
Declaration of conformity
Rev. G, July 2012 2

GENERAL DESCRIPTION MOOG INSTALLATION INSTRUCTIONS - EXD SERIES
1.1 PRINCIPAL OF OPERATION / DESCRIPTION
The principal of operation of the motor is based on an electronically commuted, brushless AC electric motor
with stator winding and permanent magnetic excitation in the rotor. The motor is operated via control
electronics using an integrated feedback system – resolver or encoder. The components are constructed in
accordance with IEC standards. The mechanical interface is represented by standardised flange dimensions
with corresponding shaft end. Technical data and the applied standards can be found in the included
installation drawing as well as in MOOG motor catalogs.
1 Cable outlet 9 Permanent magnets rotor

2 Shaft bearing B (Floating bearing) 10 Feedback device
3 Stator winding 11 Permanent magnet holding
4 Shaft bearing A (fixed bearing) brake (optional)
5 Flange 12 Connection strip
6 Radial shaft seal 13 Internal ground terminal
7 Keyway optional 14 External ground terminal
8 Shaft
Rev. G, July 2012 3

FIELD OF APPLICATION MOOG INSTALLATION INSTRUCTIONS - EXD SERIES
1.2 MODEL STRATEGY

The motors are available in various sizes. Each frame size is modularly designed. Using modular design,
changes to the active length of the motor components allow a large power range to be covered. The following
standard versions are available:
• Motor with resolver
• Motor with resolver and permanent magnet holding brake
• Motor with encoder
• Motor with encoder and permanent magnet holding brake
2. FIELD OF APPLICATION
Typical fields of application for servomotors include robotics and other handling axes, units for actuators as
well as special industrial applications. The fields of application for explosion-proofed servomotors of series
G493, G495, G496 correspond to those listed above, but for which explosion proof restrictions apply.
2.1 INFORMATION ON THE PROTECTION TYPE

The servomotor is only suitable for the protection type indicated on the name plate. To ensure danger
free operation, all installation and safety instructions must be observed. Furthermore, when using as
system components, it must be ensured that the respective explosion-proof guidelines for the entire
system are adhered to. A skilled operator may be required for handing these series of motor.
2.2 EXPLOSION-PROOF TYPE CODE

The following explosion-proof characteristics apply for the motor series described here. These
characteristics are also indicated on the motor name plate.
Rev. G, July 2012 4

TRANSPORT, INSTALLATION INSTRUCTIONS MOOG INSTALLATION INSTRUCTIONS - EXD SERIES
2.3 MOTOR NAME PLATE

The data described below can be found on the motor name plate. Motor-specific details and performance
data on the name plate are provided in this description only as labeling examples. The correct data can be
found on the name plate of the motors and motor data sheet supplied along with the Motor as per Electrical
data. Using the Motor data the user has to select a suitable drive.
Further details on your motor can be found on the name plate of the respective motor. This information is
necessary for configuring the controller and for inquires to Moog.
For this reason, please note down the information on the name plates if the name plates are not
accessible when the motor is installed.
General details
Model Motor model number
S/N Serial number
Date Production date: Year / Week
Typ Encoded information of the Motor
Brake: (optional) Details on the brake torque while at a standstill
Norms:
IP65 As per IEC60034-5
I.CL F Motor approved for insulation class F( 155 oC)
All coil materials are class H(180 oC)
IEC34 Motor fulfils all requirements of IEC34
CE We will supply the declaration of conformity upon request
Performance data (add data are specified for 25oC)

For Gas and Dust:
nN Normal speed at nominal power PN
PN Normal power (maximum continuous power )
Ud Normal operating voltage (Drive DC bus voltage)
MO Continuous stall torque
IO Continuous stall current (current at MO)
For Gas only:
J Rotor inertia
For PWM converter:
nmax Maximum speed of motor
Mmax Maximum torque of motor
Identification for explosion proof classification, see section 2.2
fsw Minimum switching frequency
nmin Minimum speed of the motor will be 0 min -1
3. TRANSPORT
Immediately upon delivery of the motor, please examine the package contents for intactness and check that
the agreed delivery contents are complete. In particular, check the shaft end and the motor connectors for
transport damage.
Please use the data on the name plate to check whether the delivered motor model matches is as per
ordered.
The cover cable glands are secured only provisionally to the housing as the connection cable must still be
connected to the motor(see section 5.1).
Rev. G, July 2012 5

INSTALLATION INSTRUCTION MOOG INSTALLATION INSTRUCTIONS - EXD SERIES
4. INSTALLATION INSTRUCTION
4.1 SAFETY AND COMMISSIONING INSTRUCTIONS

The motor used is an explosion-proof model with special safety-relevant requirements. To prevent hazards
caused by improper installation, the described instructions regarding motor and cable installation must be
adhered to. The type of explosion protection can be found on the explosion-proof type code in the operating
instructions(Section 2.2). The suitability for use in a given area must be approved by an authorised test
centre.
4.2 INSTALLATION DIMENSIONS
The installation dimensions for the respective motor model can be found in the provided installation drawing.
4.3 MOTOR INSTALLATION / DEINSTALLATION

For motor mounting, Moog recommends the use of hex socket-head screws as defined by DIN 912 8.8. The
use of an Allen key considerably simplifies installation, particularly with the G493 models. With this model
size, the screws which are used must not exceed 40 mm in length.
Moog motors can become very hot during operation. Therefore, during installation ensure that heat can
be adequately dissipated, i.e. the motor should be flanged to as a minimum 300X300X12 mm bracket.
Furthermore, adequate convection must be ensured. In some cases, it may be necessary to safeguard the
motors against physical contact, as there is a risk of injury through burning. Before mounting a coupling on
the motor shaft, the shaft should be thoroughly degreased. When using a degreaser (grease dissolving agent),
ensure that it does not penetrate the bearings, as this would compromise their lifetime lubrication. For secure
torque transfer, we recommend the use of a clamp coupling or a shrink fitting.
Impermissibly high axial or radial forces on the shaft can damage the motor during installation. The
bearing damages which may occur as a result will contribute in a reduction in the operating life of the motor.
Forcefully pushing axially the rotor shaft can affect the function of the optional brake to the point that it has
no or only reduced braking action. For this reason, excessive force and impacts on the front end of the shaft
and the rear housing cover are always to be avoided. The shocks associated with blows of a hammer will
always exceed the permissible axial and radial forces.
The maximum permissible axial and radial forces for Moog motors during installation:
G493XXXX 150 N axial force, 500 N radial force.
G496XXXX 500 N axial force, 2000 N radial force
This information is applicable during installation. Lower forces apply when the motor is rotating. See
technical data.
Rev. G, July 2012 6

4.4 ASSEMBLY OF BALL SCREW (SPECIAL MOTOR)

Values for torque see Installation drawing.
During the ballscrew assembling you must avoid, any damage on flange parts.
It must be sure, that after assembly of the ball screw, the flame path gaps per IEC / EN 60079-1
are in the described range. These values must not be exceeded in dynamic and static case.
Console and cable cleat are just fixed for transport. After disassembling for using the hexagon ( A ) to hold
against the torque by mounting the ball screw ( B ), are console( C ) and cable cleats ( D ) must be assembled as
shown in the picture above. All screws must be mounted with LOCTITE 243 or compatible glue. The assembly of
the cover ( E ) are describe into the operating instruction and will follow after connecting the cable.
5. ELECTRICAL CONNECTION
The cables described in the following table are suitable for connecting MOOG motors of series
G493, G495 and G496
The following details regarding the cable characteristics are to be adhered to in all cases.
Attention: A rotating motor can discharge dangerously high voltage. Therefore, always ensure that
current-carrying parts are safeguarded and inslated.
Rev. G, July 2012 7

ELECTRICAL CONNECTION MOOG INSTALLATION INSTRUCTIONS - EXD SERIES
The installation and deinstallation of the cables must always be performed while the control
electronics are switched off. Removal of hardware enable for the control electronics is not
sufficient. During installation, take particular care to ensure that the cross section of the earthing
conductor fulfills the applicable standards.
Attention: Small conductor cross sections result in an impermissible, excessive warming of the cable. This
can result in a loss of motor power, particularly in long supply lines. When installing the supply lines, we
recommend that the power and signal cables be shielded. The shielding is to be connected to the earthing
potential at both ends.
Selection of the cable should meet the ATEX and IECEx requirement and the application local regional
regulatory and statuary requirement.
Selection of the cable should also ensure that the temperature rating based on the selected T code and
respective ambient temperature are met. The information on the T code and ambient can be found on the
motor name plate. Higher temperature cables can be used.
5.1 INSTALLING THE CONNECTION CABLE

For motor models with moulded cables, the cable is already installed and guided out of the motor
through a special cover. Therefore, no cable needs to be connected within motors of these models.
The locally applicable installation regulations, e.g. IEC / EN 60079-14, are to be observed during
installation and setup. Cable entry must be confirmed as flame proof and dust ignition protected
“tb” product and confirming to IEC/EN 60079-1 and IEC/EN 60079-31. Contact local application
engineers for more details.
For motor models without moulded cables the following preparation to be followed,
Preparing the motor
After unpacking the motor, the cover is taken off and the sealing plugs (1) removed.
Rev. G, July 2012 8

Preparing the motor

For G495 and G496 use M10 grub screw to dissemble the motor.
Details about the position of the grub screw can be found on the istallation drawing.
Preparing the connection cable

The connection cable must be prepared on the electronics end for the connection to the motor.
Before attaching the cable lugs or parallel connectors, the cables are pulled through the mounted cable glands
on the motor cover.
• The cable glands, certified and approved in accordance with IEC60079-1and IEC/EN 60079-31, mustbe
mounted. The cable glands used, must be ATEX and IECEx certified as Ex d IIC and Ex tb IIIC with
IP65/67 accordingly. The cable gland used must be equivalent too or with higher temperature rating
based on the selected T code and respective ambient temperature. The information on the T code and
ambient can be found on the motor name plate.
• Refer accompanying installation drawing for the cable mounting location, number of cable glands and
the thread size.
• Ensure that at least 5 threads of the cable gland are engaged with the mounting thread in the motor
cover.
The cable jacket which protrudes into the motor cover is to be removed. The cable leads of the power and
signal cables are to be long enough that the cables can be mounted without difficulty, yet not unnecessarily
long. With the cables mounted, it should be possible to hinge open the cover 90° from the motor housing
(2). When stripping the insulation, the shield meshing of the power and signal cables must be retained in the
stripped section of the cable (unwind, then twist separately). The shielding is to be fitted with heat-shrink
tubing, additionally the entire area between the jacket and the stripped cable needs to be fitted with a larger
piece of heat-shrink tubing (6).
Cable installation with terminal block

• The cable glands, certified and approved in accordance with IEC/EN 60079-1 and IEC/EN 60079-31,
must be mounted.
• In particular, the permissible cable diameter must be observed.
• The motor cables are to be connected to the power and signal cables in accordance with the
accompanying installation drawing.
• The wiring diagram can be found in the installation drawing provided for the respective motor model.
Rev. G, July 2012 9
The power leads and the brake leads (optional) are to be prepared with solder-free, galvanized cable lugs
for G495 and G496 models or with wire-end sleeves for G493 models. The clamping area of the cable lugs /
wire-end sleeves is to be selected appropriately for the conductor cross section and must be suitable for the
connection clamps.
The earthing leads and the shielding are to be prepared with solder-free, galvanized cable lugs.
An M4 blind thread is provided on the inside of the motor cover for securing the earthing leads and shielding.
The signal leads are provided with wire-end sleeves and are to be connected to the corresponding
connections on the motor.
The terminal area is to be selected appropriately for the conductor cross section.
The cable lugs / wire-end sleeves for the power cable are to be connected to the corresponding connections
on the motor (see installation drawing). For G495,G496 models, after removing the clamping nut, position
the cable lugs back to-back and hand tighten! (3)
The cable lugs (4) of the earthing lead and the shielding are to be secured to the inside of the cover with a
DIN 912 M4X6 8.8 hex socket-head screw and hand tightened. A DIN 7980-4-Fst Ø 4.3 mm lock washer
must be placed between the upper cable lug and the screw head. (4)
Heat shrink tubing 2

overall
6 900
3
4 Position the cable luge
Lock washer
5 back-to-back
Rev. G, July 2012 10

Cable installation with serial conductors

• The connection diagram can be founded in the installation drawing provided for the
respective motor model.
• The cable glands, certified and approved in accordance with ith IEC / EN 60079-1 and
IEC / EN 60079-31 , must be mounted as per the installation instruction provided by
the manufacturer.
The serial connectors are to be selected appropriately for the cable cross sections and are to be
crimped to the connections on the motor with the tool designed for this purpose.
The cable lugs (4) of the earthing lead and the shielding are to be secured to the inside of the
cover with a DIN 912 M4X6-8.8 hex socket-head screw and hand tightened. A DIN 7980-4-Fst Ø
4.3mm lock washer must be placed between the upper cable lug and the screw head.
Attention : Do not operate the motor with removed cover, due to missing protective earth connection.
The fibreglass sleeve needs to overlap the serial conductor, as well as the heat shrink sleeve overlaps the fibre
sleeve by a minimum of 5mm.

OPERATING THE MOTOR MOOG INSTALLATION INSTRUCTIONS - EXD SERIES
Cover assembly
The orientation of the cover is shown in the included installation drawing.
During cover assembly, the external cables must be repositioned so that the outer cable jacket aligns evenly with the
inside of the cover to prevent cable jamming during the assembly process. Cables without jacket must not protrude
into the threaded connection. The upper part of the threaded connection is to be tightened in accordance with
the manufacturer’s specifications. The lower part is to be held in place to keep it from turning as the upper part is
tightened. The cover is to be placed on the motor housing and tightened with the DIN 912 M4x20 - 8.8 socket-head
screws to 3 Nm for models G493, M8 x 55 - 8.8 socket-head screws to 16 Nm for models G495 and M8 x 65 - 8.8
socket-head screws to 16 Nm for models G496.
Connection of the external protective earth conductor
The connection terminal (5) is provided with a protective earth symbol. The connection is carried out in accordance
with DIN 0720. The maximum cable cross section which can be accepted in the terminal for the different models is:
• G493 4 mm2 for single-wire conductors

• G495 , G496 10 mm2 for fine-wired conductors and 16 mm 2 for single-wire conductors
Note: Earth conductor to be equal or greater than the phase conductor.

Connection of the internal protective earth conductor
The connection terminal (4) is provided for the internal protective earth conductor. The terminal is suitable for
terminating 4mm2conductors.
6. OPERATING THE MOTOR
After connecting the motor to the control electronics, the motor is to be operated in accordance with
the operating instructions for the electronics. We cannot guarantee the replacement of motors which
are damaged due to incorrectly connected or unsuitable third-party electronics. Moreover, incorrect
installation, improper operation or other improper work at the motor could result in dangers such as
overheating, over voltage etc., which could compromise the desired protection for use in explosive
atmospheres. In cases where Moog electronics are used, the corresponding operating instructions for the
electronics are included. The Motor data required for the selection of the right drive can be found in the
Motor data sheet as per annex “Electrical data” supplied along with the Motor.

connection example
Voltage supply regen resistor
User Interface
Interface for tripping

the power supply to
Motor Controller the motor
( Servo Drive )
Temperature monitoring device for

the PTC temperature sensor of the
NTC/PTC/KTY Thermal sensor,

Optional connection Connection to feedback device
( Resolver or Encoder ). Brake
connection optional
Power Cable
Motor Interface
Connection from primary

PTC thermal sensor
Signal Cable
Explosion proof dynamic brushless

servo motor ExD series

Typical wiring diagram
MOTOR
POWER CONNECTION
VOLTAGE SUPPLY
U U BLACK
V V WHITE N/S
W W RED
BRAKE CONNECTION (OPTIONAL)
VOLTAGE SUPPLY + + BLACK

BRAKE ELECTROMAGNETIC
– – RED BRAKE
THERMAL SENSOR CONNECTION
TEMPERATURE PRIMARY PTC

MONITORING
DEVICE PRIMARY PTC
PRIMARY
SECONDARY
OPTIONAL THERMISTOR
CONNECTION
SECONDARY OPTIONAL
THERMISTOR
FEEDBACK CONNECTION
CONTROLLER
FEEDBACK DEVICE

MAINTENANCE MOOG INSTALLATION INSTRUCTIONS - EXD SERIES
7. MAINTENANCE
Due to their construction, the MOOG brushless servomotors of series G493 G495 and G496 are
maintenance free. The bearings are the only components subject to wear and are provided with life-
time lubrication (at least 20,000 operating hours at the specified maximum axial and radial forces). If
damage is found on the motor, it can generally be repaired by Moog.
The motor must be directly thermally monitored using Temperature monitoring device for the
PTC temperature sensor of the motor - ATEX certified to EN 50495. The PTC temperature sensor is
located in the stator coil. This is the primary protection for the safe operation of the motor.
In addition to primary PTC sensors additional set of PTC/NTC/KTY is provided in the winging as
secondary protection sensors which can be connected to the drive.
For operation without the use of actuation of the additional PTC/NTC/KTY temperature sensor by
the servocontroller, the motor unit must be sized in such a way that the trigger temperature of the
direct temperature monitor is not reached during fault-free operation.
If the device switches off, this is due to an emergency shutdown and is indicative of a malfunction
of motor operation. The cause of overheating should always be corrected before continuing
operation.
7.1 REPAIR PROCESSING

Should it be necessary to repair a MOOG motor, all non-MOOG attachment parts such as gearing,
gear wheels, pinions are to be dismounted, as MOOG cannot guarantee that they will be dismounted
correctly. Grease and dirt present at the connection flange of the motor should also be removed.
If possible, a detailed description of the malfunction or failure report is to be included with the
shipping papers. The shipping paper is to be clearly labeled with “For Repair”. The motor is to be
packed in a shockproof manner to prevent damage during transport and sent to the address listed
below or to the regional branch office.
No repairs may be performed by third parties due to reasons of product liability, as the applicable
safety regulations (e.g. IEC guidelines) and Moog quality standards cannot generally be maintained
by the customer.
8. SPECIAL CONDITIONS FOR SAFE USE

• For ambient temperatures below –10 °C and above +60 °C use field wiring suitable for both minimum
and maximum ambient temperature.
• Contact Moog for information on the dimensions of the flameproof joints.
• Yield strength of the front and rear cover assembling fasteners shall not be less than 640 MPa.
• The class of fit between the fasteners and stator frame shall be of medium fit 6H/6g.
• All cable entry devices and blanking elements shall be IECEx/ ATEX certified in type of explosion
protection flameproof enclosure “d”, dust protection “tb”, suitable for the conditions of use and cor-
rectly installed.
• The drive used along to the servomotor shall be of specification as specified by manufacturer and
suitable for the motor electrical specifications and operating characteristics.
• The o-rings and seal material on which the IP protection is relied on shall not be replaced.
• The motor can withstand peak torque for maximum 10% of the time.
• Each motor shall use a suitable thermal protector based on its rated ambient and surface temperature
class (T-code).
• Every motor covered under this certificate shall be connected to a temperature monitoring device in
field. The temperature monitoring device connected to the PTC temperature sensor in the motor shall
be ATEX certified to latest edition of the EN 50495 standard.
TAKE A CLOSER LOOK
Moog designs a range of motion control products that complement the performance of
those featured in this catalog. Visit our website for more information and contact the
Moog facility nearest you.
Argentina India Singapore

+54 11 4326 5916 +91 80 4057 6666 +65 677 36238
info.argentina@moog.com info.india@moog.com info.singapore@moog.com
Australia Ireland South Africa

+61 3 9561 6044 +353 21 451 9000 +27 12 653 6768
info.australia@moog.com info.ireland@moog.com info.southafrica@moog.com
Brazil Italy Spain

+55 11 3572 0400 +39 0332 421 111 +34 902 133 240
info.brazil@moog.com info.italy@moog.com info.spain@moog.com
Canada Japan Sweden

+1 716 652 2000 +81 46 355 3767 +46 31 680 060
info.canada@moog.com info.japan@moog.com info.sweden@moog.com
China Korea Switzerland

+86 21 2893 1600 +82 31 764 6711 +41 71 394 5010
info.china@moog.com info.korea@moog.com info.switzerland@moog.com
Finland Luxembourg United Kingdom

+358 10 422 1840 +352 40 46 401 +44 168 429 6600
info.finland@moog.com info.luxembourg@moog.com info.uk@moog.com
France The Netherlands USA

+33 1 4560 7000 +31 252 462 000 +1 716 652 2000
info.france@moog.com info.thenetherlands@moog.com info.usa@moog.com
Germany Norway
+49 7031 622 0 +47 6494 1948
info.germany@moog.com info.norway@moog.com
Hong Kong Russia

+852 2 635 3200 +7 8 31 713 1811
info.hongkong@moog.com info.russia@moog.com
Moog is a registered trademark of Moog Inc. and its subsidiaries. All trademarks as indicated herein are the Moog Controls India Pvt. Ltd.,
property of Moog Inc. and its subsidiaries. KIADB Industrial Area
No. 99P, 100P & 41P
©2012 Moog Inc. All rights reserved. All changes are reserved. Electronic city phase II, Hosur
road, Bangalore – 560100,
Brushless Servo Motors ExD Series - G493, G495 and G496 Karnataka, India
Origami/Rev. G, July 2012, Id. CB07398-001
CB07398-001
16
ATTUATORE EM
L875-603
Servomotore - Dichiarazione di Conformità CE

ATTUATORE EM
L875-603
Attuatore - Disegno di Installazione

ATTUATORE EM
L875-603
Attuatore - Istruzione di Ri-Lubrificazione

ISTRUZIONI DI
LUBRIFICAZIONE
Originale

QUESTO DOCUMENTO DESCRIVE LE ISTRUZIONI DI LUBRIFICAZIONE PER MOOG EMA L875-603.
DOCUMENTO NR. CDP37236
REVISIONE DOCUMENTO
La seguente tabella mostra la revisione del docuemnto:
0 Versione iniziale CAR BEB LOF Gennaio 2013

SOMMARIO
REVISIONE DOCUMENTO .................................................................................................................................. 2
SOMMARIO........................................................................................................................................................ 3
1. ISTRUZIONI DI RILUBRIFICAZIONE ............................................................................................................. 4
1.1. Introduzione ...................................................................................................................................... 4
1.2. Rilubrificazione gearset ..................................................................................................................... 4
1.3. Rilubrificazione vite a ricircolo di sfere e cuscinetti .......................................................................... 5
1.4. Rilubrificazione stelo ......................................................................................................................... 5
1.5. Operazioni conclusive ........................................................................................................................ 5
2. ALLEGATI .................................................................................................................................................... 6
1. ISTRUZIONI DI RILUBRIFICAZIONE
1.1. Introduzione
Fare riferimento al manuale dell’attuatore per la tipologia di grasso da utilizzare.
L’attuatore necessita di un ingrassaggio periodico di mantenimento, descritto nel seguente manuale.
Si raccomanda, dopo 3 anni di servizio, di fare revisionare l’attuatore da tecnici Moog al fine di sostituire
completamente il grasso esausto.
La seguente figura schematizza la posizione delle connessioni per l’ingrassaggio e la loro funzione.
1 2 3
Numero identificativo ingrassatore Componenti interessati durante l’ingrassamento
1 Gearset
2 Vite a ricircolo di sfere – Cuscinetti
3 Stelo
1.2. Rilubrificazione gear set

La seguente tabella mostra le operazioni da eseguire per la rilubrificazione gearset:
Operazione Descrizione
1 Intercettare l’alimentazione elettrica alla macchina

2 Collegare la pompa d’ingrassaggio all’ingrassatore (posizione 1)
3
3 Iniettare 1 cm di grasso
1.3. Rilubrificazione vite a ricircolo di sfere e cuscinetti
La seguente tabella mostra le operazioni da eseguire per la rilubrificazione a ricircolo di sfere e ciscunetti:

3
1.4. Rilubrificazione stelo

La seguente tabella mostra le operazioni da eseguire per la rilubrificazione stelo:

3
1.5. Operazioni conclusive

Si suggerisce di effettuare almeno due corse complete dell’attuatore, senza carico, per distribuire il grasso inserito con
le operazioni precedenti.
2. ALLEGATI
La seguente tabella mostra gli allegati:
Allegato Nr. Nome Allegato Descrizione Allegato
10
11
12
13
TAKE A CLOSER LOOK

+54 11 4326 5916 +353 21 451 9000 +46 31 680 060

+61 3 9561 6044 +39 0332 421 111 +41 71 394 5010

+43 664 144 65 80 +81 436 55 3767 +31 252 462 000

+55 11 5523 8011 +82 31 764 6711 +44 1564 784 777

+86 21 5854 1411 +352 40 46 401 +1 734 887 4250
Finland Norway
+358 9 2517 2730 +47 224 32927
France Russia
+33 1 4560 7000 +7 831 713 1811
Germany Singapore
+49 7031 622 0 +65 677 36238

+852 2 635 3200 +27 11 655 7030
India Spain
+91 80 4120 8785 +34 902 133 240
are reserved
ISTRUZIONI DI LUBRIFICAZIONE
Rev.0, Gennaio 2013 Document nr. CDP37236
ATTUATORE EM
L875-603
Attuatore - Dichiarazione di Conformità ATEX

ATTUATORE EM
L875-603
Servomotore - EC Type Examination Certificate

[1] EC-TYPE EXAMINATION CERTIFICATE
[2] Equipment or Protective System intended for use

in Potentially Explosive Atmospheres
Directive 94/9/EC
[3] EC-Type Examination Certificate Number: DEMKO 10 ATEX 0915070X Rev. 2
[4] Equipment or Protective System: Brushless servomotor, G493, G495 and G496 models
[5] Manufacturer: Moog Controls (India) PVT Ltd.
[6] Address: KIADB Industrial Area, No. 99, 100P & 41P, Electronics City Phase II, Hosur Road, Bangalore -
560 100, Karnataka, India
[7] This equipment or protective system and any acceptable variation thereto are specified in the schedule to this certificate and the
documents therein referred to.
[8] UL International Demko A/S, notified body number 0539 in accordance with Article 9 of the Council Directive 94/9/EC of 23 March 1994,
certifies that this equipment or protective system has been found to comply with the Essential Health and Safety Requirements relating to
design and construction of equipment and protective systems intended for use in potentially explosive atmospheres given in Annex II to
the Directive.
The examination and test results are recorded in confidential report no. 12CA02577-10ATEX0915070X

[9] Compliance with the Essential Health and Safety Requirements has been assured by compliance with:
EN 60079-0:2009 EN 60079-1:2007 EN 60079-31:2009

[10] If the sign "X" is placed after the certificate number, it indicates that the equipment or protective system is subject to special conditions for
safe use specified in the schedule to this certificate.
[11] This EC-Type examination certificate relates only to the design, examination and tests of the specified equipment or protective system in
accordance to the Directive 94/9/EC. Further requirements of the Directive apply to the manufacturing process and supply of this
equipment or protective system.
These are not covered by the certificate.
[12] The marking of the equipment or protective system shall include the following:
II 2 G Ex d IIC T3-T6 Gb
II 2 D Ex tb IIIC T200°C-T85°C Db IP 65/67
Certification Manager
JJan-Erik
Jan Erik
rik Storg
Storgaard
Storgaa
Date of issue: 2011-02-08
Re-issued: 2012-07-30
Notif
tiified Bod
Notified Body UL International Demko A/S, Borupvang 5A, 2750 Ballerup, Denmark
Tel. +45 44 85 65 65, info.dk@ul.com
www.ul-europe.com
00-IC-F0056 – Issue 6.2 This certificate may only be reproduced in its entirety and without any change, schedule included. Page 1 of 7
[13] Schedule
[14] EC-TYPE EXAMINATION CERTIFICATE No.
DEMKO 10 ATEX 0915070X Rev. 2
Report: 12CA02577-10ATEX0915070X
[15] Description of Equipment or protective system
Product is a brushless servomotor for use in gas and dust atmospheres of model numbers G493, G495, and G496. The three models
are similar in design but vary in size, volume and electrical parameters. The motor has two versions for IP rating, IP 65 and IP 67. The
motor has a built-in temperature-limiting device of NTC, PTC or KTY type. A primary thermistor which is a PTC type only and is to be
connected to a temperature monitoring device, which would trip power supply to drive on field. An optional secondary thermistor which
can be of the PTC/NTC or KTY type can also be connected. The enclosure is made of aluminum alloy. The dimensions and flame
paths remain constant for a particular motor model and only the torque and power ratings vary. The motor is available in various stack
lengths.
Nomenclature for types G493, G495, and G496:

G 3 L M 2 010 00 00 01 01 000
I II III IV V VI VII VIII IX X XI
I – Motor Series
G (Global) – Series designation
II – Motor Size
3 (493) – 70 mm square flange
III – Design
L – Moog Ex Design UL
IV – Winding Voltage
M – Low voltage
V – High voltage
V – Stack Length
0 – Non-standard stack length, between L05 and L40 for G493, between L10 and L50 for G495, and between L15 and L90
for G496
2 – L05 (G493) or L10 (G495) or L15 (G496)
4 – L15 (G493) or L20 (G495) or L30 (G496)
6 – L25 (G493) or L30 (G495) or L45 (G496)
8 – L40 (G493) or L50 (G495) or L60 (G496)
9 – L90 (G496)
VI – Nominal Speed, RPM

Any number between X – XXX, followed by motor RPM code, where the RPM code designation given as = RPM/100
VII – Electrical Option

Brake Options Cable gland position
1 2 Top Back
00 - - X -
01 X - X -
02 - X X -
03 - - - X
04 X - - X
05 - X - X
99 Special version – not affecting the electrical performance
or protection methods of the device as described in the
documents
Brake option
Brake Option
Motor Size G493 G495 G496
Low -T 1 2 Nm 14.5 Nm 22 Nm
High -T 2 4.5 Nm 22 Nm 72 Nm
Code
[13] Schedule
VIII – Mechanical Option
Keyway Shaft exit seal

00 None provided X
01 X X
99 Special version – not affecting the
electrical performance or protection
methods of the device as described in
the documents
IX – Feedback Option
Any two digit number - Not related to the protection method
X – Ignition Temperature Class
Ignition Temperature Class / Ambient (°C) +

-20 to -20 to -20 to -20 to -20 to -20 to -20 to -40 to -40 to -40 to -40 to -40 to -40 to -40 to
+40 +50 +60 +70 +80 +90 +100 +40 +50 +60 +70 +80 +90 +100
00 - - - - - - - - - - - T4 - -
01 - T4 - - - - - - - - - - - -
02 - - T4 - - - - - - - - - - -
03 T4 - - - - - - - - - - - - -
04 - - - T4 - - - - - - - - - -
05 - - - - T4 - - - - - - - - -
06 - - - - - - - T4 - - - - - -
07 - - - - - - - - T4 - - - - -
08 - - - - - - - - - T4 - - - -
09 - - - - - - - - - - T4 - - -
10 T5 - - - - - - - - - - - - -
11 - - - - - - - T5 - - - - - -
12 T6 - - - - - - - - - - - - -
13 - - - - - - - T6 - - - - - -
14 T3 - - - - - - - - - - - - -
15 - T3 - - - - - - - - - - - -
16 - - T3 - - - - - - - - - - -
17 - - - T3 - - - - - - - - - -
18 - - - - T3 - - - - - - - - -
19 - - - - - T3 - - - - - - - -
20 - - - - - - T3 - - - - - - -
21 - - - - - - - T3 - - - - - -
22 - - - - - - - - T3 - - - - -
23 - - - - - - - - - T3 - - - -
24 - - - - - - - - - - T3 - - -
25 - - - - - - - - - - - T3 - -
26 - - - - - - - - - - - - T3 -
27 - - - - - - - - - - - - - T3
99 Special version – not affecting the electrical performance or protection methods of the device as described in the documents
+
- T3 ignition temp class for size 3 & 5 up to 80°C only.
XI – Special Version
Any three digit number - Not related to the protection method
Temperature range
The ambient ranges and the temperature class details are given below. The temperature class and ambient are related based on
the power supply rating to the motor at a specific ambient range.
For G493 and G495 motors:
The relation between ambient temperature and the assigned temperature class is as follows:
Ambient temperature range Temperature class
-40 °C to +40 °C
See Electrical data
-20 °C to +40 °C
-40 °C to +50 °C
See Electrical data
-20 °C to +50 °C
-40 °C to +70 °C
See Electrical data
-20 °C to +70 °C
-40 °C to +80 °C
See Electrical data
-20 °C to +80 °C
[13] Schedule
For G496 motors:
-40 °C to +40 °C
See Electrical data
-20 °C to +40 °C
-40 °C to +50 °C
See Electrical data
-20 °C to +50 °C
-40 °C to +70 °C
See Electrical data
-20 °C to +70 °C
-40 °C to +80 °C
See Electrical data
-20 °C to +80 °C
-40 °C to +90 °C
See Electrical data
-20 °C to +90 °C
-40 °C to +100 °C
See Electrical data
-20 °C to +100 °C
Electrical data
Power ratings with corresponding range of parameters for motors are as below:
For G493:
Stack Power, Speed, Rated Torque, Peak Torque, Ambient Temperature
Length W rpm Nm Nm Rating, °C Class
0 0 0.52 1.6
L05
359 7800 0.44 1.6 -40 to +40
T4/T135°C
0 0 3.26 13.2 -20 to +40
L40
1117 3800 2.82 13.2
0 0 0.5 1.6
L05
341 7800 0.42 1.6 -40 to +50
T4/T135°C
0 0 3.13 13.2 -20 to + 50
L40
1059 3800 2.66 13.2
0 0 0.46 1.6
L05
304 7800 0.37 1.6 -40 to +60
T4/T135°C
0 0 2.88 13.2 -20 to +60
L40
942 3800 2.37 13.2
0 0 0.41 1.6
L05
253 7800 0.31 1.6 -40 to +70
T4/T135°C
0 0 2.56 13.2 -20 to +70
L40
786 3800 1.97 13.2
0 0 0.34 1.6
L05
177 7800 0.22 1.6 -40 to +80
T4/T135°C
0 0 2.14 13.2 -20 to +80
L40
552 3800 1.38 13.2
0 0 0.43 1.6
L05
273 7800 0.33 1.6 -40 to +40
T5/T100°C
0 0 2.74 13.2 -20 to +40
L40
847 3800 2.12 13.2
0 0 0.32 1.6
L05
118 7800 0.14 1.6 -40 to +40
T6/T85°C
0 0 1.99 13.2 -20 to +40
L40
364 3800 0.91 13.2
[13] Schedule
For G495:
L10 0 0 5.79 12.2
2173 4800 4.32 12.2 -40 to +40
T4/T135°C
L50 0 0 25.39 61.2 -20 to +40
4388 2000 20.95 61.2
L10 0 0 5.47 12.2
1969 4800 3.92 12.2 -40 to +50
T4/T135°C
L50 0 0 24 61.2 -20 to +50
4046 2000 19.32 61.2
L10 0 0 5.15 12.2
1746 4800 3.47 12.2 -40 to +60
T4/T135°C
L50 0 0 22.6 61.2 -20 to +60
3682 2000 17.58 61.2
L10 0 0 4.81 12.2
1489 4800 2.96 12.2 -40 to +70
T4/T135°C
L50 0 0 21.14 61.2 -20 to +70
3283 2000 15.67 61.2
L10 0 0 4.3 12.2
1035 4800 2.06 12.2 -40 to +80
T4/T135°C
L50 0 0 18.87 61.2 -20 to +80
2604 2000 12.43 61.2
L10 0 0 5.09 12.2
1581 4800 3.15 12.2 -40 to +40
T5/T100°C
L50 0 0 22.35 61.2 -20 to +40
3474 2000 16.6 61.2
L10 0 0 4.03 12.2
645 4800 1.47 12.2 -40 to +40
T6/T85°C
L50 0 0 17.68 61.2 -20 to +40
1640 2000 7.83 61.2
For G496:
Stack Power, Speed, Rated Torque, Peak Ambient Temperature
Length W rpm Nm Torque, Rating, °C Class
Nm
L15 0 0 13 40
3464 4000 8 40 -40 to +40
T3/T200°C
L90 0 0 70 240 -20 to +40
8378 2000 40 240
L15 0 0 13 40
3179 4000 8 40 -40 to +50
T3/T200°C
L90 0 0 66 240 -20 to +50
8378 2000 40 240
L15 0 0 12 40
2886 4000 7 40 -40 to +60
T3/T200°C
L90 0 0 64 240 -20 to +60
8378 2000 40 240
L15 0 0 11 40
2346 3200 7 40 -40 to +70
T3/T200°C
L90 0 0 58 240 -20 to +70
6053 1700 34 240
L15 0 0 10 40
1926 2800 7 40 -40 to +80
T3/T200°C
L90 0 0 53 240 -20 to +80
5027 1500 32 240
L15 0 0 9 40
1330 2300 6 40 -40 to +90
T3/T200°C
L90 0 0 46 240 -20 to +90
4241 1500 27 240
L15 0 0 8 40
928 2000 4 40 -40 to +100
T3/T200°C
L90 0 0 40 240 -20 to +100
3142 1250 24 240
[13] Schedule
For G496 (Continued):

L15 0 0 13 40
3464 4000 8 40 -40 to +40
T4/T135°C
L90 0 0 70 240 -20 to +40
8378 2000 40 240
L15 0 0 13 40
3179 4000 8 40 -40 to +50
T4/T135°C
L90 0 0 66 240 -20 to +50
8378 2000 40 240
L15 0 0 12 40
2622 4000 6 40 -40 to +60
T4/T135°C
L90 0 0 62 240 -20 to +60
7459 1800 39 240
L15 0 0 11 40
2346 3200 7 40 -40 to +70
T4/T135°C
L90 0 0 58 240 -20 to +70
6053 1700 34 240
L15 0 0 10 40
1926 2800 7 40 -40 to +80
T4/T135°C
L90 0 0 53 240 -20 to +80
5027 1500 32 240
L15 0 0 10 40
1875 2700 7 40 -40 to +40
T5/T100°C
L90 0 0 55 240 -20 to +40
4765 1300 35 240
L15 0 0 9 40
1256 2100 6 40 -40 to +40
T6/T85°C
L90 0 0 47 240 -20 to +40
3110 1100 27 240
The above ratings are continuous 100% duty cycle. The change in torque ratings with respect to duty cycle is as given below:
Duty Cycle Torque rating increases by

25% 85%
40% 50%
60% 25%
The duty cycle for peak torque condition is 10% i.e. 6 seconds ON and 54 seconds OFF, in a cycle time of 1 minute.
For ratings between the above stack lengths, refer to page 4 of schedule drawings CA91180, CA91181 and CB35199.
All the above ratings are at DC bus voltage of 325 volts, maximum DC bus voltage rating is 750 volts, ratings remain the same for all
voltages and hence the losses also remain the same.
Installation instructions:
All cable entry devices and blanking elements shall be ATEX certified in type of explosion protection flameproof enclosure “d”, dust
protection “tb”, suitable for the conditions of use and correctly installed.
Unused apertures shall be closed with suitable blanking elements.
For ambient temperatures below –10 °C and above +60 °C use field wiring suitable for both minimum and maximum ambient
temperature.
Mounting instructions:
Refer to “Instructions”.
Routine tests
Routine tests hydrostatic pressure test according to EN 60079-1 cl. 16 are to be carried out in accordance with work instruction
WI005306, for type G493 motors rated below -20°C as the enclosures have been tested at 1.5 times the reference pressure. All other
type G493 motors rated -20°C and above have successfully been tested at four times the reference pressure and routine tests are not
required.
Routine tests according to EN 60079-1 cl. 16 are not required, for all the type G495 and G496 motors as the enclosures have been
successfully tested at four times the reference pressure.
[13] Schedule
[16] Report No.
Project Report No.: 12CA02577-10ATEX0915070X (Hazardous Location Testing)
Documents:
Description: Drawing No.: Rev. Level: Date:
Certification Drawing - G493L Ex Motors (4 Sheets) CA91180 T 2012-06-25
Certification Drawing - G496L Ex Motors (4 Sheets) CB35199 A 2012-06-25
Name plate (For Gas Only) CA94541 F 2012-07-10
Name plate (For Gas and Dust) CB05597 F 2012-07-10
Installation instructions CB07398-001 G 2012-07
Warning Label C88053 0 2004-04-27
[17] Special conditions for safe use:

• For ambient temperatures below –10 °C and above +60 °C use field wiring suitable for both minimum and maximum ambient
temperature.
• All cable entry devices and blanking elements shall be ATEX certified in type of explosion protection flameproof enclosure
“d”, dust protection “tb”, suitable for the conditions of use and correctly installed.
• The drive used along to the servomotor shall be of specification as specified by manufacturer and suitable for the motor
electrical specifications and operating characteristics.
• Each motor shall use a suitable thermal protector based on its rated ambient and surface temperature class (T-code).
• Every motor covered under this certificate shall be connected to a temperature monitoring device in field. The temperature
monitoring device connected to the PTC temperature sensor in the motor shall be ATEX certified to latest edition of the EN
50495 standard.
[18] Essential Health and Safety Requirements

Concerning ESR this Schedule verifies compliance with the ATEX directive only. The manufacturer's Declaration of Conformity
declares compliance with other relevant Directives.
Additional information
The servo motor models G493, G495, and G496 have in addition passed the tests for Ingress Protection to IP 65 and IP67 as applicable
in accordance with EN60529: 1991/A1 2001.
The manufacturer shall inform the notified body concerning all modifications to the technical documentation as described
in ANNEX III to Directive 94/9/EC of the European Parliament and the Council of 23 March 1994.
ATTUATORE EM
L875-603
Servomotore - Product Quality Assessment
Notification

[1] PRODUCT QUALITY ASSURANCE NOTIFICATION


Directive 94/9/EC
[3] Notification Number: 09 ATEX Q148848 Rev. 0
[4] Equipment or Protective System or Components as listed: Brushless Servomotors for use
in explosive atmospheres, using the protection
principles:
Flameproof enclosure ‘d’ and
Dust protection ‘tD’
[5] Applicant: Moog Controls (India) Private Limited

KIADB Industrial Area, No. 99, 100P and 41 P, Electronic
City Phase II, Hosur Road, Bangalore - 560 100 Karnataka
India

[6] Manufacturer: Moog Controls (India) Private Limited
India

[7] UL International Demko A/S notified body number 0539 for Annex VII in accordance with Article 9 of the Council Directive 94/9/EC of 23
March 1994, notifies to the applicant that the actual manufacturer has a production quality system which complies to Annex VII of the
Directive.
[8] This notification is based on audit report No.
12CA54355, Dated 2012-10-29

This notification can be withdrawn if the manufacturer no longer satisfies the requirements of Annex VII. The Manufacturer is obliged to
inform UL International Demko A/S of any changes in their ISO 9001:2008 registration or other aspects upon which this notification has
been given.
Results of periodical re-assessment of the quality system are a part of this notification.

[9] This notification is valid until:
2015-10-27

and can be withdrawn if the manufacturer does not satisfy the product quality assurance re-assessment.

[10] According to Article 10[1] of the Directive 94/9 EC the CE marking shall be followed by the identification number 0539 identifying the
notified body involved in the production control stage.
Certification Manager This notification may only be reproduced in its entirety and without
Jan-Erik
Jan
a Erik k Storgaard
S
Sto
t ga rd any change
Notified Body UL International Demko A/S, Ballerup 5A, 2750 Ballerup, Denmark
Tel. +45 44 85 65 65, info.dk@ul.com
www.ul-europe.com
00-IC-F0073 – Issue 3.0 Page 1

EM ACTUATOR
L875-603
Maintenance & Installation Manual
Translation
Rev. 0, January 2013
THIS DOCUMENT DESCRIBES THE INSTALLATION, OPERATION AND

MAINTENANCE OF THE MOOG EM ACTUATOR L875-603.
PREFACE
This "EM ACTUATOR L875-603 - Installation & Maintenance Instructions - Translation” was drafted according to IEC
EN 62079, “Preparation of instructions - Structuring, content and presentation”. The manual was written and
checked to the best of Moog's knowledge.
Moog is not liable for its use and reserves the right to change the product and information included herein, without
prior notice.
IMPORTANT: No part of this document can be copied, duplicated, reproduced or saved to

any data storage system, translated into any language or transmitted with any data
communication system without Moog's consent
DOCUMENT VERSION
The original version of this manual was drafted in: Italiano (EN).
The language used for documents and drawings was agreed with the customer, as specified in the Order.
In the event these "Installation & Maintenance Instructions" are translated, Moog also provides the original
"Installation & Maintenance Instructions - Original" version.
REVISION INDEX
The following table lists the manual revision index:
Rev Description Prepared Checked Approved Date
0 Translation of CDS37003(0) BEB CAR LOF January 2013

INDEX
PREFACE ................................................................................................................................................................... 2
Document version .................................................................................................................................................... 3
Revision index .......................................................................................................................................................... 3
1. IDENTIFICATION ........................................................................................................................................... 6
1.1 Nameplate ....................................................................................................................................................................................................6
1.2 The Manufacturer .........................................................................................................................................................................................7
1.3 Warranty .......................................................................................................................................................................................................7
1.3.1 Prerequisites to be performed by the customer ...........................................................................................................................................7
1.4 Declaration of Conformity .............................................................................................................................................................................7
1.5 Declaration of Incorporation .........................................................................................................................................................................7
1.6 Applied standards .........................................................................................................................................................................................8
2. GENERAL DESCRIPTION ................................................................................................................................ 9

2.1 Brushless motor ..........................................................................................................................................................................................10
2.2 Gear box ......................................................................................................................................................................................................10
2.3 Torque limiter .............................................................................................................................................................................................10
2.4 Mechanical converter .................................................................................................................................................................................10
2.5 Body fixing system ......................................................................................................................................................................................10
2.6 Rod ..............................................................................................................................................................................................................10
2.7 Ends fixing system .......................................................................................................................................................................................11
2.8 Intended use ...............................................................................................................................................................................................11
2.9 Connections ................................................................................................................................................................................................12
2.11 Emissions ....................................................................................................................................................................................................12
2.12 IP Code ........................................................................................................................................................................................................12
2.13 Electromagnetic compatibility ....................................................................................................................................................................12
3. SAFETY ....................................................................................................................................................... 14
3.1 Risk assessment ..........................................................................................................................................................................................14
4. PRODUCT PREPARATION FOR USE ............................................................................................................. 15

4.1 Assembly .....................................................................................................................................................................................................15
4.2 Installation ..................................................................................................................................................................................................15
4.3 Electrical connections .................................................................................................................................................................................15
4.4 Commissioning ............................................................................................................................................................................................16
5. OPERATING INSTRUCTIONS ....................................................................................................................... 17

6. MAINTENANCE AND CLEANING ................................................................................................................. 18
6.1 Re-lubrication..............................................................................................................................................................................................18
6.2 Troubleshooting ..........................................................................................................................................................................................18
7. SPARE PARTS AND CONSUMABLES ............................................................................................................ 19

8. SERVICE AND REPAIRS ............................................................................................................................... 20
9. END OF LIFE/SCRAPING .............................................................................................................................. 21
10. ATTACHMENTS .......................................................................................................................................... 22
GLOSSARY .............................................................................................................................................................. 23
ABOUT MOOG ........................................................................................................................................................ 24
1. IDENTIFICATION
1.1 Nameplate
The EM Actuator L875-603 includes a nameplate with sensitive data to be communicated when requesting
information or other from Moog.
An illustration of the nameplate layout is provided below:
The following table includes the data found on the nameplate:
Identification Description
Mod Product model
S/N Serial number followed by the date of manufacture expressed as "month/year"
Type Intentionally left blank
Operating temperature range
ATEC certification information
The following table summarises the actuator identification data:
Serial Nr. (if applicable) All
ATEX certification for the
electrical parts of the actuator
(see the Attachment 4, Brushless servomotor - Declaration of Conformity)

mechanical parts of the
actuator II 3D c 135°C
1.2 The Manufacturer
The following table includes the manufacturer's contact details:
Name Moog Italiana S.r.l.
Address Via G. Pastore 4, 21046 Malnate (VA)
Country Italy
Telephone +39 0332 421 111
Fax + 39 0332 429 233
1.3 Warranty
The actuator is covered by a warranty according to law, unless otherwise agreed in the contract.
Refer to the purchase contract for warranty coverage details.
This warranty is valid as of the delivery date, unless otherwise agreed in the purchase contract.
1.3.1 Prerequisites to be performed by the customer

The customer is in charge of ensuring that the product is installed and used according to local and international
safety directives and guidelines. The customer must assess residual risks and prepare:
 Suitably dimensioned electrical and mechanical interfaces
 Suitable barriers and safety devices
 Tools for correct product handling
1.4 Declaration of Conformity

The Actuator L875-603 is a component, thus an EC Declaration of Conformity is not issued as per the Machine
Directive. Moreover, the Actuator is subjected to the ATEX Directive, so there is an EC Declaration of Conformity in
compliance with it (See the Attachment 7).
1.5 Declaration of Incorporation

The EM Actuator L875-603 is a component, thus an EC Declaration of Incorporation is not issued as per the Machine
Directive.
1.6 Applied standards
The actuator was designed and constructed according to currents best practices.
The following table lists the applied European Directives:
2006/95/CE Low Voltage Directive
The following table lists the applied standards:
EN 60034-1:2010 Rotating electrical machines - Part 1: Rating and performance

EN 60034-5:2006
rotating electrical machines (integral design) (IP Code) - Classification
EN 61800-3:2012
methods
IEC EN 60204-1:2006 Safety of machinery. Electrical equipment of machines - Part 1: General requirements
EN 12100:2010 Machinery safety – General design principles - Risk assessment and risk reduction
EN 60079-0:2009 Explosive atmospheres - Part 0: Equipment - General requirements
EN 60079-1:2007 Explosive atmospheres - Part 1: Equipment protection by flameproof enclosures "d"
EN 60079-31:2009 Explosive atmospheres - Part 31: Equipment dust ignition protection by enclosure "t"
EN 13463-1:2009
EN 13463-5:2011
EN 1127-1:2011
EN 61000-4-2:2009
Electromagnetic compatibility (EMC) - Part 4-3: Testing and measurement techniques - Radiated,
EN 61000-4-3:2006
radio-frequency, electromagnetic field immunity test
Electromagnetic compatibility (EMC) – Part 4-4: Testing and measurement techniques – Electrical
EN 61000-4-4:2004
fast transient/burst immunity test
EN 61000-4-5:2006
immunity test
Electromagnetic compatibility (EMC) - Part 4-6: Testing and measurement techniques - Immunity
EN 61000-4-6:2009
to conducted disturbances, induced by radio-frequency fields
The following table lists the main parts of the EM actuator L875-603:
Color Components Description Present in (Yes)/Not present in (No)*
Stelo - Yes
Sistema di fissaggio estremità stelo SPHERICAL JOINT Yes

* Please, refer to the table to identify the components of the actuator; in the following clauses there are the descriptions of the
single components, even if not present in the actuator. For more details, please refer to the attached Installation Drawing.
The following image illustrates the elements of the actuator:

2.1 Brushless motor
The brushless motor is a Moog motor Explosion Proof (ExD). It is a synchronous brushless motor, with permanent
magnets.
For further information, please see the motor manual (see Appendix 1).
2.2 Gear box

The gear box acts as a torque amplifier and it is a planetary gear box. It is dimensioned for a long working life and it
is maintenance free.
The following table lists the main characteristics of the gear box:
Feature Information
IP degree of protection N.A.
Bearing life N.A. hours, for normal functioning
2.3 Torque limiter

The torque limiter disconnects the shaft of the gear unit from the screw, when the torque exceeds the safety value.
The following table lists the main characteristics of the torque limiter:
Event Action Result
Impact between the actuator rod and Torque limiter Kinetic energy accumulated by motor and gearbox
an obstacle (moving speed) intervention NOT downloaded the screw
2.4 Mechanical converter

The mechanical converter transforms rotary motion to linear motion through a high precision ball screw.
The axial load is sustained by a double pair of high precision and low friction oblique-contact ball bearings.
The bearings and screw are lubricated with grease suited to guarantee long working life at medium to high
temperatures.
2.5 Body fixing system
The actuator may be fixed with one the following system:
 Rear flange with threaded holes or loops

 Trunnions
 Front flange with threaded holes or loops
For other details, please refer to the Installation Drawing.
2.6 Rod
The rod has the function of transmitting the force and the speed required by the application.
2.7 Ends fixing system
The rod may be fixed with one of the following system:
 Terminal with male thread

 Terminal with female thread
 Spherical bearing
2.8 Intended use

The EM actuator L875-603 is exclusively designed for industrial and professional use, in applications for Powergen.
Specifically, the EM actuator L875-603 is intended for IGV in Powergen machineries.
The following image graphically depicts Actuator application:
IMPORTANT: The actuator data included in this manual refer to use in an environment with
temperatures between 10° C and 40° C and  70% relative humidity
Different environmental conditions could alter operating parameters

The construction materials used are not specifically designed for use in chemically aggressive
environments, including exposure to saline mist and potentially explosive atmospheres
(ATEX Directive)
The actuator can work at up to 40 °C, generating reduced continuous power. The actuator may also be used for low
temperatures, not less than -40 °C.
The following table lists actuator performance at 40° C:
Feature Performance
Weight 52 kg abt.
Overall dimensions 225 x 140 x 990 mm
Rated power 20 kN
Peak power 20 kN
Max speed 70 mm/s
Stroke 95(+4,0/0)mm
Axial backlash <0,03 mm
Direction No renstriction
2.9 Connections
For mechanical and electrical connections, please see the installation drawing (see Appendix 2).
2.10 Energy consumption
For energy consumption, please see the motor manual (see Appendix 1).
2.11 Emissions
For emissions, please see the motor manual (see Appendix 1).
2.12 IP Code
The following table lists available IP protection grade features:
Feature Description
IP55 standard
N.A. optional
2.13 Electromagnetic compatibility

For electromagnetic compatibility, please see the motor manual (see Appendix 1).
2.14 Personal Protective Equipment (PPE)
GLOVES: always wear protective gloves to avoid potential abrasions or lacerations
SHOES: always wear protective shoes to avoid potential crushing
2.15 Improper use

Moog is not liable for any damages caused to property and/or people in the event of:
 Improper actuator use and/or use other than that indicated in this manual
 Incorrect installation
 Negligence or failure to follow the instructions in this manual
 Operations performed by untrained or unqualified personnel
 Actuator use beyond the admitted limits
 Lack of suitable safety guarding
3. SAFETY
3.1 Risk assessment

Sturdiness and reliability were considered in the actuator design to guarantee safe use.
WARNING: Equipment product users/maintenance personnel with the necessary personal

protection equipment foreseen by current regulations
The following table lists residual Actuator risks:
Risk factor Condition Period of exposure
Limb crushing Rod movement During operations
High voltage Loss of wire and connector insulation When live
Product weight Product fall During transport/maintenance
During operations (in high load

High temperature (up to 80° C) Product heating (parasite currents)
conditions)
The customer is in charge of assessing these risks and preparing suitable personnel protection equipment.
4. PRODUCT PREPARATION FOR USE
4.1 Assembly
The customer is not required to perform assembly operations: the EM actuator L875-603 is supplied fully assembled.
For the connection of the power cables of the motor, please see the motor manual (Attachment 1).
4.2 Installation
The actuator must be lifted using a suitable sling. Before lifting, make sure the centre of gravity is positioned
between and under the slings.
The following table lists the connection of the actuator:
Connection Part Connection Type Connection Feature Tightening Torque
Fixed structure Frontal Flange TRUNNION N.A.
Mobile part Rod – Ball joint end SPHERICAL JOINT N.A.
IMPORTANT: avoid to apply lateral loads to the actuator since they its working life and
performance
Lateral loads may be generated by offsets or eccentric loads
4.3 Electrical connections

Electrical connections between the motor and drive should be performed with the standard wires specified by
Moog. Should other wires be used, they must meet the following requirements:

2
power cable 4 x 4 + 2 x 1 mm

2
signal cable 5 x 2 x 0,25 mm shielded twisted pair
IMPORTANT: The motor wire must be connected and disconnected with the drive cut off
from the power supply
Simply turning off power does not cut off voltage
The grounding wire (PE) must be of adequate section (equal to the power conductor wire) as foreseen by current
safety regulations.
WARNING: Smaller section conductors cause unacceptable wire overheating and loss of
power
Power wire and every single signal wire conductor pair should be shielded.
4.4 Commissioning
EM Actuator L875-603 operations and performance depend on drive settings.
Selected motor torque and speed should not be higher than those indicated in the specific actuator installation
drawing.
Please see the drive manual.
Please pay the utmost attention to:
 drive speed, direct current and motor peak current settings
 connecting power and signal conductor wires; faulty connections could cause the loss of motor control with
potential damage to mechanical parts in the event of fast impact with obstacles.
Check the following at each actuator start up:
 machine sliding structure lubrication
 correct screw tightening torque
 lack of obstacles along stroke of the rod
Please commission at reduced torque and speed (1/10 rated value).
IMPORTANT: carefully avoid collisions at full motor torque and speed

The EM actuator L875-603 is designed for IGV application in a machine (Powergen).
After commissioning, the EM actuator is controlled by the drive, not included in the supply.
Thus, please see the drive manual for further information on operating instructions.
The actuator is designed to require minimal maintenance. Please re-lubricate and inspect rod seal wear every
6 months.
WARNING: Before performing any maintenance, check that:

 The actuator is in a safe position
 All electrical and mechanical power is cut off
 Drives cannot be inadvertently started
 Nearby personnel is warned of maintenance in progress
 There are no hazardous conditions due to other sources
6.1 Re-lubrication
The actuator rod, ball screw and bearings are lubricated with optimal quantity of synthetic mineral grease. Moog
recommends the following grease:
For periodic re-lubrication as per Clause 6 of this manual, the instructions are in the attachment document
CDP37237.
At the end of the related operations, perform almost two complete strokes of the actuator, without load, to
distribute the inserted grease.
6.2 Troubleshooting
A list of the most common problems is provided below.
Problem Possible cause Solution Notes
Incorrect controller settings See the motor drive manual

Noisy operations
Offset or lateral loads Check alignment
Actuator stopped with Incorrect motor - mechanical Check shaft parallel key
motor running converter connection connections
Incorrect controller settings Check drive settings

Actuator stalled
Excessive load or friction Check load and alignments
External overheating Check heat shield
Motor overheating Refer to

Seizure of motor, converter or Remove the actuator and find
Moog Italiana
connected mobile part the seized element
S.r.l.
No spare parts or consumables are foreseen.
8. SERVICE AND REPAIRS
Unscheduled operations needed to restore product operations must be performed by Moog or qualified Moog
personnel.
Visit www.moog.com to find your nearest Moog service centre.
When repairs are required, all parts not originally included in the product must be removed since Moog cannot
guarantee their correct assembly/dismantling.
Grease and dust should also be removed.
The equipment should be suitably packaged to avoid damages during transport.
9. END OF LIFE/SCRAPING
Proceed as follows at the end of the actuator's working life:
 Separate metallic parts according to their type (aluminum, steel, etc.)
WARNING: do not dismantle the motor. Permanent motor magnets generate high
forces that could severely injure the operator
Operators assigned to this activity do not require special training.

When removing and dismantling metallic parts, wear protective gloves to avoid potential abrasions with sharp parts.
Follow local waste disposal regulations to recycle parts mentioned in the previous paragraphs.
10. ATTACHMENTS
The following table lists the attachments:
Attachment # Description Revision
1 Servomotor – Installation Instructions CB07398-001 Rev. G
2 Servomotor – EC Declaration of Conformity Rev. B
3 Actuator – Installation Drawing CB53763 Rev. A
4 Actuator – Re-Lubrication Instructions CDP37327 Rev. 0
5 Actuator – ATEX Declaration of Conformity MRQ37890 Rev. 0
Servomotor – EC Type Examination Certificate 10 ATEX

6 Rev. B
0915070X
Servomotor – Product Quality Assessment Notification

7 Rev. 0
09 ATEX Q148848
GLOSSARY
The following table lists the abbreviations used:
Abbreviation Description
EM Actuator Electro-Mechanical Actuator
Symbol Description
IMPORTANT: Warnings and notes on important functions or helpful information
WARNING: Personal hazard (even fatal)
GLOVES: Protective gloves to avoid potential abrasions or lacerations (PPE)
SHOES: Protective shoes to avoid potential crushing (PPE)

ABOUT MOOG
Moog Industrial Group designs and constructs high performance motion control solutions using electrical, hydraulic
and hybrid technologies with the help of experts in a wide range of applications including testing, simulation and the
plastic, heavy metal and powergen industries.
Moog customers include leading automobile and aerospace manufacturers, test laboratories and automobile racing
teams.
Moog helps businesses design and develop new generation machines.
Moog Industrial Group is a member of Moog Inc.
For further information visit www.moog.com/industrial.

Via G. Pastore 4
Tel. +39 0332 421 111
Fax + 39 0332 429 233
info.italy@moog.com
TAKE A CLOSER LOOK

+54 11 4326 5916 +353 21 451 9000 +46 31 680 060

+61 3 9561 6044 +39 0332 421 111 +41 71 394 5010

+43 664 144 65 80 +81 436 55 3767 +31 252 462 000

+55 11 5523 8011 +82 31 764 6711 +44 1564 784 777

+86 21 5854 1411 +352 40 46 401 +1 734 887 4250
Finland Norway
+358 9 2517 2730 +47 224 32927
France Russia
+33 1 4560 7000 +7 831 713 1811
Germany Singapore
+49 7031 622 0 +65 677 36238

+852 2 635 3200 +27 11 655 7030
India Spain
+91 80 4120 8785 +34 902 133 240
EM ACTUATOR L875-603
Rev. 0, January 2013, Document Nr. CDS37004
.
EM ACTUATOR
L875-603
CDS37004 - Attachment 1
Servomotor - Installation Instructions
DOCUMENT Nr. CDS37004 - Attachment 1


ExD SERIES
Rev. G, July 2012

WITH ATEX AND IECEx
1

TABLE OF CONTENT
INTRODUCTION ....................................................................................................................................................................................... 2
1.2 Model strategy ..................................................................................................................................................................... 4
2.3 Motor name plate ............................................................................................................................................................... 5
3 TRANSPORT ................................................................................................................................................................................... 5
7 MAINTENANCE ........................................................................................................................................................................... 15
ANNEX
Electrical data
Rev. G, July 2012 2


8 Shaft
Rev. G, July 2012 3

1.2 MODEL STRATEGY



Rev. G, July 2012 4


General details
S/N Serial number
Norms:

For Gas and Dust:
For Gas only:
J Rotor inertia
For PWM converter:
3. TRANSPORT
transport damage.
ordered.
Rev. G, July 2012 5


centre.

technical data.
Rev. G, July 2012 6


G493, G495 and G496
Rev. G, July 2012 7


Preparing the motor
Rev. G, July 2012 8

Preparing the motor


on the motor cover.
the thread size.
cover.

must be mounted.
Rev. G, July 2012 9
connection clamps.

overall
6 900
3
Lock washer
5 back-to-back


the manufacturer.

Cover assembly



connection example
User Interface

the power supply to
( Servo Drive )


connection optional
Power Cable
Motor Interface

PTC thermal sensor
Signal Cable


MOTOR
POWER CONNECTION
VOLTAGE SUPPLY
U U BLACK
V V WHITE N/S
W W RED

– – RED BRAKE

MONITORING
DEVICE PRIMARY PTC
PRIMARY
SECONDARY
OPTIONAL THERMISTOR
CONNECTION
SECONDARY OPTIONAL
THERMISTOR
FEEDBACK CONNECTION
CONTROLLER
FEEDBACK DEVICE

7. MAINTENANCE
operation.

by the customer.

rectly installed.
class (T-code).
TAKE A CLOSER LOOK

+54 11 4326 5916 +91 80 4057 6666 +65 677 36238

+61 3 9561 6044 +353 21 451 9000 +27 12 653 6768
Brazil Italy Spain

+55 11 3572 0400 +39 0332 421 111 +34 902 133 240
Canada Japan Sweden

+1 716 652 2000 +81 46 355 3767 +46 31 680 060

+86 21 2893 1600 +82 31 764 6711 +41 71 394 5010

+358 10 422 1840 +352 40 46 401 +44 168 429 6600

+33 1 4560 7000 +31 252 462 000 +1 716 652 2000
Germany Norway
+49 7031 622 0 +47 6494 1948
Hong Kong Russia

+852 2 635 3200 +7 8 31 713 1811
No. 99P, 100P & 41P
CB07398-001
16
EM ACTUATOR
L875-603
Servomotor - EC Declaration of Conformity

EM ACTUATOR
L875-603
Actuator - Installation drawing

EM ACTUATOR
L875-603
Actuator - Re-Lubrication Instructions

RE-LUBRICATION
INSTRUCTIONS
Translation
Rev. 0, February 2013

THIS DOCUMENT DESCRIBES THE RE-LUBRICATION INSTRUCTIONS FOR MOOG EMA L875-603.
DOCUMENT NR. CDP37237
DOCUMENT REVISION
The following table lists the document revisions:
Traduzione di
0 CAR BEB LOF February 2013
CDP37236(0)
INDEX
Document revision ............................................................................................................................................ 2
INDEX ................................................................................................................................................................. 3
1. Re-Lubrication Instructions ....................................................................................................................... 4
1.1. Introduction ....................................................................................................................................... 4
1.2. Gear set re-lubrication....................................................................................................................... 4
1.3. Ball screw and bearings re-lubrication .............................................................................................. 5
1.4. Rod re-lubrication .............................................................................................................................. 5
1.5. Final step............................................................................................................................................ 5
2. Attachments .............................................................................................................................................. 6
1. RE-LUBRICATION INSTRUCTIONS
1.1. Introduction
Refer to the actuator manual for the grease type to use.
A periodical greasing maintenance is necessary for the actuator and it is described in this manual.
After 3 years of operation, it is recommended to ask for a revision of the actuator to the Moog technicians; the
purpose is to substitute completely the exhaust grease.
The following scheme describes the positions of the connections for greasing:
The following table lists the nipple greasers and their functions:
Nipple greaser ID Nr. Components involved during greasing
1 Gear set
2 Bearings & Ball screw
3 Rod
1.2. Gear set re-lubrication

The following table lists the necessary steps to perform the gear set re-lubrication:
Step Description
1 Cut off the power supply of the machine
2 Connect the grease pump to the nipple greaser (position 1)

3
3 Inject 1 cm of grease
1.3. Ball screw and bearings re-lubrication
The following table lists the necessary steps for the ball screw and bearings re-lubrication:
Step Description

3
1.4. Rod re-lubrication

The following table lists the necessary steps for the rod re-lubrication
Step Description

3
1.5. Final step

It is recommended to perform at least two full strokes of the actuator, with no load, to distribute the inserted grease
with the above steps.
2. ATTACHMENTS
The following table lists the attachments
10
11
12
13
TAKE A CLOSER LOOK

+54 11 4326 5916 +353 21 451 9000 +46 31 680 060

+61 3 9561 6044 +39 0332 421 111 +41 71 394 5010

+43 664 144 65 80 +81 436 55 3767 +31 252 462 000

+55 11 5523 8011 +82 31 764 6711 +44 1564 784 777

+86 21 5854 1411 +352 40 46 401 +1 734 887 4250
Finland Norway
+358 9 2517 2730 +47 224 32927
France Russia
+33 1 4560 7000 +7 831 713 1811
Germany Singapore
+49 7031 622 0 +65 677 36238

+852 2 635 3200 +27 11 655 7030
India Spain
+91 80 4120 8785 +34 902 133 240
rved
RE-LUBRICATION INSTRUCTIONS
Rev. 0, February 2013 Document nr. CDP37237
EM ACTUATOR
L875-603
Actuator - ATEX Declaration of Conformity

EM ACTUATOR
L875-603
Servomotor - EC Type Examination Certificate


Directive 94/9/EC
the Directive.

EN 60079-0:2009 EN 60079-1:2007 EN 60079-31:2009

JJan-Erik
Jan Erik
rik Storg
Storgaard
Storgaa
Re-issued: 2012-07-30
Notif
tiified Bod
Tel. +45 44 85 65 65, info.dk@ul.com
www.ul-europe.com
[13] Schedule
lengths.

G 3 L M 2 010 00 00 01 01 000
I – Motor Series
II – Motor Size
III – Design
M – Low voltage
V – High voltage
V – Stack Length
for G496
2 – L05 (G493) or L10 (G495) or L15 (G496)
4 – L15 (G493) or L20 (G495) or L30 (G496)
6 – L25 (G493) or L30 (G495) or L45 (G496)
8 – L40 (G493) or L50 (G495) or L60 (G496)
9 – L90 (G496)


1 2 Top Back
00 - - X -
01 X - X -
02 - X X -
03 - - - X
04 X - - X
05 - X - X
documents
Brake option
Brake Option
Low -T 1 2 Nm 14.5 Nm 22 Nm
High -T 2 4.5 Nm 22 Nm 72 Nm
Code
[13] Schedule

00 None provided X
01 X X
the documents

+40 +50 +60 +70 +80 +90 +100 +40 +50 +60 +70 +80 +90 +100
00 - - - - - - - - - - - T4 - -
01 - T4 - - - - - - - - - - - -
02 - - T4 - - - - - - - - - - -
03 T4 - - - - - - - - - - - - -
04 - - - T4 - - - - - - - - - -
05 - - - - T4 - - - - - - - - -
06 - - - - - - - T4 - - - - - -
07 - - - - - - - - T4 - - - - -
08 - - - - - - - - - T4 - - - -
09 - - - - - - - - - - T4 - - -
10 T5 - - - - - - - - - - - - -
11 - - - - - - - T5 - - - - - -
12 T6 - - - - - - - - - - - - -
13 - - - - - - - T6 - - - - - -
14 T3 - - - - - - - - - - - - -
15 - T3 - - - - - - - - - - - -
16 - - T3 - - - - - - - - - - -
17 - - - T3 - - - - - - - - - -
18 - - - - T3 - - - - - - - - -
19 - - - - - T3 - - - - - - - -
20 - - - - - - T3 - - - - - - -
21 - - - - - - - T3 - - - - - -
22 - - - - - - - - T3 - - - - -
23 - - - - - - - - - T3 - - - -
24 - - - - - - - - - - T3 - - -
25 - - - - - - - - - - - T3 - -
26 - - - - - - - - - - - - T3 -
27 - - - - - - - - - - - - - T3
+
Temperature range
-40 °C to +40 °C
See Electrical data
-20 °C to +40 °C
-40 °C to +50 °C
See Electrical data
-20 °C to +50 °C
-40 °C to +70 °C
See Electrical data
-20 °C to +70 °C
-40 °C to +80 °C
See Electrical data
-20 °C to +80 °C
[13] Schedule
For G496 motors:
-40 °C to +40 °C
See Electrical data
-20 °C to +40 °C
-40 °C to +50 °C
See Electrical data
-20 °C to +50 °C
-40 °C to +70 °C
See Electrical data
-20 °C to +70 °C
-40 °C to +80 °C
See Electrical data
-20 °C to +80 °C
-40 °C to +90 °C
See Electrical data
-20 °C to +90 °C
-40 °C to +100 °C
See Electrical data
-20 °C to +100 °C
Electrical data
For G493:
0 0 0.52 1.6
L05
359 7800 0.44 1.6 -40 to +40
T4/T135°C
0 0 3.26 13.2 -20 to +40
L40
1117 3800 2.82 13.2
0 0 0.5 1.6
L05
341 7800 0.42 1.6 -40 to +50
T4/T135°C
0 0 3.13 13.2 -20 to + 50
L40
1059 3800 2.66 13.2
0 0 0.46 1.6
L05
304 7800 0.37 1.6 -40 to +60
T4/T135°C
0 0 2.88 13.2 -20 to +60
L40
942 3800 2.37 13.2
0 0 0.41 1.6
L05
253 7800 0.31 1.6 -40 to +70
T4/T135°C
0 0 2.56 13.2 -20 to +70
L40
786 3800 1.97 13.2
0 0 0.34 1.6
L05
177 7800 0.22 1.6 -40 to +80
T4/T135°C
0 0 2.14 13.2 -20 to +80
L40
552 3800 1.38 13.2
0 0 0.43 1.6
L05
273 7800 0.33 1.6 -40 to +40
T5/T100°C
0 0 2.74 13.2 -20 to +40
L40
847 3800 2.12 13.2
0 0 0.32 1.6
L05
118 7800 0.14 1.6 -40 to +40
T6/T85°C
0 0 1.99 13.2 -20 to +40
L40
364 3800 0.91 13.2
[13] Schedule
For G495:
L10 0 0 5.79 12.2
2173 4800 4.32 12.2 -40 to +40
T4/T135°C
L50 0 0 25.39 61.2 -20 to +40
4388 2000 20.95 61.2
L10 0 0 5.47 12.2
1969 4800 3.92 12.2 -40 to +50
T4/T135°C
L50 0 0 24 61.2 -20 to +50
4046 2000 19.32 61.2
L10 0 0 5.15 12.2
1746 4800 3.47 12.2 -40 to +60
T4/T135°C
L50 0 0 22.6 61.2 -20 to +60
3682 2000 17.58 61.2
L10 0 0 4.81 12.2
1489 4800 2.96 12.2 -40 to +70
T4/T135°C
L50 0 0 21.14 61.2 -20 to +70
3283 2000 15.67 61.2
L10 0 0 4.3 12.2
1035 4800 2.06 12.2 -40 to +80
T4/T135°C
L50 0 0 18.87 61.2 -20 to +80
2604 2000 12.43 61.2
L10 0 0 5.09 12.2
1581 4800 3.15 12.2 -40 to +40
T5/T100°C
L50 0 0 22.35 61.2 -20 to +40
3474 2000 16.6 61.2
L10 0 0 4.03 12.2
645 4800 1.47 12.2 -40 to +40
T6/T85°C
L50 0 0 17.68 61.2 -20 to +40
1640 2000 7.83 61.2
For G496:
Nm
L15 0 0 13 40
3464 4000 8 40 -40 to +40
T3/T200°C
L90 0 0 70 240 -20 to +40
8378 2000 40 240
L15 0 0 13 40
3179 4000 8 40 -40 to +50
T3/T200°C
L90 0 0 66 240 -20 to +50
8378 2000 40 240
L15 0 0 12 40
2886 4000 7 40 -40 to +60
T3/T200°C
L90 0 0 64 240 -20 to +60
8378 2000 40 240
L15 0 0 11 40
2346 3200 7 40 -40 to +70
T3/T200°C
L90 0 0 58 240 -20 to +70
6053 1700 34 240
L15 0 0 10 40
1926 2800 7 40 -40 to +80
T3/T200°C
L90 0 0 53 240 -20 to +80
5027 1500 32 240
L15 0 0 9 40
1330 2300 6 40 -40 to +90
T3/T200°C
L90 0 0 46 240 -20 to +90
4241 1500 27 240
L15 0 0 8 40
928 2000 4 40 -40 to +100
T3/T200°C
L90 0 0 40 240 -20 to +100
3142 1250 24 240
[13] Schedule

L15 0 0 13 40
3464 4000 8 40 -40 to +40
T4/T135°C
L90 0 0 70 240 -20 to +40
8378 2000 40 240
L15 0 0 13 40
3179 4000 8 40 -40 to +50
T4/T135°C
L90 0 0 66 240 -20 to +50
8378 2000 40 240
L15 0 0 12 40
2622 4000 6 40 -40 to +60
T4/T135°C
L90 0 0 62 240 -20 to +60
7459 1800 39 240
L15 0 0 11 40
2346 3200 7 40 -40 to +70
T4/T135°C
L90 0 0 58 240 -20 to +70
6053 1700 34 240
L15 0 0 10 40
1926 2800 7 40 -40 to +80
T4/T135°C
L90 0 0 53 240 -20 to +80
5027 1500 32 240
L15 0 0 10 40
1875 2700 7 40 -40 to +40
T5/T100°C
L90 0 0 55 240 -20 to +40
4765 1300 35 240
L15 0 0 9 40
1256 2100 6 40 -40 to +40
T6/T85°C
L90 0 0 47 240 -20 to +40
3110 1100 27 240

25% 85%
40% 50%
60% 25%
temperature.
Routine tests
required.
[13] Schedule
[16] Report No.
Documents:
Warning Label C88053 0 2004-04-27

temperature.
50495 standard.

EM ACTUATOR
L875-603
Servomotor - Product Quality Assessment
Notification



Directive 94/9/EC
principles:

India

India

Directive.
12CA54355, Dated 2012-10-29

been given.

2015-10-27


Jan-Erik
Jan
a Erik k Storgaard
S
Sto
t ga rd any change
Tel. +45 44 85 65 65, info.dk@ul.com
www.ul-europe.com

ELECTRO MECHANICAL
ACTUATOR FOR IGV
L081-602
ATTACHMENT 3 – Servo Drive - Maintenance &
Instructions Manual
Rev. 0, April 2013

DS2000XP SERIES OPERATIONS GUIDE
CZ140100 Model Electric Servodrive
GB-4572 Rev.1 - Feb/13

Page 2 of 66
INDEX OF REVISIONS
Revision Date Description Upd. Section

00 Jan 13 Preliminary Release All
01 Mar 13 Some drawings updated 1, 3
Page 3 of 66
INDEX OF CONTENTS
Index Table of Contents I

Using the Guide I.1
Accident protection I.2
EC Declarations of Conformity I.3
EC Requirements I.4
IECEx Certification I.5
Section 1 Application 1.1

General Description Drive Description 1.2
Drive Assembly 1.3
Identification Plates 1.4
Section 2 Start-up Sequence 2.1

Basic Operation Drive Parameters 2.2
Fault Reaction 2.3
Section 3 Inspection 3.1

Installation Environmental Considerations 3.2
Mechanical Installation 3.3
Electrical Installation 3.4
Cable Glands 3.5
Stroke Calibration 3.6
Section 4 Troubleshooting 4
Troubleshooting
Section 5 Drive Maintenance 5.1

Maintenance
Section 6 General Specifications 6

General Specifications
Page 4 of 66
List of Figures
Figure 1.1 Drive Cut-Away View

Figure 3.1 Drive Envelope
Figure 3.2 Enclosure – Components Wiring
Figure 3.3 Terminal Block – Layout
Figure 3.4 Terminal Block - External Connections
Figure 3.5 Terminal Block - Internal Connections
Figure 3.6 Digital Card - Connections
Figure 3.7 Cable Glands – Holes
Figure 3.8 C3WLSE Cable Glands – Dimensions
Figure 3.9 8163/2 Cable Glands – Dimensions
Figure 5.1 CWLSE Cable Gland – Assembly Instructions
Page 5 of 66
I.1 USING THE GUIDE
This guide provides installation, maintenance, and operating instructions for the
DS2000XP series, CZ140100 model Drive.
Every attempt has been made to provide sufficient information in this guide for the proper
operation and preventive maintenance of the drive. It is recommended that the user read
this guide in its entirety.
Operating the CZ140100 model in accordance with instructions herein ensures long term
and reliable operation.
If additional information is required, please contact Moog.
Page 6 of 66
I.2 ACCIDENT PROTECTION
The safety instructions provided in this Guide are included to prevent injury to personnel
(WARNINGS) or damage to equipment (CAUTIONS).
WARNING: High Voltage. Device can have 530Vdc voltage even after
switching off (capacitive voltage).
Discharge Time approx. 6 Minutes.
WARNING: do not open the door of the drive enclosure when an explosive
atmosphere may be present
WARNING: do not open the door of the drive enclosure when energized
WARNING: do not remove or replace fuse inside the drive enclosure when
energized
CAUTION: replace fuse inside the drive enclosure only with Mod. No.1221025 by
Italweber or with an equivalent model compliant with IEC 60269-3
CAUTION: make sure that the correct input voltage, 400Vac nominal, has been
connected
Page 7 of 66
I.3 EC DECLARATIONS OF CONFORMITY
I.3.1 Drive
Page 8 of 66
Page 9 of 66
I.4 EC REQUIREMENTS
• Cautionary Marking. See Accident Protection page.
• Protection against electric shock. Electronic Equipment intended for installation in

closed electrical enclosure kept locked. The lock shall be only opened by authorized
person and the access only allowed to skilled persons whilst energized. Where the
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.
• 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 provided by the EMC filter mounted inside the drive enclosure and
by the cable shielding. The shields of the cables must be connected at both ends to the
proper housing via full circumferential bond to the metallic cable glands or connectors.
• Second Environment (EMC). 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).
It is not intended to be used on a low-voltage public network which supplies domestic
premises (first environment). Radio frequency interference is expected if used on such a
network.
̇ Large-Scale Stationary Industrial Tools (EU Directives WEEE, RoHS). Equipment

intended for installation as part of large-scale stationary industrial tools and so not
covered by the scope of the European Directive 2002/96/EC (WEEE) according to the
exception of Annex IA, No.6, and not covered by the scope of the European Directive
2011/65/EU (RoHS 2) according to Article 2.
• Special conditions for safe use (ATEX). Equipment intended for installation
exclusively in Zone 2 according to EN 60079 standards resp. in Zone 22 according to
EN 61241 standards, where the explosion risk is due to the mixture of IIA, IIB+H2
gas+air mixture, resp. the mixture of flammable dusts and air.
• Maximum surface temperature (ATEX). The permissible maximum surface

temperature is 100°C for the drive.
• Environments with combustible dusts (ATEX). In environments where combustible

dusts may be present, the user must assure a regular cleaning of the apparatus so as to
prevent build-up of dust on the surface.
Page 10 of 66
I.5 IECEx CERTIFICATION
The updated IECEx certifications, including the Certificates of Conformity (CoC), the Ex
Test Reports (ExTR), the Quality Assessment Reports (QAR) and the conditions of
certification can be found at
http://iecex.iec.ch/iecex/iecexweb.nsf/welcome?openform
Write MOOG ITALIANA in the “Free Text Search” and press search.
Page 11 of 66
THIS PAGE INTENTIONALLY BLANK
Page 12 of 66
This publication covers operation, installation and maintenance instructions for the
DS2000XP Drive, CZ140100 model, manufactured by MOOG Italiana, Casella Site.
1.1 Application
The CZ140100 model is designed to meet general industrial motion control requirements
for high temperature hazardous locations. Typical applications include gas turbine nozzle
guide vane, compressor inlet guide vane and valve motion control.
1.2 Drive Description

The drive, a special model of DS2000XP series, is a full digital brushless servodrive which
control the brushless DC motor, to position the actuator based on position feedback from
the resolver.
The main features are:

- inrush current limiting “soft start” circuitry
- high frequency Switch Mode Power Supply (SMPS) circuitry to feed control circuits
- IGBT motor regenerative power control circuit
- digital control board which performs local sequence and loop control
- analog and digital interfaces
Note: The digital board analog and discrete interfaces are electrically isolated. The drive
RS232 serial interface is NOT electrically isolated.
The Moog code of the drive is: CZ140100
1.3 Drive Assembly

The drive is contained within an enclosure with IP66 protection. The enclosure, which
dissipates the thermal losses through an heatsink on the back side, includes also:
- recovery resistor
- EMC filter
- feed-through terminal block with screw connection
- input fuse
- DC/DC converter to supply the brake
- isolated current transducers for Analog Input and Analog Output
- solid state relays for System Enable, System OK and System Brake Enable
See Figure 1.1.
1.4 Identification Plate

A product identification plate is provided on the drive. See Section 6 for an explanation of
the ATEX/IECEx markings.
Page 13 of 66
8657 8657
1 2 1 2
+ - + -
J1
EMC Filter
J6
J2
2 1+ 2 1+ 2 1+
J7
J8
J2C
4 3+ 4 3+ 4 3+
DC/DC Converter
BRAKE SUPPLY
1 2 3 4 5 6 7 8
SRR: solid state relay

ITR: isolated current transducer
Figure 1.1 Drive Cut-Away View
Page 14 of 66
2 BASIC OPERATION
This section describes the basic operation of the Drive.
2.1 Start-up Sequence

- Drive is OFF (not powered).
- Power the drive with 400 Vac.
- Set the Analog Input to 4 mA
- Start of inizialisation sequence; Analog Output signal stays at 10 mA until initialisation
sequence is not completed
- Analog Output signal moves to 4 mA with Home Retract selected (or close to 19.3 mA
with Home Extend selected); System OK comes ON; drive becomes ready to make
homing sequence.
- Start of homing sequence at System Enable command.
- Performance of homing sequence (Analog Output signal changes and can go out of
range during the sequence)
- At completion of stroke verification the actuators goes to programmed home position:
Analog Output indicates the home position.
- Actuator ready to follow the Commanded Position.
Tab.2.1 - LEDs during Start-up Sequence
Drive Display Drive Drive Drive Drive Analog Pin 21-22

1st LED 2nd LED 3rd LED 4th LED Feedback LED
Red Yellow Yellow Green Green
Initialization in Off Off Off Off 10 mA Off
progress
Moog DS2000 Off ON Off Off 10 mA Off
Moog DS2000 ON ON ON Off 0 mA Off
Moog DS2000 Off ON ON Off See note Off
Waiting for Off Off Off Off See note ON
command
Note
If home sequence is programmed “retract”, the output is 4 mA
If home sequence is programmed “extend”, the output is 19.3 mA
To start the system apply 24Vdc at pins 23-24 (System Enable) of Terminal Block. The
green LED at the same pins (Input Monitor) becomes ON.
Tab.2.2 - LEDs in normal operation
Drive Display Drive Drive Drive Drive Analog

1st LED 2nd LED 3rd LED 4th LED Feedback
Red Yellow Yellow Green
Moog DS2000 Off Off Off ON Following
analog
output
Page 15 of 66
2.2 Drive Parameters
The DS2000XP employs several parameters to define its functionality. These parameters
can be downloaded through the RS232 interface to the DS2000XP using the GUI XP
software.
To install the GUI XP software in a laptop PC:

- Install the Java utilities (if not already installed)
- Launch setup.exe
- Follow the default settings
- Copy the file DSG2010_Database (parameter definition) in a dedicated folder (e.g.
C:\DS2000XP_V2\Databases)
To use the GUI XP software in the first installation:

- Open the GUI DS2000XP icon
- Open the “File” menu
- Open the “Communication Setup” screen (see par.2.2.1)
- Select “Template Model”
- Browse for “DSG2010_Database” in the above folder
- Load it and press OK
- Exit (the program save this configuration on exiting)
The drive parameters are divided in two sections:

- Model Parameters
- Drive Parameters
The Actuator Control Loops are performed by the Model section. The Drive section can be
used for test issues, using the drive mainly in manual mode.
Page 16 of 66
2.2.1 Communication Setup
The first step to be done is setting the Communication Setup as in the following screen.
Update of values could be made after first commissioning.
Page 17 of 66
2.2.2 Model Parameters: Geometry, Units and I/O
No changes are required in this screen
Analog Calibration allows a better linearity in the Analog Command and Output.
Note: the above picture is only a reference and will be updated after first commissioning
with final tuning data.
Page 18 of 66
2.2.3 Model Parameters: Command, Control, Motion and Tuning Parameters.
After final tuning, customer has to adjust only Usable Stroke Input parameter (in mm) to
match real available stroke to the “stroke verification sequence” performed by homing
sequence on exit.
Press Update (Write Parameters)
Press Update (Force Model Recalc)
Go to To Save Page for instructions.
Notes:
- for troubleshooting, Tuning Parameters can be changed “on the fly and acquired”; to be
placed in the Model in a permanent way, Model need to be Updated and then Saved;
home is done again.
- every time the model is recalculated, home data is lost and home sequence is performed
again.
- the above picture is only a reference and will be updated after first commissioning with
final tuning data.
Page 19 of 66
2.2.4 Model Parameters: Homing, I-T Foldback, Thermal
In this page it is possible to adjust homing sequence and the limits of force and speed to
be used in the homing sequence.
Home Offset is the offset from home to be added to avoid hits for overshooting in position
in retract position.
Post Home Additional Stroke is the offset from stroke end to be subtracted to avoid hits for
overshooting in position, in extend position.
Page 20 of 66
2.2.5 Model Motor Parameters
The parameters are related to motor physical data.

They must not be changed.
Motor Torque Constant Input is required to tune the drive protection in physical units.
Page 21 of 66
2.2.6 Model Monitor
Page 22 of 66
2.2.7 Combined Tuning
To work properly the drive needs to be configured as follows (see the above screen):
- Loop Execution Order: Model only

- Control Mode: Position
- Reference Source: Analog
Page 23 of 66
2.2.8 Drive Configuration
The Model needs to be enabled for a right actuator control, with home sequence and all
protections active.
Page 24 of 66
2.2.9 Regen Resistor Configuration
2.2.10 Motor Parameters
Page 25 of 66
2.2.11 Analog reference
Page 26 of 66
2.2.12 Faults
The Faults screen includes the alarms of:
- positioning card not latched and latched fault (MCC)

- control card DSP and HW fault
- Warnings
- generic SW Faults
When an alarm is active the relevant strip becomes red.
Page 27 of 66
2.2.13 Model Faults & Warnings Monitor
This screen shows the alarms of the “model” section, with alarms related to the position
control and the to the homing sequence.
2.2.14 Drive Control – Save Parameters
Page 28 of 66
2.2.15 Other screens
The following screens must not be used:
- Function generator
- Variables
- Hyperface Parameters
Page 29 of 66
2.3 Fault Reaction
The drive performs the following faults reaction.
2.3.1 Release motion control and System OK
The drive releases motion control and System OK after the following faults:
- Motor OVT
- Drive OVT
- Control sections Fault (no more control is possible)
- Error in Positioning
For these faults, the drive looses the control and the System OK doesn’t remains active.
Releasing System Enable and applying it again, the condition is reset, the actuator comes
back in proper control doing homing sequence.
Page 30 of 66
3 INSTALLATION
The purpose of this section is to aid personnel in the installation, placement, and
environmental considerations to be observed for the CZ140100 model and associated
equipment.
3.1 Inspection
The CZ140100 model should be inspected immediately after unpacking. Check for
damage, paying particular attention to the external lead wires.
Note: Retain the original shipping container. In the event of future transportation
requirements, this container will minimize damage during shipment.
3.2 Environmental Considerations

The drive will operate satisfactorily with ambient air temperature from -20 °C to +55 °C.
The CZ140100 model is designed as an assembly intended for use in areas with explosive
atmospheres.
CAUTION: Solvent/water may enter the electronics area during a high-pressure

wash.
3.3 Mechanical Installation

Figure 3-1 shows external dimensions and mounting provisions for the drive. The user
should ensure additional swing clearance as required.
Page 31 of 66
3.4 Electrical Installation
The CZ140100 model is suitable for use in hazardous locations. See nameplate for
certifications. Care should be taken to ensure compliance with the factory
recommendations. Wiring must be in accordance with local authorities jurisdiction.
3.4.1 EMC Considerations
Compliance with the European EMC Directive 2004/108/EC is required for all electric and
electronic products brought onto the European market after December 31st, 1995.
DS2000XP series drives meet the following EMC product standard related to the Directive:
EN 61800-3:2004 "Adjustable speed electrical power drive systems. Part 3: EMC product
standard including specific test methods".
Second environment (industrial) compatibility levels.
Note: equipments not intended to be used on a low-voltage public network which supplies
domestic premises. May cause radio frequency interference.
Tests have been made in an independent test house.
The installer is responsible for ensuring compliance with the EMC regulations that apply
where the drive is to be used. Compliance can be ensured via proper filtering and wiring.
3.4.1.1 EMC Filtering
The following EMC filter is mounted inside the drive enclosure:

FN 258-16/07 by Schaffner
3.4.1.2 EMC Wiring
To be compliant with the EMC Directive all the cables must be armoured and shielded.
The armours of the cables must be connected at both ends to the proper housing via full
circumferential bond to metallic cable glands. The shields of the cables must be connected
at both ends to the nearest ground connection. Wire exposed beyond the shield should be
as short as possible.
CAUTION: this drive is EMC Directive compliant (CE marking) using shielded/
armoured cable with armour RF (360°) connected to the cable glands. Improper
connection can invalidate EMC Directive compliance.
Note: "noisy" cables must be kept away from "sensitive" cables using separate conduits.
Noisy cables include input-power wires and motor power wiring. Sensitive cables include
analog or digital signal cables: resolver cable; enable and OK cable; RS232 serial link.
Note: where noisy cables must cross power cables, this must be done with angles as near
to 90° as possible.
Page 33 of 66
3.4.2 Wiring Specifications and Requirements
3.4.2.1 Power and Resolver wiring from drive to motor
The power and resolver wiring from the drive to the motor is supplied by Moog.
3.4.2.2 Power and Signal wiring from Engine controller to drive
Power Supply Recommended Wiring

Under normal operation and load, the CZ140100 model requires 6 A input current.
Under transient operation (under load) the CZ140100 model may require up to 22 amps of
current.
The recommended wiring is a 10 to 25 mm2 armoured cable.
See Fig.3.8 for the cable dimensions (inner and outer sheath diameter) acceptable for the
provided cable gland, type C3WLSE 32/M32.
Signal Harness Recommended Wiring

The signal harness contains both analog and digital inputs and outputs. The analog inputs
and outputs are 4mA to 20mA and are electrically isolated up to 2771 Vdc from the
400Vac power.
The recommended wiring is a minimum of 8-conductor shielded cable containing twisted-
pair wires with individual shields for analog signals and a minimum of 9-conductor shielded
cable containing 3-conductor wires with individual shields for digital signals. A wire size of
1.5 mm2 is recommended.
Serial Wiring
The serial inputs are not electrically isolated. Isolation must be provided when connecting
to a computer.
CAUTION: serial inputs are not electrically isolated. Failure to properly isolate the
user serial interface could result in drive or computer damage. Use separate
conduits for power and signal wiring. Close proximity to power lines may cause
signal interference.
3.4.3 Wire Lists
This section will provide CZ140100 wire hook-up information.
Page 34 of 66
8657 865 7
1 2 1 2
+ - + -
J1
EMC Filter
J6
J2
2 1+ 2 1+ 2 1+
J7
J8
J2C
4 3+ 4 3+ 4 3+
DC/DC Converter
BRAKE SUPPLY
1 2 3 4 5 6 7 8
SRR: solid state relay

ITR: isolated transducer
Figure 3-2: Enclosure – Components Wiring
Page 35 of 66
Figure 3-3: Terminal Block - Layout
Page 36 of 66
white 1
1 MOTOR S1
brown 1 RESOLVER
2 MOTOR S3
white 2 3 MOTOR R1
brown 2 4 MOTOR R2
white 3 5 MOTOR S2
brown 3 6 MOTOR S4
white 5
7 PTC/NTC
brown 5 8 PTC/NTC
shield 9 RESOLVER SHIELD
10 RS232 RXD
SERIAL-LINE
11 RS232 TXD
12 RS232 GND
13 RS232 SHIELD
14 CAN_IN_LOW
FIELDBUS
15 CAN_IN_COM
16 CAN_IN_HI
17 COMUNICATION SHIELD
18 CAN_OUT_LOW
19 CAN_OUT_COM
20 CAN_OUT_HI
21 RELAY_COM
SIGNALS
22 RELAY_NO
23 SYSTEM ENABLE-
24 SYSTEM ENABLE+
shield
25 SHIELD
26 AN_IN1-
27 AN_IN1+
28 AN_OUT1+
29 AN_OUT-
shield SHIELD
30
INPUT
R 31 (FUSE)
IN_POWER POWER
Phase R
S IN_POWER
32 (FUSE)
Phase S
T IN_POWER
33 (FUSE)
Phase T
GND
34 IN_GROUND TERMINAL
black U
35 MOTOR_U MOTOR
blue V PHASE
36 MOTOR_V OUTPUT
brown W + BRAKE
37 MOTOR_W
brown +
38 BRAKE+
white -
39 BRAKE-
green-yellow PE
40 MOTOR_PE
Figure 3-4: Terminal Block - External connections
Page 37 of 66
Figure 3-5: Terminal Block-Internal Connections
Page 38 of 66
Figure 3-6: Digital Card - Connections
Page 39 of 66
Table 3-4 shows the wiring specifications.
WIRING SPECIFICATION:
Cable from: Description: AWG mm² Terminal:

22 MOTOR S1
MOTOR S3
RESOLVER
22
RESOLVER
4 Pairs cables,
22 MOTOR R1
each pair twisted
CABLE
MOOG
22 MOTOR R2
and individually
Moog Motor 22 MOTOR S2
shielded, with an
indipendent 22 MOTOR S4
overallshield 22 PTC/NTC
22 PTC/NTC
RESOLVER SHIELD
1.5 RS232 RXD
SERIAL-LINE
COMMUNICATION
1.5 RS232 TXD

Shielded cable
1.5 RS232 GND
RS232 SHIELD
CABLE
Engine Controller 1.5 CAN_IN_LOW

FIELDBUS
(RS232 serial link or 1.5 CAN_IN_COM
Can bus) 1.5 CAN_IN_HI
Shielded cable(s) COMUNICATION SHIELD
1.5 CAN_OUT_LOW
1.5 CAN_OUT_COM
1.5 CAN_OUT_HI
1.5 RELAY_COM SIGNALS

Engine Controller 1.5 RELAY_NO
SIGNAL CABLE
(System OK Output 1.5 SYSTEM ENABLE-

and 4 Pairs cables, 1.5 SYSTEM ENABLE+
System Enable Input each pair twisted SHIELD
Analog Input and individually 1.5 AN_IN1-
and shielded 1.5 AN_IN1+
Analog Output; 1.5 AN_OUT1+
4-20mA) 1.5 AN_OUT-
SHIELD
IN_POWER
8
INPUT
POWER SUPPLY CABLE
Phase R
POWER
Input 8 IN_POWER
Phase S
Power
Supply
(400Vac)
8 IN_POWER
Phase T
8 IN_GROUND TERMINAL
4 MOTOR_U MOTOR
PHASE
4 MOTOR_V
OUTPUT
MOTOR
CABLE
MOOG
+ BRAKE
Moog Motor Shielded cable(s) 4 MOTOR_W
1 BRAKE+
1 BRAKE-
4 MOTOR_PE
Note: The signal wiring must be segregated from the power wiring.
Table 3-4: CZ140100 Drive Wire List
Page 40 of 66
3.5 Cable Glands
To enter the input/output cables in the enclosure, five cable glands are provided. The
cable glands are ATEX/IECEx certified.
Figure 3-7 Holes for Cable Glands at the bottom of the drive enclosure
The following cable glands have been approved to be used in the CZ140100 model.
Power Supply cable: Mod.No.C3WLSE 32/M32 by Peppers Cable Glands Ltd

Signal cable: Mod.No.C3WLSE 20/M20 by Peppers Cable Glands Ltd
Serial cable: Mod.No.C3WLSE 20/M20 by Peppers Cable Glands Ltd
Motor power cable: Mod.8163/2-25-T3CDS-M25 by R Stahl Gmbh
Resolver cable: Mod.No. 8163/2-20-T3CDS-M20 by R Stahl Gmbh
The cable glands by Peppers shall have the following accessories: ACSLN (stainless steel
locknut), ACPSW (PTFE IP washer) and ACSSIO (Silicone shroud).
Page 41 of 66
Figure 3-8 C3WLSE Cable Glands by Peppers - Dimensions
Page 42 of 66
Figure 3-9 8163/2 Cable Glands by Stahl Gmbh - Dimensions
Page 43 of 66
3.6 Stroke Calibration
Start DS2000XP GUI.
• From the main screen select Model and then Homing IT FoldBack-Thermal
Page 44 of 66
• Starting from this window, check the stroke doing “homing” sequence
Page 45 of 66
• To move the starting point (4 mA) insert the required mm in Home Offset (e.g. 15 mm).
Page 46 of 66
• Press Update (Write Parameters)
Page 47 of 66
• Disable the drive
• Press Update (Force Model Recalc)
When Enabled again, the drive perform the “Homing Sequence”.
Page 48 of 66
• To modify the stroke end position (20 mA), go to the main screen, select Model and
then Cmnd-Ctrl-Motion-Tuning
Page 49 of 66
• Then reduce the Useable Stroke Input to the required value (e.g. 96mm)
Page 50 of 66
• Press Update (Write Parameters)
Page 51 of 66
• Disable the drive
• Press Update (Force Model Recalc)
When Enabled again, the drive perform the “Homing Sequence”.
CAUTION: if the Home Offset value plus the Useable Stroke value is larger than 118
mm, the drive goes in alarm as the stroke verification can’t be performed.
Page 52 of 66
• Repeat the tuning process until the effective stroke matches the needs.
• Then go to the main screen and click on the Save icon
Page 53 of 66
• Press Model dot in the Save Parameters section, then Update (Write Parameters).
The new setup is now stored in the drive
Page 54 of 66
4 TROUBLESHOOTING
The information contained in this section is intended to aid maintenance technicians in
troubleshooting and isolating causes of malfunctions in the CZ140100 model.
The CZ140100 model makes use of highly reliable components and should not develop
service problems under normal operating conditions. However, over a period of time and
service, failures may occur. Personnel responsible for fault analysis should be thoroughly
acquainted with physical and electrical configurations, Basic Operation (Section 2), and
Installation (Section 3).
WARNING: continuing to operate the drive in a malfunctioning condition is

hazardous to personnel and can cause property damage.
Table 4-1 lists some common failures that can occur upon initial actuator installation. Table
4-2 lists some common failures that can occur after initial installation.
In addition, the CZ140100 model has some on-board troubleshooting capability. The GUI
XP software has a faults screen useful to find the specific fault. See Section 2.
Page 55 of 66
Table 4-1 CZ140100 model Installation Troubleshooting Chart
Symptom Probable Causes Corrective Action

Drive Inoperative – System Power Wires not connected Ensure power wires
OK not present correctly connected to Driver
Power supply < 360 Vac Ensure 400 Vac Primary
System Power at Drive
Drive Inoperative - NO No System Enable Ensure signal wires correctly
FAULT alarm command connected to Drive
Ensure System Enable
command at Drive
Actuator moves toward Analog Input <4mA or Ensure consistent Analog
HOME then stops or moves >20mA Input signal
toward HOME intermittently
Ensure correct power supply
Power supply <360V
Increase position Window
Position Error too low
Increase homing force
Homing Force too low
Check mechanical stroke
Available stroke less than and reduce useable stroke
expected
Actuator finds HOME then No Analog Input signal Ensure signal wires correctly
moves to STOP position connected
Analog Input <4mA or Ensure correct Analog Input
>20mA
Actuator does not track No position demand signal Ensure signal wires correctly
position demand connected
Motor current too low Increase Torque Limit
Actuator does not hold Varying position demand Ensure stable position
consistent position, signal demand at the actuator
oscillates or dithers
Too large backlash in the Check mechanical
mechanical transmission transmission
No position feedback Position feedback wires not Ensure Analog Outputs
connected wires correctly connected
Page 56 of 66
Table 4- CZ140100 model In-Service Troubleshooting Chart
Symptom Probable Causes Corrective Action

Drive Operative – System Open circuit Ensure signal wires correctly
OK not present connected
Internal FAULT Contact Moog
RS232 Interface Inoperative Incorrect wiring Ensure RS232 wires

correctly connected to Drive
and laptop PC.
No or low Vac power Ensure 400 Vac Primary
System Power at Drive
Incorrect setup Correct Communication
setup
COM1 not connected
Check laptop/PC com port
Drive interface defective
Contact Moog
FAULT alarm Various Check Faults screen at
(see also Tab.4-3) Sec.2 to identify the fault
and contact Moog
OVER TEMP alarm Ambient temperature limit Wait for a reduced ambient
(see also Tab.4-3) exceeded temperature
Drive or Motor winding
temperature out of range Check the load
Actuator overtemperature
Ensure that actuator re-
lubrication has been done
according to maintenance
instructions
Page 57 of 66
Table 4-3 LEDs in Fault status
FAULT LED DISPLAY FAULT DESCRIPTION

1 2 3 4 Action
red yel yel grn
IGBT Fault X Fatal over current or short circuit

condition in output bridge
IGBT Fault X Fatal over current or short circuit
Recovery condition in regeneration
power circuit
Bus X Fatal DC bus over voltage
Overvoltage
Bus X Fatal DC bus undervoltage
Undervoltage
Unstable Bus X Fatal excessive DC bus voltage
variation at low or no power
output
No bus X Fatal DC bus less than 500 Vdc
Flash X Fatal drive internal memory
Checksum checksum error
Error
Flash Settings X Fatal error in stored parameter
Error value(s)
Drive X Fatal drive power stage heatsink
Temperature over temperature
Fault
Motor X Fatal motor over temperature
Temperature
Fault
Max Speed X Fatal actual speed greater than
Error 10% of maximum allowed
speed
Resolver Error X Fatal errors on resolver feedback
signals
+ 15 Power X Fatal +15 vdc control voltage out
Error of tolerance
- 15 Power X Fatal -15 vdc control voltage out
Error of tolerance
Current I-T X non-fatal Current demand exceeds
Foldback limit motor continuous limit for specified
current time; current demand limited
to continuous until demand
falls below threshold
Position X Fatal position error exceeds +/-
Following error limit for a defined time
Error interval
Home Fault X X Fatal failure of Home cycle
Application X X X Fatal parameter range or sign
Parameter error
Error
After a fatal fault a power off/on is required.
Page 58 of 66
5 MAINTENANCE
5.1 Drive Maintenance

A protection fuse is provided on the terminal block inside the drive enclosure. Replace the
fuse when blown.
CAUTION: replace fuse only with Mod. No.1221025 by Italweber or with an

equivalent model compliant with IEC 60269-3
WARNING: always shut off the drive power supply before replacing the fuse.
5.1.1 Cable Glands – Assembly Instructions
The cable glands can be removed and reassembled. The assembly instructions for the
cable glands by Peppers are in the following figures.
The assembly instructions for the cable glands by Stahl are detailed in the Manual of the
motor.
CAUTION: cable gland installation should only be carried out by a competent

electrician, skilled in cable gland installations
Page 59 of 66
Figure 5.1a C3WLSE Cable Gland - Assembly Instructions
Page 60 of 66
Figure 5.1b C3WLSE Cable Gland - Assembly Instructions
Page 61 of 66
THIS PAGE INTENTIONALLY BLANK
Page 62 of 66
6 GENERAL SPECIFICATIONS
Power Input
Nominal Voltage: 400 Vac – 50 Hz – 3-phase
Minimum Voltage: 360 Vac
Maximum Voltage: 440 Vac
Nominal Current: 6 A
Typical Transient Current: 22A < 500ms
System Enable Command Input

ON Voltage: 5 to 30 Vdc; +24 Vdc Nominal
ON Current: 2.6 mA Nominal @ 5 Vdc
OFF Voltage: 1 Vdc Maximum
System OK Output
OFF Voltage: 32 Vdc Maximum
ON Current Range: 0.02 to 3A Maximum
ON Voltage Drop: 1.5 Vdc Maximum
System Brake Enable Output

OFF Voltage: 24 Vdc Nominal
ON Current Range: 0.02 to 3A Maximum
ON Voltage Drop: 1.5 Vdc Maximum
Analog Command Input

Current Nominal Range: 4 to 20 mA
Current Maximum Range: 0 to 50 mA
Voltage: 10 Vdc Maximum
Analog Command Output

Current Nominal Range: 4 to 20 mA
Current Maximum Range: 0 to 50 mA
Voltage: 10 Vdc Maximum
Load Resistance: 180 Ω Maximum
Drive Temperature Limits

Operating Ambient: -20 °C to +55 °C
Storage: -40 °C to +85 °C
Page 63 of 66
Environmental Ratings
IP66
MTBF
126.900 hours
EMC
EN 61800-3:2004, PDS in the Second Environment (Industrial), Category C3 (not intended
for use in the First Environment)
IECEx
IECEx BKI 10.0001 X
Ex nA IIB+H2 T5 Gc
Note: IECEx coding:

• BKI 10.0002 X = Name of the IECEx certificate issuer followed by last two figures of the
year of the certificate followed by four character reference for the certificate in that year
followed by the symbol “X” indicating specific conditions of use. The updated specific
conditions of use for motor and drive can be found at the IECEx web site, see par.I.5.
• Ex = symbol which precedes the type of protection of the electrical equipment
• nA = non sparking protection for explosive gas atmospheres (electrical equipment)
• t = protection by enclosure for explosive dust atmospheres (electrical equipment)
• IIB+H2 = Subdivision B of Group II. A typical gas of IIB subdivision is Ethylene. H2
means that also Hydrogen (of subdivision IIC) is covered.
• IIIC = Subdivision C of Group III, covering conductive dust.
• T3, T200°C, ..T5 = maximum surface temperature, where T3=200°C, T5=100°C.
• Gc = equipment for explosive gas atmospheres having a “enhanced” level of protection
(Equipment Protection Level).
• Dc = equipment for explosive dust atmospheres having a “enhanced” level of protection
(Equipment Protection Level).
Page 64 of 66
ATEX
II 3GD
Note: ATEX coding:

• = ATEX marking of explosion protection
• II = Group II (non-mining products). Equipment intended for use in places, other than
mines, likely to become endangered by explosive atmospheres.
• 3 = Category 3, covering areas in which explosive atmospheres caused by mixtures of
air and gases, vapours, mists or air/dust mixtures are unlikely to occur and if they do
occur, do so infrequently and for a short period of time only. Category 3 corresponds to
Zone 2.
• G = Gas.
• D = Dust.
European Directive Compliance (CE Marking)

94/9/EC, Equipment and protective systems in potentially explosive atmospheres (ATEX)
2004/108/EC, Electromagnetic Compatibility (EMC)
2006/95/EC, Low Voltage Equipment (LVD)
Page 65 of 66
Argentina
Australia
Austria
Brazil
China
Finland
France
Germany
India
Ireland
Italy
L a M O O G I t a l i a n a Sr l s i r i s e r v a d i a p p o r t a r e m o d i f i c h e e a g g i o r n a m e n t i s e n z a p r e a v v i s o
Japan
Korea
Luxembourg
Norway
Russia
Singapore
South Africa
Spain
Sweden
United Kingdom
USA

Electric Division
Via Avosso, 94-16015 Casella (Genova) - Italy
Telephone: (+39) 010 96711
Fax:(+39) 010 9671280
For the location nearest to you, contact
www.moog.com/worldwide
GB-4572 Rev.1 - Feb/13
Codice IGV 3-4-273
DSG2010 HV (400V)
M Drive Wire List
Rev.
Data
01
29-01-13
IECEx Certification Schedule Document

Preparato da Emesso da
UTC R6D
Firma Claudio Repetto Pag. 1 of 1
Data 29-01-13
ELECTRO MECHANICAL
ACTUATOR FOR IGV
L081-602
ATTACHMENT 4 – Power cable Data Sheet
Rev. 0, April 2013

RADOX 155 cable screened RN
4x4mm2 + 1x2x1mm2
General Properties :
Excellent high temperature, low temperature, ozone and weathering resistance, flame retardant, soldering iron
resistant, flexible, easy to strip.
Application :
For permanent installation inside and outside to connect fixed and moving parts.
1 6
2 BU 7
BN GNYE
4 8
WH
BK
5 BN
9
3
10
1. Centre RADOX -- Filler
2. 4 Cores 4.0 mm2 Conductor: stranded tin plated copper 56 x 0.30 mmD
Insulation: RADOX 155 D: 4.2 mm
Colours: black, brown, blue, green--yellow
3. 1 Pair 2x1.0 mm2 Conductor: stranded tin plated copper 32 x 0.20 mmD
Colours: brown, white
4. Wrapping Tape
5. Standard EMC--screen Tin plated copper braid D : 13.0 mm
6. Wrapping Tape
7. Sheath REMS, colour : black D : 14.2 mm
8. Rodent resistant Steel braid of 0.2 mm steel wires D : 15.1 mm
9. Wrapping Tape
10. Sheath RADOX 155, colour : black D : 18.8 mm
Printing on sheath : HUBER+SUHNER SWITZERLAND RADOX 155 85006411--zzzzzzz

Production lot number
Copyright 2012 Huber + Suhner AG. This document may not be copied nor be passed on to third
parties without our written permission HUBER+SUHNER AG
Uncontrolled copy when printed [will not be updated]. Low Frequency Division
The product fulfils the test and specification requirements described in this document for the stated CH--8330 Pfäffikon
areas of application and operating conditions. HUBER+SUHNER AG does not expressly or implicitly
guarantee performance under additional or changed conditions. Deviations are to be agreed upon in
+41 (0)44 952 22 11
writing. FAX +41 (0)44 952 26 40
www.hubersuhner.com
Issue Release Supersedes issue Technical Datasheet
14.11.2012 / 2447 2339 Page 1/2 85 006 411 A (e)
4x4mm2 + 1x2x1mm2
Technical data:
Conductor resistance at 20 C . . . . . . . . 4.0 mm2 . . . . . . . . . . < 5.09 . . . . . . . . .  / km
Voltage rating U0/U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 / 1000 . . . . . . V
Test voltage, 50 Hz, 1 min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 500 . . . . . . . . . . V
Temperature range . . . . . . . . . . . . . . . . . . fixed . . . . . . . . . . . . . . -- 55 ... +155 . . . . C
Minimum temperature . . . . . . . . . . . . . . . flexing . . . . . . . . . . . . -- 40 . . . . . . . . . . . C
Maximum conductor temperature at short circuit ( max. 5s ) . . + 280 . . . . . . . . . . C
Min. bending radius . . . . . . . . . . . . . . . . . . fixed . . . . . . . . . . . . . . 4 x cable dia.

flexing . . . . . . . . . . . . 5 x cable dia.
Cable weight per 100 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 64 . . . . . kg

14.11.2012 / 2447 2339 Page 2/2 85 006 411 A (e)
ELECTRO MECHANICAL
ACTUATOR FOR IGV
L081-602
ATTACHMENT 5 – Signal cable Data Sheet
Rev. 0, April 2013

5 x 2 x 0.25 mm2
Application :
1
1 6
1
2 5 2 7
2
5
3 8
3
4
4
4 3
9

2. 5 Pairs 2x0.25 mm2 Conductor: stranded tin plated copper 19 x 0.13 mmD
Two cores twisted D: 2.9 mm
Colours: brown, white, each pair numbred 1/1; 2/2; 3/3; 4/4; 5/5
3. Wrapping Tape
5. Wrapping Tape
8. Wrapping Tape
Printing on sheath : HUBER+SUHNER SWITZERLAND RADOX 155 RADOX 85006392--zzzzzzz

+41 (0)44 952 22 11
writing. FAX +41 (0)44 952 26 40
1006243 www.hubersuhner.com
15.11.2012 / 2447 2339 Page 1/1 85 006 392 A (e)
5 x 2 x 0.25 mm2
Technical data:
Conductor resistance at 20 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 88.5 . . . . . . . . .  / km
Voltage rating U0/U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 / 750 . . . . . . . V
Cable weight per 100 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 21.7 . . . kg

15.11.2012 / 2447 2339 Page 2/1 85 006 392 A (e)
ELECTRO MECHANICAL
ACTUATOR FOR IGV
L081-602
ATTACHMENT 6 – Servo Actuator - Label Installation
drawing
Rev. 0, April2013

Numero Nome Documento Descrizione Documento Revisione
1 CDS37899_L081-601_AI+Attachment(B) Documento principale - Manuale 1
2.1 CB57097 Cavo utilizzato per test 0
2.2 CB57098 Cavo utilizzato per test 0
2.3 Radox 155 Specifica cavi utilizzati per test 0
EPS37128_L081x-601_ATP-L107-L875-
3 Procedura di prova di test 1
603(B)
MRE37217_L081x-601_TDR-L875-
4 Test Data Report (Test eseguiti in Moog)
603_L104
5 CDP37912 (CDP37913 en) Procedura di collegamento elettrico 1
5.1 CB62738(B) Electrical Connections 1

PARTLY COMPLETED
MACHINERY
Electro Mechanical
Actuator for IGV
Rev. 0, November 2012

THIS DOCUMENT DESCRIBES THE INSTALLATION, OPERATION AND MAINTENANCE OF THE MOOG PARTLY COMPLETED
MACHINERY Electro Mechanical Actuator for IGV.
FOREWORD
This manual "PARTLY COMPLETED MACHINERY Electro Mechanical Actuator for IGV – Assembly Instructions" has been
prepared in accordance with CEI EN 62079, "Preparation for instructions - Structuring, content and presentation."
The manual was written and checked at the best experience of Moog.
Moog written this technical documentation complied with the requirements of the Machinery Directive 2006/42/EC.
IMPORTANT: No part of this document may be copied, duplicated, reproduced, stored in a data
storage system, translated into different language, or transmitted by data communication system,
without the consent of Moog
ABOUT MOOG
Moog’s Industrial Group designs and manufactures high performance motion control solutions combining electric,
hydraulic, and hybrid technologies with expert consultative support in a range of applications including test,
simulation, plastics, metal forming, and power generation.
Moog customers include leading automotive manufacturers, aerospace manufacturers, testing labs and global
automotive racing teams.
We help performance-driven companies design and develop their next-generation machines.
Moog’s Industrial Group is part of Moog Inc.
For more information please visit www.moog.com/industrial.
Info Description
Via G. Pastore, 4
Address
Tel +39 0332 421 111
Fax +39 0332 429 233

DOCUMENT VERSION
The following table shows the version of this document and all other possible versions:
ES DA DE EL EN FR IT NL PT FL SV CS ET LV HU MT PL SK SL BG RO GA
The language of documents and drawings are subject to contractual negotiations with the Customer.
IN case of “Translation of the Original Instructions”, the manufacturer of the machinery supplies also the “Original
Instructions”.
REVISION RECORD
The following table shows the revision record:
0 First issue BEB CAR, FAP LOF November 2012

GLOSSARY
The following table shows the abbreviations adopted in Moog documents:
Abbreviation Explanation
EMA Electro Mechanical Actuator
EH Electro Hydraulic Actuator
EHA Electro Hydrostatic Actuator
MSD Moog Servo Drive
The following table shows the symbols adopted in Moog documents:
Symbol Explanation
IMPORTANT: Warning and notes about important operations and useful information
ATTENTION: Danger to persons, including death

CONTENTS
Foreword ........................................................................................................................................................... 2
About Moog ....................................................................................................................................................... 2
Document version ............................................................................................................................................. 3
Revision record .................................................................................................................................................. 3
Glossary ............................................................................................................................................................. 4
Contents ............................................................................................................................................................ 5
1. Identification ............................................................................................................................................. 8
1.1. Nameplate and type designation ...................................................................................................... 8
1.2. Manufacturer name and address .................................................................................................... 10
1.3. Warranty and Liability ..................................................................................................................... 10
1.4. Declaration of Incorporation ........................................................................................................... 11
1.5. Applicable standards ....................................................................................................................... 11
2. General description ................................................................................................................................. 13
Servo Actuator ............................................................................................................................................. 14
Driver ........................................................................................................................................................... 14
Cables .......................................................................................................................................................... 14
2.1. Intended use .................................................................................................................................... 14
2.2. Dimensions and weight ................................................................................................................... 15
2.3. Connections ..................................................................................................................................... 15
2.4. Energy consumption and conditions ............................................................................................... 15
2.5. Emissions ......................................................................................................................................... 15
2.5.1. Noise, gases, water .................................................................................................................. 15
2.5.2. Radiations ................................................................................................................................ 15
2.6. IP code ............................................................................................................................................. 15
2.7. Electromagnetic compatibility......................................................................................................... 15
2.8. PPE ................................................................................................................................................... 16
2.9. Reasonably foreseeable misuse ...................................................................................................... 16
3. Safety ....................................................................................................................................................... 17
3.1. General warnings ............................................................................................................................. 17
3.2. Recommendations for safe application........................................................................................... 17
3.3. Environmental conditions and limits ............................................................................................... 19
3.4. Disposal............................................................................................................................................ 19
3.5. Risks ................................................................................................................................................. 20
3.5.1. Hazards arising from incorrect use .......................................................................................... 20
3.5.2. Residual risks ........................................................................................................................... 20
3.5.3. Particular risks due to certain applications ............................................................................. 20
3.6. Protections ...................................................................................................................................... 20
3.6.1. Safe design measures .............................................................................................................. 20
3.6.2. Safeguarding measures ........................................................................................................... 20
3.6.3. Protective measures ................................................................................................................ 20
3.6.4. Complementary protective measures ..................................................................................... 21
4. Preparing the product for use ................................................................................................................. 22
4.1. Transport ......................................................................................................................................... 22
4.2. Storage............................................................................................................................................. 22
4.3. Installation and assembly ................................................................................................................ 22
4.3.1. Procedures for unpacking ........................................................................................................ 22
4.3.2. Inventory checklist................................................................................................................... 22
4.3.3. Fixing/anchoring and vibration damping requirements.......................................................... 22
4.3.4. Foundation block or similar base ............................................................................................ 22
4.3.5. Provisions against emissions ................................................................................................... 22
4.3.6. Minimum space needed for use, maintenance and repair ..................................................... 22
4.3.7. Layout plan .............................................................................................................................. 23
4.3.8. Installation plan ....................................................................................................................... 23
4.3.9. Interconnection diagrams ....................................................................................................... 23
4.3.10. Methods of connection ........................................................................................................... 23
4.3.11. Permissible environmental conditions .................................................................................... 23
4.3.12. Waste removal/disposal .......................................................................................................... 23
4.4. Commissioning ................................................................................................................................ 23
5. Operating instructions ............................................................................................................................. 24
5.1. Safe functioning ............................................................................................................................... 24
5.2. Normal function............................................................................................................................... 24
5.3. Secondary functions ........................................................................................................................ 24
5.4. Exceptional functions ...................................................................................................................... 24
5.5. Signal to be observed ...................................................................................................................... 24
6. Maintenance and cleaning ...................................................................................................................... 25
6.1. Safety precautions ........................................................................................................................... 25
6.2. By users............................................................................................................................................ 25
6.2.1. Nature and frequency of maintenance operations ................................................................. 25
6.2.2. Preventive maintenance .......................................................................................................... 25
6.2.3. Maintenance schedules ........................................................................................................... 25
6.2.4. Inspection for safety ................................................................................................................ 26
6.2.5. Safety warnings for running or live equipment ....................................................................... 26
6.2.6. Drawings and diagrams ........................................................................................................... 26
6.2.7. Cleaning ................................................................................................................................... 26
6.3. Trouble-shooting, fault diagnosis, and repair ................................................................................. 26
6.3.1. Fault diagnosis and identification............................................................................................ 26
6.3.2. Repair and adjustments........................................................................................................... 26
6.3.3. Built-in diagnostic systems ...................................................................................................... 26
6.3.4. Checking of warning devices ................................................................................................... 26
7. Spare parts and consumables.................................................................................................................. 27
7.1. Identification ................................................................................................................................... 27
7.2. Bill of material ................................................................................................................................. 27
7.3. Source of supply .............................................................................................................................. 27
8. Workstations ........................................................................................................................................... 28
9. Tool characteristics .................................................................................................................................. 29
9.1. Standards tools ................................................................................................................................ 29
9.2. Special tools ..................................................................................................................................... 29
9.3. Source of supply .............................................................................................................................. 29
10. Decommissioning ................................................................................................................................ 30
10.1. Destruction .................................................................................................................................. 30
10.2. Recycling ...................................................................................................................................... 30
10.3. Disposal........................................................................................................................................ 30
11. Attachments ........................................................................................................................................ 31
1. IDENTIFICATION
1.1. Nameplate and type designation

The following image shows an example of the label of the servo actuator of the partly completed machinery
Electro Mechanical Actuator for IGV:
In this label there are three (3) fields to define the characteristics of the servo actuator. The following table shows
these three fields:
Mod: Model L875-603
Date Manufacturing date (month/year) See on the nameplate
NP Purchasing Code Nuovo Pignone Purchasing Code RAO21196
The following image shows an example of the label of the motor of the partly completed machinery Electro
The following table lists the fields of the nameplate of the servo motor:
Model Motor Model G495L1007
Serial Serial Number See on the nameplate
Mfg.Date Manufacturing date (year/month) See on the nameplate

-1
nN [min ] Nominal Speed 2.000
PN [kW] Nominal Power 2,451
Ud [V] Voltage 565
Mo [Nm] Nominal Torque 18,39
Io [Arms] Current 10,43

2
J [kgcm ] Moment of Inertia 19,4080
Temp. class Temperature class T4
Am. Temp. Ambient temperature -40° C/ +80° C
Weight [kg] Weight 22
Brake [Nm] Brake torque 22
Type Motor Type G-5LV8-020-02-99-01-00-000

-1
nmax [min ] Maximum Speed 4.260
Mmax [Nm] Maximum Torque 61,26
Fsw [kHz] Switching Frequency 4
The following image shows an example of the labels of the driver of the partly completed machinery Electro
In this label there are eight (8) fields to define the characteristics of the servo actuator. The following table shows
these eight fields:
IECEx BKI 10.0001X

IECEx Certificate
- Ex nA IIB+H2 T5 Gc
IECEx Certification
Code Model code CZ140100
S/N Serial Number 1310001
Vin Voltage 400 Vac +/-10%
Iin In current 6 Arms
Iout Out current 6 Arms 22 Apeak
- ATEX Certification II 3GD
IP66
- Environmental conditions
-20°C≤Ta≤+55°C
1.2. Manufacturer name and address

The following table shows all the information regarding the manufacturer:
Info Description
Via G. Pastore, 4
Address
Tel +39 0332 421 111
Fax +39 0332 429 233
1.3. Warranty and Liability

In principle, Moog general terms and conditions for delivery and payment apply. These shall be available to the
buyer at the latest at the time the sales contract is completes. See the document: “General Terms and Conditions
of Sale and Delivery of Moog Italiana S.r.l. (Malnate)”.
1.4. Declaration of Incorporation
The following image shows an example of the Declaration of Incorporation supplied with the partly completed
A hard copy of the Declaration of Incorporation related to the partly completed machinery Electro Mechanical
Actuator for IGV is supplied to the Customer together with this Instructions manual and the partly completed
machinery itself (see Attachment 1).
1.5. Applicable standards

The following table shows the applicable European Directives:
2006/95/EC Low Voltage Directive
2004/108/EC EMC Directive
94/9/EC ATEX Directive

The following table shows the applicable standards:
Explosive atmospheres - Explosion prevention and protection - Part 1: Basic concepts and
EN 1127-1:2011
methodology
EN ISO 12100: 2010 Safety of machinery – General principles for design – risk assessment and risk reduction
Non-electrical equipment for use in potentially explosive atmospheres - Part 1: Basic method
EN 13463-1: 2009
and requirements
EN 13463-5:2011: Non-electrical equipment intended for use in potentially explosive atmospheres - Part 5:
2011 Protection by constructional safety ‘c’
EN 50178: 1997 Electronic equipment for use in power installations
EN 60034-1: 2010 Rotating electrical machines - Part 1: Rating and performance
EN 60034-5:2006
rotating electrical machines (IP code) - Classification
EN 60079-0: 2009 Explosive atmospheres - Part 0: Equipment - General requirements
EN 60079-1: 2007 Explosive atmospheres - Part 1: Equipment protection by pressurized enclosure ‘p’
EN 60079-7: 2007 Explosive atmospheres - Part 7: Equipment protection by increased safety ‘e’
EN 60079-15: 2010 Explosive atmospheres - Part 15: Equipment protection by type of protection ‘n’
EN 60079-31: 2009 Explosive atmospheres - Part 31: Equipment dust ignition protection by enclosure ‘t’
IEC EN 60204-1:2006 Safety of machinery - Electrical equipment of machines - Part 1: General requirements
Low-voltage fuses - Part 3: Supplementary requirements for fuses for use by unskilled persons
EN 60269-3: 2007 (fuses mainly for household or similar applications) - Examples of standardized systems of
fuses A to F
EN 60529:1991 Degrees of protection provided by enclosures (IP Code)
EN 61000-4-2:2009
EN 61000-4-3:2006
Radiated, radio-frequency, electromagnetic field immunity test
Electromagnetic compatibility (EMC) – Part 4-4: Testing and measurement techniques –
EN 61000-4-4:2004
Electrical fast transient/burst immunity test
EN 61000-4-5:2006
immunity test
EN 61000-4-6:2009
Immunity to conducted disturbances, induced by radio-frequency fields
EN 61800-3:2011
methods
Adjustable speed electrical power drive systems - Part 5-1: Safety requirements - Electrical,
EN 61800-5-1: 2007
thermal and energy
The product is made up of the following parts:
Parts Description
L875-603 Servo Actuator
CZ140100 Servo Driver
CB54994 Power cable
CB54995 Signal cable
The following image shows a general sketch of the partly completed machinery Electro Mechanical Actuator for
IGV:
EMA ACTUATOR
SERVO DRIVE
Servo Actuator
The mechanical converter performs motor torque amplification through a planetary gear train and converts rotary to
linear movement by a ball screw.
The motor is a synchronous DC motor with electronic commutation and permanent magnet field excitation.
Driver
The drive is a full digital brushless servo drive which control the brushless DC motor; the drive permits a close loop in
position, using the feedback from the resolver.
Cables
The power and signal cables connect the servo actuator to the servo drive, which need to be connected to the power.
Please, refer to the Attachments 4 and 5 for further information.
2.1. Intended use

Partly completed machinery Electro Mechanical Actuator for IGV is a work machine use to control the IGV of the
Nuovo Pignone FRAME 5-2E gas turbine.
The partly completed machinery Electro Mechanical Actuator for IGV is designed for industrial applications.
For its intended use, the following applies:
 Observance of the “Assembly Instructions” manual
 Handling the partly completed machinery safety
 Adhering to the inspection and maintenance instructions from the customer for the plant of installation
 Following all of the corresponding relevant supplemental documentation in accordance with the
application
 Observance of the relevant regulations applicable nationally and internationally, as well as applicable
standards and directives (such as e.g. the EU Machinery Directive and the applicable regulations by the
Employer’s Liability Insurance Association, TUEV or VDE) as amended
 Modification to the design or repairs and maintenance work or improperly performances are
unauthorised
 Adhering to all technical data during storage, transport, assembly, disassembly, connecting, start-up,
configuring, operating, cleaning, repairing or resolving any possible failures, especially to the ambient
conditions
 Avoiding improper storage, transport, assembly, disassembly, connection, start-up, configuration,
operation, cleaning, repairing, resolving any possible failures or disposal
 Avoiding the use of unsuitable or defective accessories or rather unsuitable or defective spare parts
 Catastrophic events beyond our control or acts of Gods are not under Moog responsibility
2.2. Dimensions and weight
For the main dimensions and weight of the partly completed machinery Electro Mechanical Actuator for IGV,
please refer to the following attachments 2, 3, 4 and 5.
For the mechanical characteristics of the partly completed machinery Electro Mechanical Actuator for IGV, please
refer to the Attachment 2.
For the electrical characteristics of the partly completed machinery Electro Mechanical Actuator for IGV, please
refer to Attachments 2, 3, 4 and 5.
2.3. Connections
For the installation drawings in which it is possible to find all the indications for mechanical connections of the
partly completed machinery Electro Mechanical Actuator for IGV, please refer to the Attachments 2 and 3.
For the electrical connection drawings of the partly completed machinery Electro Mechanical Actuator for IGV,
please refer to the Attachment 2 and 3.
2.4. Energy consumption and conditions

For consumption data of the motors of the partly completed machinery Electro Mechanical Actuator for IGV,
please refer to the Attachment 2.
2.5. Emissions
2.5.1. Noise, gases, water

Not applicable.
2.5.2. Radiations
Not applicable.
2.6. IP code
For the IP code of the partly completed machinery Electro Mechanical Actuator for IGV, please refer to the
Attachments 2 and 3.
2.7. Electromagnetic compatibility

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 provided by the EMC filter mounted inside the drive enclosure and by the cable shielding.
The shields of the cables must be connected at both ends to the proper housing via full circumferential bond to
the metallic cable glands or connectors.
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).
It is not intended to be used on a low-voltage public network which supplies domestic premises (first
environment). Radio frequency interference is expected if used on such a network.
2.8. PPE
Personal Protective Equipment could be required to move, to mount, to dismount, to perform any activities with
the partly completed machinery. The general and also the local regulations on the prevention of accidents and on
environmental protection should be observed.
2.9. Reasonably foreseeable misuse
IMPORTANT: Use of the product in any other way than as described under “Intended use” is
considered to be misuse and is therefore not permitted
Misuse is connected to operating the partly completed machinery outside the specifically defined application and
environmental conditions in relation to:
 Force, speed and stroke
 Temperature
 Shock/vibration
 Protection class
 Electrical and electromagnetic connections
 Operation in explosion hazardous areas if permitted for use in Zone 2, according to EN 60079 standards
resp. in Zone 22 according to EN 61241 standards, where the explosion risk is due to the mixture of IIA,
IIB+H2 gas+air mixture, resp. the mixture of flammable dusts and air. The permissible maximum surface
temperature is 200°C for the motor, 150°C for the actuator and 100°C for the drive. In environments
where combustible dusts may be present, the user must assure a regular cleaning of the apparatus so as
to prevent build-up of dust on the surface.
3. SAFETY
3.1. General warnings

The product has been manufactured according to generally accepted standards of good engineering practice.
Nevertheless, if these safety instructions are not adhered to, there is a risk of personal injury and damage to
property when using the product.
IMPORTANT: Before commencing any work with the product, be sure to read the product
documentation carefully and completely
IMPORTANT: Make sure these safety instructions and the product documentation are
always accessible to all users
IMPORTANT: When passing the product on to third parties, always include these safety
instructions and all the required documentation
IMPORTANT: The product may only be mounted, started up and maintained in accordance
with these safety instructions and the information given in the product documentation
3.2. Recommendations for safe application
IMPORTANT: Do not apply impacts and shocks; do not use a hammer during installation
IMPORTANT: High Voltage. Device can have 140Vdc voltage even after switching off
(capacitive voltage). Discharge Time approx. 6 Minutes
IMPORTANT: do not open the door of the drive enclosure when an explosive atmosphere
may be present
IMPORTANT: do not open the door of the drive enclosure when energized
IMPORTANT: do not open or disassemble the terminal box of the motor when energized
IMPORTANT: do not remove or replace fuse inside the drive enclosure when energized
ATTENTION: Never change wiring while power is active; make sure of power non-active
before servicing the product, otherwise it may result in electric shock or personal injury
ATTENTION: replace fuse inside the drive enclosure only with Mod. No.1320050 (marking
code: 2212004-01) by Italweber or with an equivalent model compliant with IEC 60269-3
ATTENTION: make sure that the correct input voltage, 110Vdc nominal, has been connected
3.3. Environmental conditions and limits
The following table shows the environmental conditions and limits:
Environmental
Servo Actuator Limit Driver Limit Cables Limit
condition
Operating
-20° C/+80° C -40° C/+55° C -55° C/+155° C
Temperature
Degree of
IP65 IP66 IP66
protection
Electrical parts
II 2D Ex tb IIIC T200°C – T85°C
ATEX Db IP65/67 II 3GD N/A
Mechanical parts
II 3G c IIB+H2 135°C
II 3D c 135°C

Procedure I, Fig.514.2-2, curve AR
Vibration (2 g, 5 - 2000 Hz) N/A N/A
Procedure I (Half-sine, 10 g, 11ms)
3.4. Disposal
Proceed as follows at the end of the partly completed machinery's working life:
 Separate metallic parts according to their type (aluminium, steel, etc.)
ATTENTION: do not dismantle the motor. Permanent motor magnets generate high forces
that could severely injure the operator
Operators assigned to this activity do not require special training. When removing and dismantling metallic parts,
wear protective gloves to avoid potential abrasions with sharp parts.
Observe the locally valid regulation to recycle the previous mentioned parts.
3.5. Risks
3.5.1. Hazards arising from incorrect use

The partly completed machinery Electro Mechanical Actuator for IGV has been constructed according to current
technological standards and accepted safety regulations.
To avoid danger to the operator or damage the product, it may be put to use only for its intended use (see
chapter 2.1 “Intended use”) and in a technically flawless and safe state.
3.5.2. Residual risks
ATTENTION: Hot surfaces can cause serious burns. Touch the servo motor and the gearbox
housing only when wearing protective gloves or after they have been at standstill for some
time
ATTENTION: Solvents and lubricants can pollute soil and water. Use and dispose of cleaning
solvents as well as lubricants appropriately
3.5.3. Particular risks due to certain applications

The only possible application of the partly completed machinery Electro Mechanical Actuator for IGV is related
with the control of the IGV in the Nuovo Pignone FRAME 5-2E gas turbine.
3.6. Protections
3.6.1. Safe design measures

Not applicable.
The final application of the partly completed machinery Electro Mechanical Actuator for IGV is strictly connected
Electro Mechanical Actuator for IGV in its machine.
3.6.2. Safeguarding measures

Not applicable.
3.6.3. Protective measures

Not applicable.
3.6.4. Complementary protective measures
Not applicable.
4. PREPARING THE PRODUCT FOR USE
4.1. Transport
IMPORTANT: Don’t overturn the package during transport. Check the anchor points

For further information, please refer to the Attachments 2, 3, 4 and 5.
4.2. Storage
For the environmental conditions of the storage of the partly completed machinery Electro Mechanical Actuator
for IGV, please refer to the Attachments 2 and 3.
4.3. Installation and assembly
4.3.1. Procedures for unpacking

The following table shows the steps necessary for unpacking the product:
Step Description
1 Check the package list and all documents attached
2 Open the package following the indications of the external labels
3 Check if the contents of the package correspond to the package list
4 Check for damage, paying particular attention to the external lead wires
Retain the actuator’s original shipping container. In the event of future transportation requirements, this
container will minimize damage during shipment.
4.3.2. Inventory checklist

Please, refer to the BOM for the packaging checklist.
4.3.3. Fixing/anchoring and vibration damping requirements

Not applicable.
4.3.4. Foundation block or similar base

Not applicable.
4.3.5. Provisions against emissions

Not applicable.
4.3.6. Minimum space needed for use, maintenance and repair

4.3.7. Layout plan
Not applicable.
4.3.8. Installation plan

Not applicable.
4.3.9. Interconnection diagrams

Please, see the installation drawings (ref. to chapter 2.3).
4.3.10. Methods of connection

Please, see the Attachments 2, 3, 4 and 5.
4.3.11. Permissible environmental conditions

Please, refer to Chapter 3.3 for the environmental conditions and limits.
4.3.12. Waste removal/disposal

Please, observe the locally valid regulation for disposals.
4.4. Commissioning
Please, see the Order Confirmation to check the applicability and all the details.
5.1. Safe functioning

5.2. Normal function

5.3. Secondary functions

5.4. Exceptional functions

5.5. Signal to be observed

6.1. Safety precautions

Please, see the chapter 3, Safety.
6.2. By users
6.2.1. Nature and frequency of maintenance operations

Frequency of maintenance operations depends from the working cycle of the partly completed machinery Electro
Mechanical Actuator for IGV and from the installation plant.
6.2.2. Preventive maintenance

The following table shows the preventive maintenance operations to be operated on the partly completed
Every
Every
8.000
Every 6 27.000 When
Preventive maintenance operation working
months working blow
hours/12
hours
months

Major inspection X
6.2.3. Maintenance schedules

The following table shows the maintenance schedules to be operated on the partly completed machinery Electro
Every
Every
8.000
Every 6 27.000 When
Maintenance operation working
months working blow
hours/12
hours
months

Major inspection X

6.2.4. Inspection for safety
Not applicable.
6.2.5. Safety warnings for running or live equipment

Not applicable.
6.2.6. Drawings and diagrams

Not applicable.
6.2.7. Cleaning
Not applicable.
6.3. Trouble-shooting, fault diagnosis, and repair
6.3.1. Fault diagnosis and identification

6.3.2. Repair and adjustments

6.3.3. Built-in diagnostic systems

6.3.4. Checking of warning devices

7.1. Identification
Not applicable.
7.2. Bill of material

Please, see the BOM.

Not applicable.
8. WORKSTATIONS
Not applicable.
9. TOOL CHARACTERISTICS
9.1. Standards tools

Not applicable.
9.2. Special tools

Not applicable.

Not applicable.
10.DECOMMISSIONING
10.1. Destruction
Please, observe the locally valid regulation for destruction, or contact Moog Italiana S.r.l. (Malnate).
10.2. Recycling
Please, observe the locally valid regulation for recycling, or contact Moog Italiana S.r.l. (Malnate).
10.3. Disposal
Please, observe the locally valid regulation for disposal, or contact Moog Italiana S.r.l. (Malnate).
11.ATTACHMENTS
The following table shows the attachments:
MRQ36757_L081-601_DoI.pdf
Declaration of Incorporation
1 MRQ37884_L081-
Declaration of Conformity ATEX
601_ATEX_DoC.pdf
2 Servo Actuator - Installation & Maintenance Instructions CDS37897_L875-603_MIM.pdf
CZ140100 Model Operations Manual

Rev0.pdf
3-4-269-01_1.pdf
3 Servo Drive - Model Operations Manual
MRE37113_L081-601_ECS.pdf
MRE37114_L081-601_TBDCD.pdf
MRE37118_L081-601_WD.pdf
CB54994.pdf
4 Power cables data sheet
DOC-0000413342 power.pdf
CB54995.pdf
5 Signal cables data sheet
DOC-0000413459 signal.pdf
TAKE A CLOSER LOOK

+54 11 4326 5916 +353 21 451 9000 +46 31 680 060

+61 3 9561 6044 +39 0332 421 111 +41 71 394 5010

+43 664 144 65 80 +81 436 55 3767 +31 252 462 000

+55 11 5523 8011 +82 31 764 6711 +44 1564 784 777

+86 21 5854 1411 +352 40 46 401 +1 734 887 4250
Finland Norway
+358 9 2517 2730 +47 224 32927
France Russia
+33 1 4560 7000 +7 831 713 1811
Germany Singapore
+49 7031 622 0 +65 677 36238

+852 2 635 3200 +27 11 655 7030
India Spain
+91 80 4120 8785 +34 902 133 240
All rights reserved. All changes are reserved
PARTLY COMPELTED MACHINERY
Rev. , 20 Document nr.
ELECTRO MECHANICAL
ACTUATOR FOR IGV
L081-601
ATTACHMENT 1 – DECLARATION OF INCORPORATION/
DECLARATION OF CONFORMITY ATEX

M O O G I T A L I A N A S . r . l .
CERTIFICATO DI CONFORMITA' Nº 055/13

CERTIFICATE OF COMPLIANCE 055/13
EN 10204:2004 – Type 2.1
Pagina/Page 1 di/of 1
1.Destinatario: 2.Riferimento d'ordine e data:
Purchase: Order reference and date:
NUOVO PIGNONE SPA Ordine Cliente:

VIA FELICE MATTEUCCI, 2 439877117 del 27giu-2013
50127 FIRENZE FI
4.Documento spedito a: 6a.Materiale spedito a:
Mailed to: Shipped to:
NUOVO PIGNONE SPA NUOVO PIGNONE SPA
VIA FELICE MATTEUCCI, 2 VIA FELICE MATTEUCCI, 2
50127 FIRENZE FI 50127 FIRENZE FI
5.Da (Fornitore) 6b.Numero d'ordine di spedizione Parziale Totale

From (Supplier) Shipment number on order Partial Total
MOOG ITALIANA S.r.l. 066316 del 25/09/2013 X

Via G. Pastore, 4 Nr. 56DDT132232
I - 21046 Malnate (VA)
7. Si certifica che la totalità delle forniture sotto specificate è conforme in ogni parte alle specifiche, ai disegni e all'ordine cui si
riferiscono, ad eccezione delle deroghe/rinunce annotate alla casella 17 e che le forniture sono state verificate e provate in conformità
con le condizioni ed i requisiti dell’ordine.
We certify that, apart from the deviations as in box 17, all the supplies detailed below are conform in all respects to the
specification(s), drawing(s) and referring order, and that supplies have been inspected and tested in accordance with the
requirements of the order.
Descrizione/description Codice/Code Serial Number

a. Servo Drive CZ 140100 1331004
b. Electrical Actuator L875-603 D 105
c. Power cable CB54994 -
d. Signal cable CB54995 -
8. L’oggetto b (servo drive) della presente fornitura, è conformi allo standard IECEx per installazioni in zona 2, in riferimento ai
certificato nr. BKI 10.0001X, rilasciato da ente BKI riconosciuto; esso presenta la seguente marcatura:
The item b, is in compliance with IECEx standards (BKI nr 10.0001X) for installations in zone 2 and it will show this marking
Servo drive CZ 140100
IECEx BKI 10.0001X
Ex nA IIB+H2 T5 Gc
-20°C ≤ Tamb ≤ +55°C
9. Gli oggetti a, e b della presente fornitura sono conformi alla direttiva ATEX 94/9/CE per installazioni in zona 2 per i Gas e zona 22
per le Polveri, e presentano la seguente marcatura:
The items in points a & b are in compliance with ATEX directive 94/9/EC for installations in zone 2 for Gases and zone 22 for Dust
and they will show these markings:
Servo drive CZ 140100 Actuator L875-603
II 3G D II 3G c IIB+H2 135 °C
II 3D c 135°C
-20°C ≤ Tamb ≤ +55°C -40 °C ≤ Tamb ≤ +80 °C
DATA/DATA FIRMA/SIGNATURE NOME/NAME

25 Sept 2013 (PRINTED)
Paolo Battaglia
10.N.Voce 11.Lotto/Numero particolare e descr. 12.Quantità 13.N.imballo 14.Da spedire 15.Q.tà ricevuta
Item n Stock/Part. N. and name Quantità Package N Undelivered Q.ty received
01 IGV ELECTRICAL ACTUATOR SYSTEM L081-601 1

16.Riferimento del Delegante/ Delegator’s Reference
17. Deviazioni / deroghe - Deviations/waivers

ELECTRO MECHANICAL
ACTUATOR FOR IGV
L081-601
ATTACHMENT 2 – SERVO ACTUATOR – Installation &
Maintenance Instructions

ATTUATORE EM
L875-603
Istruzioni di Installazione & Manutenzione
Originale
QUESTO DOCUMENTO DESCRIVE L’INSTALLAZIONE, IL FUNZIONAMENTO E LA

MANUTENZIONE DELL’ATTUATORE MOOG EM L875-603.
DOCUMENTO N. CDS37003
PREFAZIONE
Il presente manuale “ATTUATORE EM L875-603 - Istruzioni di Installazione & Manutenzione - Originale” è stato
redatto in conformità alla CEI EN 62079, “Preparazione di istruzioni – Struttura, contenuto e presentazione”. Il
manuale è stato scritto e controllato al meglio dell’esperienza di Moog
Moog non è responsabile per il suo utilizzo e si riserva il diritto di modificare il prodotto e le informazioni di seguito
riportate, senza necessariamente darne informazione.
IMPORTANTE: Nessuna parte di questo documento può essere copiata, duplicate,

riprodotta, memorizzata con qualunque sistema di archiviazione dati, tradotta in qualunque
lingua o trasmessa con qualunque sistema di comunicazione dati senza il consenso da parte
di Moog
VERSIONE DEL DOCUMENTO
La version originale di questo manuale è stata redatta in: Italiano (IT).
La lingua utilizzata per documentazione e disegni è stata concordata con il Cliente, come da specifica d’Ordine.
In caso di traduzione del presente manuale, Moog fornisce anche la versione originale “Istruzioni di Installazione &
Manutenzione – Originale”.
INDICE DI REVISIONE
La seguente tabella riporta l’indice di revisione del manuale:
Rev Descrizione Preparato Controllato Approvato Data
0 Versione iniziale BEB CAR LOF Gennaio 2013

INDICE
PREFAZIONE ............................................................................................................................................................. 2
VERSIONE DEL DOCUMENTO .................................................................................................................................... 3
INDICE DI REVISIONE ................................................................................................................................................ 3
1. IDENTIFICAZIONE ......................................................................................................................................... 6
1.1 Targa e Designazione ....................................................................................................................................................................................6
1.2 Il Costruttore .................................................................................................................................................................................................7
1.3 Garanzia ........................................................................................................................................................................................................7
1.3.1 Predisposizioni a carico del Cliente ...............................................................................................................................................................7
1.4 Dichiarazione di Conformità ..........................................................................................................................................................................7
1.5 Dichiarazione di Incorporazione ....................................................................................................................................................................7
1.6 Standard applicati .........................................................................................................................................................................................8
2. DESCRIZIONE GENERALE .............................................................................................................................. 9

2.1 Motore brushless ........................................................................................................................................................................................10
2.2 Riduttore .....................................................................................................................................................................................................10
2.3 Limitatore di coppia ....................................................................................................................................................................................10
2.4 Convertitore meccanico ..............................................................................................................................................................................10
2.5 Sistema di fissaggio del corpo .....................................................................................................................................................................10
2.6 Stelo ............................................................................................................................................................................................................10
2.7 Sistema di fissaggio delle estremità ............................................................................................................................................................11
2.8 Uso previsto ................................................................................................................................................................................................11
2.9 Connessioni .................................................................................................................................................................................................12
2.10 Consumo energetico ...................................................................................................................................................................................12
2.11 Emissioni .....................................................................................................................................................................................................12
2.12 Codice IP .....................................................................................................................................................................................................12
2.13 Compatibilità elettromagnetica ..................................................................................................................................................................12
2.14 Dispositivi di Protezione Individuale (DPI) ...................................................................................................................................................13
2.15 Uso improprio .............................................................................................................................................................................................13
3. SICUREZZA ................................................................................................................................................. 14
3.1 Valutazione dei rischi ..................................................................................................................................................................................14
4. PREPARAZIONE DEL PRODOTTO PER L’UTILIZZO ........................................................................................ 15

4.1 Montaggio ...................................................................................................................................................................................................15
4.2 Installazione ................................................................................................................................................................................................15
4.3 Connessioni elettriche.................................................................................................................................................................................15
4.4 Messa in servizio .........................................................................................................................................................................................16
5. ISTRUZIONI DI FUNZIONAMENTO .............................................................................................................. 17

6. MANUTENZIONE E PULIZIA ........................................................................................................................ 18
6.1 Rilubrificazione............................................................................................................................................................................................18
6.2 Risoluzione dei problemi .............................................................................................................................................................................18
7. PARTI DI RICAMBIO E MATERIALI DI CONSUMO ........................................................................................ 19

8. ASSISTENZA E RIPARAZIONE ...................................................................................................................... 20
9. DEMOLIZIONE ............................................................................................................................................ 21
10. ALLEGATI ................................................................................................................................................... 22
GLOSSARIO ............................................................................................................................................................. 23
A PROPOSITO DI MOOG ......................................................................................................................................... 24
1. IDENTIFICAZIONE
1.1 Targa e Designazione

L’Attuare EM L875-603 presenta una targa metallica con i dati sensibili da comunicare in caso di richiesta
informazioni o simili a Moog.
La seguente immagine mostra il layout della targa:
La seguente tabella riporta i dati presenti in targa:
Identificazione Descrizione
Mod Modello del prodotto
S/N Numero di serie
Date Data di produzione (AAAA-MM)
NP Purchasing Code Codice di acquisto del cliente
Intervallo di temperatura ambiente di utilizzo consensito
Dati certificazione ATEX
La seguente tabella riassume i dati identificativi dell’attuatore:
Serial Nr. (if applicable) N.A.
ATEX certification for the electrical
parts of the actuator
(vedi Allegato 4, Brushless servomotor - Declaration of Conformity)

mechanical parts of the actuator II 3D c 135°C
1.2 Il Costruttore
La seguente tabella riporta i dati di contatto del costruttore:
Nome Moog Italiana S.r.l.
Indirizzo Via G. Pastore 4, 21046 Malnate (VA)
Paese Italy
Telefono +39 0332 421 111
Fax + 39 0332 429 233
1.3 Garanzia
L’attuatore è coperto da garanzia secondo le prescrizioni di legge, fatto salvo eventuali accordi contrattuali diversi.
Per i dettagli della copertura riferirsi al contratto d’acquisto.
Il decorso di tale garanzia è da intendersi a partire dalla data di consegna, salvo diverso accordo riportato nel
contratto d’acquisto.
1.3.1 Predisposizioni a carico del Cliente

È responsabilità del Cliente assicurarsi che il prodotto sia installato e utilizzato seguendo le direttive e le linee guida
locali e internazionali in materia di sicurezza. Il Cliente deve analizzare i rischi residui e predisporre:
 Interfacce elettriche e meccaniche adeguatamente dimensionate
 Opportune barriere e dispositivi di sicurezza
 Attrezzature per una corretta movimentazione/manipolazione del prodotto
1.4 Dichiarazione di Conformità

L’Attuatore EM L875-603 è un componente, per tanto non viene emessa Dichiarazione di Conformità CE ai sensi
della Direttiva Macchine. Tuttavia, l’Attuatore è soggetto alla Direttiva ATEX, per la quale è emessa Dichiarazione di
Conformità (vedi Allegato 7).
1.5 Dichiarazione di Incorporazione

L’Attuatore EM L875-603 è un componente, per tanto non viene emessa Dichiarazione di Incorporazione ai sensi
della Direttiva Macchine.
1.6 Standard applicati
L’attuatore è stato progettato e realizzato secondo la corretta prassi in uso.
La seguente tabella riporta le Direttive Europee applicate:
Direttiva Descrizione
2006/95/CE Direttiva Bassa Tensione
La seguente tabella riporta gli standard applicati:
Standard Descrizione
EN 60034-1:2010 Macchine elettriche rotanti – Parte 1: Caratteristiche nominali e di funzionamento

Macchine elettriche rotanti – Parte 5: Gradi di protezione degli involucri delle macchine rotanti
EN 60034-5:2006
(progetto integrale) (Codice IP) - Classificazione
Azionamenti elettrici a velocità variabile - Parte 3: Requisiti di compatibilità elettromagnetica e
EN 61800-3:2012
metodi di prova specifici
IEC EN 60204-1:2006 Sicurezza del macchinario. Equipaggiamento elettrico delle macchine - Parte 1: Regole generali
Sicurezza del macchinario - Principi generali di progettazione - Valutazione del rischio e riduzione
EN 12100:2010
del rischio
EN 60079-0:2009 Atmosfere esplosive - Parte 0: Apparecchiature - Prescrizioni generali
Atmosfere esplosive - Parte 1: Apparecchiature protette mediante custodie a prova d'esplosione
EN 60079-1:2007
"d"
Atmosfere esplosive - Parte 31: Apparecchi con modo di protezione mediante custodie "t"
EN 60079-31:2009
destinati a essere utilizzati in presenza di polveri combustibili
EN 13463-1:2009
EN 13463-5:2011
EN 1127-1:2011
Compatibilità elettromagnetica (EMC) - Parte 4-2: Tecniche di prova e di misura - Prove di
EN 61000-4-2:2009
immunità a scariche di elettricità statica
Compatibilità elettromagnetica (EMC) - Parte 4-3: Tecniche di prova e di misura - Prova
EN 61000-4-3:2006
d'immunità ai campi elettromagnetici a radiofrequenza irradiati
EN 61000-4-4:2004
immunità a transitori/raffiche di impulsi elettrici veloci
EN 61000-4-5:2006
immunità ad impulso
Compatibilità elettromagnetica (EMC) - Parte 4-6:Tecniche di prova e di misura - Immunità ai
EN 61000-4-6:2009
disturbi condotti, indotti da campi a radiofrequenza
2. DESCRIZIONE GENERALE
La seguente tabella mostra le parti principali dell’attuatore EM L875-603:
Colore Componente Descrizione Presente (Yes)/Non presente (No)*
Stelo - Yes
Sistema di fissaggio estremità stelo GIUNTO SFERICO Yes

* Fare rifermento alla tabella per identificare i componenti presenti nell’attuatore oggetto di questo manuale; nei paragrafi
sottostanti sono riportate le descrizione delle singole parti, anche se non contenute nell’attuatore in oggetto Per ulteriori dettagli
fare riferimento al Disegno di Installazione in allegato.
La seguente figura mostra le parti dell’Attuatore:

2.1 Motore brushless
Il motore brushless è un Servomotore Moog Explosion Proof (ExD). Si tratta di un motore sincrono brushless, con
eccitazione permanente del campo magnetico.
Per ulteriori informazioni, consultate il manuale del motore (vedi Allegato 1).
2.2 Riduttore
Il riduttore agisce come amplificatore di coppia ed è del tipo a ingranaggi planetari, dimensionato per una lunga vita
in servizio senza richiesta di particolari interventi di manutenzione.
La seguente tabella riporta le caratteristiche principali del riduttore:
Caratteristica Informazioni
Grado di protezione N.A.
Durata cuscinetti N.A. ore, in condizioni di funzionamento nominale
2.3 Limitatore di coppia

Il imitatore di coppia disconnette l’albero del riduttore dall’albero della vite, quando la coppia supera il valore di
sicurezza.
La seguente tabella riporta la casistica di intervento del limitatore:
Evento Azione Risultato
Impatto tra stelo attuatore ed Intervento limitatore Energia cinetica accumulata da motore e riduttore
ostacolo (movimento in velocità) di coppia NON scaricata sulla vite
2.4 Convertitore meccanico

Il convertitore meccanico effettua la conversione del moto da rotatorio a lineare, attraverso una vite a ricircolo di
sfere, ad alta precisione. Il carico assiale è sostenuto da una doppia coppia di cuscinetti a sfere a contatto obliquo, ad
alta precisione e basso attrito.
I cuscinetti e la vite sono lubrificati con lubrificante idoneo a garantire una lunga durata a temperature medio alte.
2.5 Sistema di fissaggio del corpo

L’attuatore può essere fissato con una delle tre opzioni evidenziata in figura:
 Flangia posteriore con fori filettati o passanti

 Trunnion
 Flangia frontale con fori filettati o passanti
Vedere Disegno di installazione per ulteriori particolari
2.6 Stelo
Lo stelo ha la funzione di trasmettere la forza e la velocità richieste dall’applicazione.

2.7 Sistema di fissaggio delle estremità
Lo stelo può essere collegato con una delle seguenti opzioni:
 Terminale con filetto maschio

 Terminale con filetto femmina
 Snodo sferico
2.8 Uso previsto

L’attuatore EM L875-603 è progettato esclusivamente per utilizzo industriale e professionale, in applicazioni
Powergen.
In particolare, l’attuatore EM L875-603 è destinato al IGV di macchine Powergen.
La seguente figura mostra una visualizzazione grafica dell’applicazione dell’Attuatore:
IMPORTANTE: Le caratteristiche dell’attuatore riportate nel presente manuale si riferiscono

a un utilizzo in ambiente con temperature comprese tra 10° C e 40° C e a un tasso di umidità
 70%
Differenti condizioni ambientali possono alterare i parametri di funzionamento
I materiali utilizzati per la costruzione non sono specificatamente studiati per l’impiego del
componente in ambienti chimicamente aggressivi, compresa l’esposizione a nebbia salina o
in atmosfere potenzialmente esplosive (Direttiva ATEX)
L’attuatore è in grado operare fino a 40 °C, sviluppando forze continuative ridotte. L’attuatore può anche essere
utilizzato a basse temperature, non inferiori a -40 °C.
La seguente tabella riporta le prestazioni dell’attuatore a 40° C:
Caratteristica Prestazioni
Massa 52 kg ca.
Dimensioni di ingombro 225 x 140 x 990 mm
Forza nominale 20 kN
Forza di picco 20 kN
Velocità max 70 mm/s
Corsa 95(+4,0/0)mm
Gioco <0,03 mm
Orientamento Nessuna restrizione
2.9 Connessioni
Per le connessioni meccaniche ed elettriche, vedere il disegno di installazione (vedi Allegato 2).
2.10 Consumo energetico
Per il consumo energetico, vedere il manuale del motore (vedi Allegato 1).
2.11 Emissioni
Per le emissioni, vedere il manuale del motore (vedi Allegato 1).
2.12 Codice IP
La seguente tabella riporta le caratteristiche del grado di protezione IP disponibili:
Caratteristica Descrizione
IP55 standard
N.A. optional
2.13 Compatibilità elettromagnetica

Per la compatibilità elettromagnetica, vedere il manuale del motore (vedi Allegato 1).
2.14 Dispositivi di Protezione Individuale (DPI)
GUANTI: utilizzare sempre guanti protettivi per evitare possibili abrasioni o lacerazioni
SCARPE: utilizzare sempre scarpe protettive per evitare possibili schiacciamenti
2.15 Uso improprio

Moog declina ogni responsabilità per danni causati a cose e/o persone in caso di:
 Uso dell’attuatore improprio e/o diverso da quanto indicato nel presente manuale
 Errata installazione
 Mancata o errata osservanza delle istruzioni riportate nel presente manuale
 Operazioni condotte da personale non addestrato o non qualificato
 Impiego dell’attuatore oltre i limiti consenti
 Mancanza di idonei ripari atti a garantire la sicurezza
3. SICUREZZA
3.1 Valutazione dei rischi

Robustezza e affidabilità sono state considerate nel progetto dell’attuatore per garantire un utilizzo sicuro.
ATTENZIONE: Dotare il personale addetto all’utilizzo/manutenzione del prodotto dei

necessari dispositivi di protezione individuali previsti dalle vigenti normative
La seguente tabella riporta i rischi residui relativi all’Attuatore:
Fattore di rischio Condizione Periodo d’esposizione
Schiacciamento arti Spostamento dello stelo Durante il funzionamento
Alta tensione Perdita d’isolamento di cavi e connettori Durante l’alimentazione
Massa del prodotto Caduta del prodotto Durante il trasporto/manutenzione
Riscaldamento del prodotto (correnti Durante il funzionamento (in

Alta temperatura (fino a 80° C)
parassite) condizioni di alto carico)
È compito del Cliente analizzare tali rischi e predisporre gli opportuni equipaggiamenti di salvaguardia del personale.
4. PREPARAZIONE DEL PRODOTTO PER L’UTILIZZO
4.1 Montaggio
Non sono previste operazioni di montaggio da parte del Cliente: l’attuatore EM L875-603 viene fornito montato in
tutte le sue parti.
Per la connessione dei cavi di potenza del motore, fare riferimento al manuale del motore stesso (Allegato 1)
4.2 Installazione
L’attuatore deve essere sollevato mediante idonee imbracature o utilizzando gli appositi golfari eventualmente
presenti sull’attuatore. Prima del sollevamento assicurarsi che il centro di gravità sia posizionato tra e sotto le
imbracature.
La seguente tabella mostra le connessioni dell’attuatore:
Caratteristiche della
Parte in connessione Tipo di connessione Coppia si serraggio
connessione
Struttura fissa Snodo basculante TRUNNION N.A.
Parte mobile Stelo – terminale a snodo GIUNTO SFERICO N.A.
IMPORTANTE: evitare di sottoporre l’attuatore a carichi laterali in quanto essi riducono la

vita utile e le prestazioni dell’attuatore
I carichi laterali possono generarsi per disallineamento o carichi eccentrici
4.3 Connessioni elettriche

Le connessioni elettriche tra motore e relativo azionamento dovrebbero essere eseguite con i cavi standard
specificati dalla Moog. Qualora si utilizzino altri cavi devono essere soddisfatti i seguenti requisiti:

2
cavo di potenza 4 x 4 + 2 x 1 mm

2
cavo di segnale: 5 x 2 x 0,25 mm schermati e intrecciati a coppie
IMPORTANTE: La connessione e la sconnessione del cavo motore deve essere effettuata con
azionamento non alimentato
La semplice disabilitazione non è sufficiente ad intercettare la tensione
Il cavo di messa a terra (PE) deve essere di sezione adeguata (pari a quella del conduttore di potenza) come previsto
dalle vigenti norme di sicurezza.
ATTENZIONE: Conduttori di sezione ridotta provocano un inaccettabile surriscaldamento
dei cavi e perdita di potenza
Si raccomanda la schermatura dei cavi di potenza e di ogni singola coppia di conduttori del cavo di segnale.
4.4 Messa in servizio

Il funzionamento e le prestazioni dell’attuatore EM L875-603 dipendono dalla scelta dei parametri inseriti
nell’azionamento.
I valori di coppia e velocità del motore selezionati non devono essere maggiori di quelli riportati sul disegno specifica
dell’attuatore.
Si prega di consultare il manuale dell’azionamento del motore.
Occorre riporre molta cura:
 nell’impostare sull’azionamento la velocità, la corrente continuativa e quella di picco del motore
 nel collegare i conduttori dei cavi di potenza e di segnale; una connessione errata può provocare la
perdita di controllo del motore con possibili danneggiamenti dei componenti meccanici in caso di
impatto veloce contro ostacoli
Prima di comandare il movimento dell’attuatore verificare i seguenti:
 la lubrificazione della struttura scorrevole della macchina
 il corretto serraggio delle viti
 l’assenza di ostacoli lungo la corsa dello stelo
Si consiglia di eseguire la messa in servizio a coppia e velocità ridotte (1/10 del valore nominale).
IMPORTANTE: evitare accuratamente urti a piena coppia e velocità motore

5. ISTRUZIONI DI FUNZIONAMENTO
L’Attuatore EM L875-603 è progettato per il IGV in una macchina per (Powergen).
A seguito dell’installazione, deve essere regolata la movimentazione dell’Attuatore mediante l’azionamento del
motore, non incluso nella fornitura.
Consultare, quindi, il manuale dell’azionamento del motore per ogni informazione circa le istruzioni di
funzionamento.
6. MANUTENZIONE E PULIZIA
L’attuatore è progettato per richiedere una manutenzione assai ridotta. Si raccomanda una ri-lubrificazione e
un’ispezione semestrale dello stato di usura delle guarnizioni di tenuta sullo stelo ogni sei mesi.
ATTENZIONE: Prima di eseguire ogni azione manutentiva verificare che:

 L’attuatore è in posizione sicura
 È assente potenza elettrica o meccanica
 Le alimentazioni non possono essere inavvertitamente attivate
 Il personale adiacente è avvertito della manutenzione in corso
 Non ci sono condizioni di pericolo derivanti da altre fonti
6.1 Rilubrificazione
Lo stelo dell’attuatore, la vite a sfere e i cuscinetti vengono forniti con quantità di grasso ottimale, ove non
specificato diversamente. Moog raccomanda il seguente lubrificante:
Nel caso di ri-lubrificazione periodica come indicato nel capitolo 6 del presente manuale, le istruzioni sono
contenute nel seguente documento CDP37236 in allegato.
Al termine di queste operazioni effettuare almeno 2 corse complete dell’attuatore senza carico per distribuire il
grasso inserito.
6.2 Risoluzione dei problemi

Si riporta di seguito una lista per la risoluzione dei problemi più comuni.
Problema Possibile causa Soluzione Note
Consultare manuale
Funzionamento Parametrizzazione errata controllore
azionamento motore
rumoroso
Disallineamento o carichi laterali Controllare allineamento
Attuatore fermo con Improprio collegamento meccanico Controllare connessione

motore in rotazione motore-convertitore mediante chiavetta
Controllare scelta parametri

Parametrizzazione errata controllore
Attuatore in stallo azionamento
Carico o attrito eccessivo Verificare carico e allineamenti
Riscaldamento esterno Controllare schermo termico

Surriscaldamento Rivolgersi a
motore Grippaggio motore, convertitore o Smontare attuatore e
Moog Italiana
parte mobile collegata determinare elemento grippato
S.r.l.
7. PARTI DI RICAMBIO E MATERIALI DI CONSUMO
Non sono previste parti di ricambio, né materiali di consumo.
8. ASSISTENZA E RIPARAZIONE
Le operazioni non programmate necessarie a ripristinare la funzionalità del prodotto devono essere eseguite da
Moog o da personale qualificato da Moog.
Collegandosi al sito www.moog.com è possibile individuare il più vicino centro d’assistenza Moog.
Quando è necessaria una riparazione tutte le parti non facenti parte del prodotto devono essere rimosse in quanto
Moog non può garantirne il corretto montaggio/smontaggio.
Dovrebbero essere altresì rimossi grasso e polvere.
L’equipaggiamento deve essere adeguatamente imballato per evitare danneggiamenti durante il trasporto.
9. DEMOLIZIONE
Alla fine della vita operativa dell’attuatore procedere come segue:
 Rimuovere il cartellino di identificazione e tenerlo insieme al presente manuale e la documentazione
data dalla ditta fornitrice
 Rimuovere e separare le parti elettriche
 Rimuovere e separare le parti in plastica
 Separare le parti metalliche a seconda della loro tipologia (alluminio, acciaio, ecc.)
ATTENZIONE: non disassemblare il motore. I magneti permanenti del motore

sviluppano alte forze che possono ferire gravemente l’operatore
Gli operatori addetti alla sopracitata attività non necessitano di speciale addestramento.
Durante la rimozione e lo smontaggio delle parti metalliche, utilizzare dei guanti protettivi, in modo da evitare
possibili abrasioni con le parti taglienti.
Seguite le procedure di eliminazione conformi alle disposizioni locali per la raccolta differenziata delle parti citate nei
paragrafi precedenti.
10. ALLEGATI
La seguente tabella mostra gli allegati al presente manuale:
Brushless servomotor – Installation Instructions

1 Rev. G
Explosion Proof (ExD)
2 Installation drawing CB53763 Rev. A
3 Procedura di ri-lubrificazione CDP37326/CDP37327 Rev. 0
4 Brushless servomotor – Declaration of Conformity Rev. B
Brushless servomotor – EC Type Examination Certificate

5 Rev. B
10 ATEX 0915070X
Brushless servomotor – Product Quality Assessment

6 Rev. 0
Notification 09 ATEX Q148848
7 Attuatore – Declaration of Conformity Rev. -

GLOSSARIO
La seguente tabella riporta le abbreviazioni utilizzate:
Abbreviazione Descrizione
Attuatore EM Attuatore Elettro Meccanico
Simbolo Descrizione
IMPORTANTE: Avvisi e note a proposito di funzionalità importanti o di informazioni utili
ATTENZIONE: Pericolo per le persone (anche mortale)
GUANTI: guanti protettivi per evitare possibili abrasioni o lacerazioni (DPI)
SCARPE: scarpe protettive per evitare possibili schiacciamenti (DPI)

A PROPOSITO DI MOOG
L’Industrial Group di Moog progetta e costruisce “motion control solution” ad alte performance, utilizzando
tecnologie elettriche, idrauliche ed ibride, con il supporto di esperti in una vasta gamma di applicazioni, tra cui test,
simulazione, industria plastica, industria dei metalli pesanti e powergen.
scuderie automobilistiche.
Moog aiuta le aziende a progettare e sviluppare macchine di nuova generazione.
L’Industrial Group di Moog è parte di Moog Inc.
Per maggiori informazioni visitare il sito www.moog.com/industrial.

Via G. Pastore 4
Tel. +39 0332 421 111
Fax + 39 0332 429 233
info.italy@moog.com
TAKE A CLOSER LOOK

+54 11 4326 5916 +353 21 451 9000 +46 31 680 060

+61 3 9561 6044 +39 0332 421 111 +41 71 394 5010

+43 664 144 65 80 +81 436 55 3767 +31 252 462 000

+55 11 5523 8011 +82 31 764 6711 +44 1564 784 777

+86 21 5854 1411 +352 40 46 401 +1 734 887 4250
Finland Norway
+358 9 2517 2730 +47 224 32927
France Russia
+33 1 4560 7000 +7 831 713 1811
Germany Singapore
+49 7031 622 0 +65 677 36238

+852 2 635 3200 +27 11 655 7030
India Spain
+91 80 4120 8785 +34 902 133 240
ATTUATORE EM L875-603
Rev. 0, , Documento N. CDS37003
.
EM ACTUATOR
L875-603
Installation & Maintenance Instructions
Translation
THIS DOCUMENT DESCRIBES THE INSTALLATION, OPERATION AND

MAINTENANCE OF THE MOOG EM ACTUATOR L875-603.
PREFACE
This "EM ACTUATOR L875-603 - Installation & Maintenance Instructions - Translation” was drafted according to IEC
EN 62079, “Preparation of instructions - Structuring, content and presentation”. The manual was written and
checked to the best of Moog's knowledge.
Moog is not liable for its use and reserves the right to change the product and information included herein, without
prior notice.
IMPORTANT: No part of this document can be copied, duplicated, reproduced or saved to

any data storage system, translated into any language or transmitted with any data
communication system without Moog's consent
DOCUMENT VERSION
The original version of this manual was drafted in: Italiano (EN).
The language used for documents and drawings was agreed with the customer, as specified in the Order.
In the event these "Installation & Maintenance Instructions" are translated, Moog also provides the original
"Installation & Maintenance Instructions - Original" version.
REVISION INDEX
The following table lists the manual revision index:
Rev Description Prepared Checked Approved Date
0 Translation of CDS37003(0) BEB CAR LOF January 2013

INDEX
PREFACE ................................................................................................................................................................... 2
Document version .................................................................................................................................................... 3
Revision index .......................................................................................................................................................... 3
1. IDENTIFICATION ........................................................................................................................................... 6
1.1 Nameplate ....................................................................................................................................................................................................6
1.2 The Manufacturer .........................................................................................................................................................................................7
1.3 Warranty .......................................................................................................................................................................................................7
1.3.1 Prerequisites to be performed by the customer ...........................................................................................................................................7
1.4 Declaration of Conformity .............................................................................................................................................................................7
1.5 Declaration of Incorporation .........................................................................................................................................................................7
1.6 Applied standards .........................................................................................................................................................................................8
2. GENERAL DESCRIPTION ................................................................................................................................ 9

2.1 Brushless motor ..........................................................................................................................................................................................10
2.2 Gear box ......................................................................................................................................................................................................10
2.3 Torque limiter .............................................................................................................................................................................................10
2.4 Mechanical converter .................................................................................................................................................................................10
2.5 Body fixing system ......................................................................................................................................................................................10
2.6 Rod ..............................................................................................................................................................................................................10
2.7 Ends fixing system .......................................................................................................................................................................................11
2.8 Intended use ...............................................................................................................................................................................................11
2.9 Connections ................................................................................................................................................................................................12
2.11 Emissions ....................................................................................................................................................................................................12
2.12 IP Code ........................................................................................................................................................................................................12
2.13 Electromagnetic compatibility ....................................................................................................................................................................12
3. SAFETY ....................................................................................................................................................... 14
3.1 Risk assessment ..........................................................................................................................................................................................14
4. PRODUCT PREPARATION FOR USE ............................................................................................................. 15

4.1 Assembly .....................................................................................................................................................................................................15
4.2 Installation ..................................................................................................................................................................................................15
4.3 Electrical connections .................................................................................................................................................................................15
4.4 Commissioning ............................................................................................................................................................................................16
5. OPERATING INSTRUCTIONS ....................................................................................................................... 17

6. MAINTENANCE AND CLEANING ................................................................................................................. 18
6.1 Re-lubrication..............................................................................................................................................................................................18
6.2 Troubleshooting ..........................................................................................................................................................................................18
7. SPARE PARTS AND CONSUMABLES ............................................................................................................ 19

8. SERVICE AND REPAIRS ............................................................................................................................... 20
9. END OF LIFE/SCRAPING .............................................................................................................................. 21
10. ATTACHMENTS .......................................................................................................................................... 22
GLOSSARY .............................................................................................................................................................. 23
ABOUT MOOG ........................................................................................................................................................ 24
1. IDENTIFICATION
1.1 Nameplate
The EM Actuator L875-603 includes a nameplate with sensitive data to be communicated when requesting
information or other from Moog.
An illustration of the nameplate layout is provided below:
The following table includes the data found on the nameplate:
Identification Description
Mod Product model
S/N Serial number followed by the date of manufacture expressed as "month/year"
Type Intentionally left blank
Operating temperature range
ATEC certification information
The following table summarises the actuator identification data:
Serial Nr. (if applicable) N.A.
ATEX certification for the
electrical parts of the actuator
(see the Attachment 4, Brushless servomotor - Declaration of Conformity)

mechanical parts of the
actuator II 3D c 135°C
1.2 The Manufacturer
The following table includes the manufacturer's contact details:
Name Moog Italiana S.r.l.
Address Via G. Pastore 4, 21046 Malnate (VA)
Country Italy
Telephone +39 0332 421 111
Fax + 39 0332 429 233
1.3 Warranty
The actuator is covered by a warranty according to law, unless otherwise agreed in the contract.
Refer to the purchase contract for warranty coverage details.
This warranty is valid as of the delivery date, unless otherwise agreed in the purchase contract.
1.3.1 Prerequisites to be performed by the customer

The customer is in charge of ensuring that the product is installed and used according to local and international
safety directives and guidelines. The customer must assess residual risks and prepare:
 Suitably dimensioned electrical and mechanical interfaces
 Suitable barriers and safety devices
 Tools for correct product handling
1.4 Declaration of Conformity

The Actuator L875-603 is a component, thus an EC Declaration of Conformity is not issued as per the Machine
Directive. Moreover, the Actuator is subjected to the ATEX Directive, so there is an EC Declaration of Conformity in
compliance with it (See the Attachment 7).
1.5 Declaration of Incorporation

The EM Actuator L875-603 is a component, thus an EC Declaration of Incorporation is not issued as per the Machine
Directive.
1.6 Applied standards
The actuator was designed and constructed according to currents best practices.
The following table lists the applied European Directives:
2006/95/CE Low Voltage Directive
The following table lists the applied standards:
EN 60034-1:2010 Rotating electrical machines - Part 1: Rating and performance

EN 60034-5:2006
rotating electrical machines (integral design) (IP Code) - Classification
EN 61800-3:2012
methods
IEC EN 60204-1:2006 Safety of machinery. Electrical equipment of machines - Part 1: General requirements
EN 12100:2010 Machinery safety – General design principles - Risk assessment and risk reduction
EN 60079-0:2009 Explosive atmospheres - Part 0: Equipment - General requirements
EN 60079-1:2007 Explosive atmospheres - Part 1: Equipment protection by flameproof enclosures "d"
EN 60079-31:2009 Explosive atmospheres - Part 31: Equipment dust ignition protection by enclosure "t"
EN 13463-1:2009
EN 13463-5:2011
EN 1127-1:2011
EN 61000-4-2:2009
Electromagnetic compatibility (EMC) - Part 4-3: Testing and measurement techniques - Radiated,
EN 61000-4-3:2006
radio-frequency, electromagnetic field immunity test
Electromagnetic compatibility (EMC) – Part 4-4: Testing and measurement techniques – Electrical
EN 61000-4-4:2004
fast transient/burst immunity test
EN 61000-4-5:2006
immunity test
Electromagnetic compatibility (EMC) - Part 4-6: Testing and measurement techniques - Immunity
EN 61000-4-6:2009
to conducted disturbances, induced by radio-frequency fields
The following table lists the main parts of the EM actuator L875-603:
Color Components Description Present in (Yes)/Not present in (No)*
Stelo - Yes
Sistema di fissaggio estremità stelo SPHERICAL JOINT Yes

* Please, refer to the table to identify the components of the actuator; in the following clauses there are the descriptions of the
single components, even if not present in the actuator. For more details, please refer to the attached Installation Drawing.
The following image illustrates the elements of the actuator:

2.1 Brushless motor
The brushless motor is a Moog motor Explosion Proof (ExD). It is a synchronous brushless motor, with permanent
magnets.
For further information, please see the motor manual (see Appendix 1).
2.2 Gear box

The gear box acts as a torque amplifier and it is a planetary gear box. It is dimensioned for a long working life and it
is maintenance free.
The following table lists the main characteristics of the gear box:
Feature Information
IP degree of protection N.A.
Bearing life N.A. hours, for normal functioning
2.3 Torque limiter

The torque limiter disconnects the shaft of the gear unit from the screw, when the torque exceeds the safety value.
The following table lists the main characteristics of the torque limiter:
Event Action Result
Impact between the actuator rod and Torque limiter Kinetic energy accumulated by motor and gearbox
an obstacle (moving speed) intervention NOT downloaded the screw
2.4 Mechanical converter

The mechanical converter transforms rotary motion to linear motion through a high precision ball screw.
The axial load is sustained by a double pair of high precision and low friction oblique-contact ball bearings.
The bearings and screw are lubricated with grease suited to guarantee long working life at medium to high
temperatures.
2.5 Body fixing system
The actuator may be fixed with one the following system:
 Rear flange with threaded holes or loops

 Trunnions
 Front flange with threaded holes or loops
For other details, please refer to the Installation Drawing.
2.6 Rod
The rod has the function of transmitting the force and the speed required by the application.
2.7 Ends fixing system
The rod may be fixed with one of the following system:
 Terminal with male thread

 Terminal with female thread
 Spherical bearing
2.8 Intended use

The EM actuator L875-603 is exclusively designed for industrial and professional use, in applications for Powergen.
Specifically, the EM actuator L875-603 is intended for IGV in Powergen machineries.
The following image graphically depicts Actuator application:
IMPORTANT: The actuator data included in this manual refer to use in an environment with
temperatures between 10° C and 40° C and  70% relative humidity
Different environmental conditions could alter operating parameters

The construction materials used are not specifically designed for use in chemically aggressive
environments, including exposure to saline mist and potentially explosive atmospheres
(ATEX Directive)
The actuator can work at up to 40 °C, generating reduced continuous power. The actuator may also be used for low
temperatures, not less than -40 °C.
The following table lists actuator performance at 40° C:
Feature Performance
Weight 52 kg abt.
Overall dimensions 225 x 140 x 990 mm
Rated power 20 kN
Peak power 20 kN
Max speed 70 mm/s
Stroke 95(+4,0/0)mm
Axial backlash <0,03 mm
Direction No renstriction
2.9 Connections
For mechanical and electrical connections, please see the installation drawing (see Appendix 2).
2.10 Energy consumption
For energy consumption, please see the motor manual (see Appendix 1).
2.11 Emissions
For emissions, please see the motor manual (see Appendix 1).
2.12 IP Code
The following table lists available IP protection grade features:
Feature Description
IP55 standard
N.A. optional
2.13 Electromagnetic compatibility

For electromagnetic compatibility, please see the motor manual (see Appendix 1).
2.14 Personal Protective Equipment (PPE)
GLOVES: always wear protective gloves to avoid potential abrasions or lacerations
SHOES: always wear protective shoes to avoid potential crushing
2.15 Improper use

Moog is not liable for any damages caused to property and/or people in the event of:
 Improper actuator use and/or use other than that indicated in this manual
 Incorrect installation
 Negligence or failure to follow the instructions in this manual
 Operations performed by untrained or unqualified personnel
 Actuator use beyond the admitted limits
 Lack of suitable safety guarding
3. SAFETY
3.1 Risk assessment

Sturdiness and reliability were considered in the actuator design to guarantee safe use.
WARNING: Equipment product users/maintenance personnel with the necessary personal

protection equipment foreseen by current regulations
The following table lists residual Actuator risks:
Risk factor Condition Period of exposure
Limb crushing Rod movement During operations
High voltage Loss of wire and connector insulation When live
Product weight Product fall During transport/maintenance
During operations (in high load

High temperature (up to 80° C) Product heating (parasite currents)
conditions)
The customer is in charge of assessing these risks and preparing suitable personnel protection equipment.
4. PRODUCT PREPARATION FOR USE
4.1 Assembly
The customer is not required to perform assembly operations: the EM actuator L875-603 is supplied fully assembled.
For the connection of the power cables of the motor, please see the motor manual (Attachment 1).
4.2 Installation
The actuator must be lifted using a suitable sling. Before lifting, make sure the centre of gravity is positioned
between and under the slings.
The following table lists the connection of the actuator:
Connection Part Connection Type Connection Feature Tightening Torque
Fixed structure Frontal Flange TRUNNION N.A.
Mobile part Rod – Ball joint end SPHERICAL JOINT N.A.
IMPORTANT: avoid to apply lateral loads to the actuator since they its working life and
performance
Lateral loads may be generated by offsets or eccentric loads
4.3 Electrical connections

Electrical connections between the motor and drive should be performed with the standard wires specified by
Moog. Should other wires be used, they must meet the following requirements:

2
power cable 4 x 4 + 2 x 1 mm

2
signal cable 5 x 2 x 0,25 mm shielded twisted pair
IMPORTANT: The motor wire must be connected and disconnected with the drive cut off
from the power supply
Simply turning off power does not cut off voltage
The grounding wire (PE) must be of adequate section (equal to the power conductor wire) as foreseen by current
safety regulations.
WARNING: Smaller section conductors cause unacceptable wire overheating and loss of
power
Power wire and every single signal wire conductor pair should be shielded.
4.4 Commissioning
EM Actuator L875-603 operations and performance depend on drive settings.
Selected motor torque and speed should not be higher than those indicated in the specific actuator installation
drawing.
Please see the drive manual.
Please pay the utmost attention to:
 drive speed, direct current and motor peak current settings
 connecting power and signal conductor wires; faulty connections could cause the loss of motor control with
potential damage to mechanical parts in the event of fast impact with obstacles.
Check the following at each actuator start up:
 machine sliding structure lubrication
 correct screw tightening torque
 lack of obstacles along stroke of the rod
Please commission at reduced torque and speed (1/10 rated value).
IMPORTANT: carefully avoid collisions at full motor torque and speed

The EM actuator L875-603 is designed for IGV application in a machine (Powergen).
After commissioning, the EM actuator is controlled by the drive, not included in the supply.
Thus, please see the drive manual for further information on operating instructions.
The actuator is designed to require minimal maintenance. Please re-lubricate and inspect rod seal wear every
6 months.
WARNING: Before performing any maintenance, check that:

 The actuator is in a safe position
 All electrical and mechanical power is cut off
 Drives cannot be inadvertently started
 Nearby personnel is warned of maintenance in progress
 There are no hazardous conditions due to other sources
6.1 Re-lubrication
The actuator rod, ball screw and bearings are lubricated with optimal quantity of synthetic mineral grease. Moog
recommends the following grease:
For periodic re-lubrication as per Clause 6 of this manual, the instructions are in the attachment document
CDP37787.
At the end of the related operations, perform almost two complete strokes of the actuator, without load, to
distribute the inserted grease.
6.2 Troubleshooting
A list of the most common problems is provided below.
Problem Possible cause Solution Notes
Incorrect controller settings See the motor drive manual

Noisy operations
Offset or lateral loads Check alignment
Actuator stopped with Incorrect motor - mechanical Check shaft parallel key
motor running converter connection connections
Incorrect controller settings Check drive settings

Actuator stalled
Excessive load or friction Check load and alignments
External overheating Check heat shield
Motor overheating Refer to

Seizure of motor, converter or Remove the actuator and find
Moog Italiana
connected mobile part the seized element
S.r.l.
No spare parts or consumables are foreseen.
8. SERVICE AND REPAIRS
Unscheduled operations needed to restore product operations must be performed by Moog or qualified Moog
personnel.
Visit www.moog.com to find your nearest Moog service centre.
When repairs are required, all parts not originally included in the product must be removed since Moog cannot
guarantee their correct assembly/dismantling.
Grease and dust should also be removed.
The equipment should be suitably packaged to avoid damages during transport.
9. END OF LIFE/SCRAPING
Proceed as follows at the end of the actuator's working life:
 Separate metallic parts according to their type (aluminum, steel, etc.)
WARNING: do not dismantle the motor. Permanent motor magnets generate high
forces that could severely injure the operator
Operators assigned to this activity do not require special training.

When removing and dismantling metallic parts, wear protective gloves to avoid potential abrasions with sharp parts.
Follow local waste disposal regulations to recycle parts mentioned in the previous paragraphs.
10. ATTACHMENTS
Brushless servomotor – Installation Instructions

1 Version 1.0 | 10/2008
Explosion Proof (ExD)
2 Installation drawing CB53763 Rev. A
3 Re-lubrication procedure CDP37326/CDP37327 Rev. 0
4 Brushless servomotor – Declaration of Conformity Rev. B
Brushless servomotor – EC Type Examination Certificate

5 Rev. B
10 ATEX 0915070X
Brushless servomotor – Product Quality Assessment

6 Rev. 0
Notification 09 ATEX Q148848
7 Actuator – Declaration of Conformity Rev. -

GLOSSARY
The following table lists the abbreviations used:
Abbreviation Description
EM Actuator Electro-Mechanical Actuator
Symbol Description
IMPORTANT: Warnings and notes on important functions or helpful information
WARNING: Personal hazard (even fatal)
GLOVES: Protective gloves to avoid potential abrasions or lacerations (PPE)
SHOES: Protective shoes to avoid potential crushing (PPE)

ABOUT MOOG
Moog Industrial Group designs and constructs high performance motion control solutions using electrical, hydraulic
and hybrid technologies with the help of experts in a wide range of applications including testing, simulation and the
plastic, heavy metal and powergen industries.
Moog customers include leading automobile and aerospace manufacturers, test laboratories and automobile racing
teams.
Moog helps businesses design and develop new generation machines.
Moog Industrial Group is a member of Moog Inc.
For further information visit www.moog.com/industrial.

Via G. Pastore 4
Tel. +39 0332 421 111
Fax + 39 0332 429 233
info.italy@moog.com
TAKE A CLOSER LOOK

+54 11 4326 5916 +353 21 451 9000 +46 31 680 060

+61 3 9561 6044 +39 0332 421 111 +41 71 394 5010

+43 664 144 65 80 +81 436 55 3767 +31 252 462 000

+55 11 5523 8011 +82 31 764 6711 +44 1564 784 777

+86 21 5854 1411 +352 40 46 401 +1 734 887 4250
Finland Norway
+358 9 2517 2730 +47 224 32927
France Russia
+33 1 4560 7000 +7 831 713 1811
Germany Singapore
+49 7031 622 0 +65 677 36238

+852 2 635 3200 +27 11 655 7030
India Spain
+91 80 4120 8785 +34 902 133 240
EM ACTUATOR L875-603
Rev. 0, January 2013, Document Nr. CDS37004
.
EMA ACTUATOR
L875-603
ATTACHMENT 1 – BRUSHLESS SERVOMOTOR –
Installation Instructions Explosion Proof (ExD)
DOCUMENT NR. CDS37003/CDS37004 – Att. 1


ExD SERIES
Rev. G, July 2012

WITH ATEX AND IECEx
1

TABLE OF CONTENT
INTRODUCTION ....................................................................................................................................................................................... 2
1.2 Model strategy ..................................................................................................................................................................... 4
2.3 Motor name plate ............................................................................................................................................................... 5
3 TRANSPORT ................................................................................................................................................................................... 5
7 MAINTENANCE ........................................................................................................................................................................... 15
ANNEX
Electrical data
Rev. G, July 2012 2


8 Shaft
Rev. G, July 2012 3

1.2 MODEL STRATEGY



Rev. G, July 2012 4


General details
S/N Serial number
Norms:

For Gas and Dust:
For Gas only:
J Rotor inertia
For PWM converter:
3. TRANSPORT
transport damage.
ordered.
Rev. G, July 2012 5


centre.

technical data.
Rev. G, July 2012 6


G493, G495 and G496
Rev. G, July 2012 7


Preparing the motor
Rev. G, July 2012 8

Preparing the motor


on the motor cover.
the thread size.
cover.

must be mounted.
Rev. G, July 2012 9
connection clamps.

overall
6 900
3
Lock washer
5 back-to-back


the manufacturer.

Cover assembly



connection example
User Interface

the power supply to
( Servo Drive )


connection optional
Power Cable
Motor Interface

PTC thermal sensor
Signal Cable


MOTOR
POWER CONNECTION
VOLTAGE SUPPLY
U U BLACK
V V WHITE N/S
W W RED

– – RED BRAKE

MONITORING
DEVICE PRIMARY PTC
PRIMARY
SECONDARY
OPTIONAL THERMISTOR
CONNECTION
SECONDARY OPTIONAL
THERMISTOR
FEEDBACK CONNECTION
CONTROLLER
FEEDBACK DEVICE

7. MAINTENANCE
operation.

by the customer.

rectly installed.
class (T-code).
TAKE A CLOSER LOOK

+54 11 4326 5916 +91 80 4057 6666 +65 677 36238

+61 3 9561 6044 +353 21 451 9000 +27 12 653 6768
Brazil Italy Spain

+55 11 3572 0400 +39 0332 421 111 +34 902 133 240
Canada Japan Sweden

+1 716 652 2000 +81 46 355 3767 +46 31 680 060

+86 21 2893 1600 +82 31 764 6711 +41 71 394 5010

+358 10 422 1840 +352 40 46 401 +44 168 429 6600

+33 1 4560 7000 +31 252 462 000 +1 716 652 2000
Germany Norway
+49 7031 622 0 +47 6494 1948
Hong Kong Russia

+852 2 635 3200 +7 8 31 713 1811
No. 99P, 100P & 41P
CB07398-001
16
EMA ACTUATOR
L875-603
ATTACHMENT 2 – ISTALLATION DRAWING CB53763

EMA ACTUATOR
L875-603
ATTACHMENT 3 – RE-LUBRICATION PROCEDURE
CDP37236/CDS37237

ISTRUZIONI DI
LUBRIFICAZIONE
Originale

QUESTO DOCUMENTO DESCRIVE LE ISTRUZIONI DI LUBRIFICAZIONE PER MOOG EMA L875-603.
REVISIONE DOCUMENTO
La seguente tabella mostra la revisione del docuemnto:
0 Versione iniziale CAR BEB LOF Gennaio 2013

SOMMARIO
REVISIONE DOCUMENTO .................................................................................................................................. 2
SOMMARIO........................................................................................................................................................ 3
1. ISTRUZIONI DI RILUBRIFICAZIONE ............................................................................................................. 4
1.1. Introduzione ...................................................................................................................................... 4
1.2. Rilubrificazione gearset ..................................................................................................................... 4
1.3. Rilubrificazione vite a ricircolo di sfere e cuscinetti .......................................................................... 5
1.4. Rilubrificazione stelo ......................................................................................................................... 5
1.5. Operazioni conclusive ........................................................................................................................ 5
2. ALLEGATI .................................................................................................................................................... 6
1. ISTRUZIONI DI RILUBRIFICAZIONE
1.1. Introduzione
Fare riferimento al manuale dell’attuatore per la tipologia di grasso da utilizzare.
L’attuatore necessita di un ingrassaggio periodico di mantenimento, descritto nel seguente manuale.
Si raccomanda, dopo 3 anni di servizio, di fare revisionare l’attuatore da tecnici Moog al fine di sostituire
completamente il grasso esausto.
La seguente figura schematizza la posizione delle connessioni per l’ingrassaggio e la loro funzione.
1 2 3
Numero identificativo ingrassatore Componenti interessati durante l’ingrassamento
1 Gearset
2 Vite a ricircolo di sfere – Cuscinetti
3 Stelo
1.2. Rilubrificazione gear set

La seguente tabella mostra le operazioni da eseguire per la rilubrificazione gearset:

3
1.3. Rilubrificazione vite a ricircolo di sfere e cuscinetti
La seguente tabella mostra le operazioni da eseguire per la rilubrificazione a ricircolo di sfere e ciscunetti:

3
1.4. Rilubrificazione stelo

La seguente tabella mostra le operazioni da eseguire per la rilubrificazione stelo:

3
1.5. Operazioni conclusive

Si suggerisce di effettuare almeno due corse complete dell’attuatore, senza carico, per distribuire il grasso inserito con
le operazioni precedenti.
2. ALLEGATI
10
11
12
13
TAKE A CLOSER LOOK

+54 11 4326 5916 +353 21 451 9000 +46 31 680 060

+61 3 9561 6044 +39 0332 421 111 +41 71 394 5010

+43 664 144 65 80 +81 436 55 3767 +31 252 462 000

+55 11 5523 8011 +82 31 764 6711 +44 1564 784 777

+86 21 5854 1411 +352 40 46 401 +1 734 887 4250
Finland Norway
+358 9 2517 2730 +47 224 32927
France Russia
+33 1 4560 7000 +7 831 713 1811
Germany Singapore
+49 7031 622 0 +65 677 36238

+852 2 635 3200 +27 11 655 7030
India Spain
+91 80 4120 8785 +34 902 133 240
are reserved
ISTRUZIONI DI LUBRIFICAZIONE
Rev.0, Gennaio 2013 Document nr. CDP37236
RE-LUBRICATION
INSTRUCTIONS
Translation

THIS DOCUMENT DESCRIBES THE RE-LUBRICATION INSTRUCTIONS FOR MOOG EMA L875-603.
DOCUMENT REVISION
The following table lists the document revisions:
Traduzione di
0 CAR BEB LOF February 2013
CDP37236(0)
INDEX
Document revision ............................................................................................................................................ 2
INDEX ................................................................................................................................................................. 3
1. Re-Lubrication Instructions ....................................................................................................................... 4
1.1. Introduction ....................................................................................................................................... 4
1.2. Gear set re-lubrication....................................................................................................................... 4
1.3. Ball screw and bearings re-lubrication .............................................................................................. 5
1.4. Rod re-lubrication .............................................................................................................................. 5
1.5. Final step............................................................................................................................................ 5
2. Attachments .............................................................................................................................................. 6
1. RE-LUBRICATION INSTRUCTIONS
1.1. Introduction
Refer to the actuator manual for the grease type to use.
A periodical greasing maintenance is necessary for the actuator and it is described in this manual.
After 3 years of operation, it is recommended to ask for a revision of the actuator to the Moog technicians; the
purpose is to substitute completely the exhaust grease.
The following scheme describes the positions of the connections for greasing:
The following table lists the nipple greasers and their functions:
Nipple greaser ID Nr. Components involved during greasing
1 Gear set
2 Bearings & Ball screw
3 Rod
1.2. Gear set re-lubrication

The following table lists the necessary steps to perform the gear set re-lubrication:
Step Description

3
1.3. Ball screw and bearings re-lubrication
The following table lists the necessary steps for the ball screw and bearings re-lubrication:
Step Description

3
1.4. Rod re-lubrication

The following table lists the necessary steps for the rod re-lubrication
Step Description

3
1.5. Final step

It is recommended to perform at least two full strokes of the actuator, with no load, to distribute the inserted grease
with the above steps.
2. ATTACHMENTS
The following table lists the attachments
10
11
12
13
TAKE A CLOSER LOOK

+54 11 4326 5916 +353 21 451 9000 +46 31 680 060

+61 3 9561 6044 +39 0332 421 111 +41 71 394 5010

+43 664 144 65 80 +81 436 55 3767 +31 252 462 000

+55 11 5523 8011 +82 31 764 6711 +44 1564 784 777

+86 21 5854 1411 +352 40 46 401 +1 734 887 4250
Finland Norway
+358 9 2517 2730 +47 224 32927
France Russia
+33 1 4560 7000 +7 831 713 1811
Germany Singapore
+49 7031 622 0 +65 677 36238

+852 2 635 3200 +27 11 655 7030
India Spain
+91 80 4120 8785 +34 902 133 240
rved
RE-LUBRICATION INSTRUCTIONS
Rev. 0, February 2013 Document nr. CDP37237
EMA ACTUATOR
L875-603
ATTACHMENT 4 – BRUSHLESS SERVOMOTOR –
Declaration of Conformity

EMA ACTUATOR
L875-603
ATTACHMENT 5 – BRUSHLESS SERVOMOTOR – EC Type
Examination Certificate 10 ATEX 0915070X


Directive 94/9/EC
the Directive.

EN 60079-0:2009 EN 60079-1:2007 EN 60079-31:2009

JJan-Erik
Jan Erik
rik Storg
Storgaard
Storgaa
Re-issued: 2012-07-30
Notif
tiified Bod
Tel. +45 44 85 65 65, info.dk@ul.com
www.ul-europe.com
[13] Schedule
lengths.

G 3 L M 2 010 00 00 01 01 000
I – Motor Series
II – Motor Size
III – Design
M – Low voltage
V – High voltage
V – Stack Length
for G496
2 – L05 (G493) or L10 (G495) or L15 (G496)
4 – L15 (G493) or L20 (G495) or L30 (G496)
6 – L25 (G493) or L30 (G495) or L45 (G496)
8 – L40 (G493) or L50 (G495) or L60 (G496)
9 – L90 (G496)


1 2 Top Back
00 - - X -
01 X - X -
02 - X X -
03 - - - X
04 X - - X
05 - X - X
documents
Brake option
Brake Option
Low -T 1 2 Nm 14.5 Nm 22 Nm
High -T 2 4.5 Nm 22 Nm 72 Nm
Code
[13] Schedule

00 None provided X
01 X X
the documents

+40 +50 +60 +70 +80 +90 +100 +40 +50 +60 +70 +80 +90 +100
00 - - - - - - - - - - - T4 - -
01 - T4 - - - - - - - - - - - -
02 - - T4 - - - - - - - - - - -
03 T4 - - - - - - - - - - - - -
04 - - - T4 - - - - - - - - - -
05 - - - - T4 - - - - - - - - -
06 - - - - - - - T4 - - - - - -
07 - - - - - - - - T4 - - - - -
08 - - - - - - - - - T4 - - - -
09 - - - - - - - - - - T4 - - -
10 T5 - - - - - - - - - - - - -
11 - - - - - - - T5 - - - - - -
12 T6 - - - - - - - - - - - - -
13 - - - - - - - T6 - - - - - -
14 T3 - - - - - - - - - - - - -
15 - T3 - - - - - - - - - - - -
16 - - T3 - - - - - - - - - - -
17 - - - T3 - - - - - - - - - -
18 - - - - T3 - - - - - - - - -
19 - - - - - T3 - - - - - - - -
20 - - - - - - T3 - - - - - - -
21 - - - - - - - T3 - - - - - -
22 - - - - - - - - T3 - - - - -
23 - - - - - - - - - T3 - - - -
24 - - - - - - - - - - T3 - - -
25 - - - - - - - - - - - T3 - -
26 - - - - - - - - - - - - T3 -
27 - - - - - - - - - - - - - T3
+
Temperature range
-40 °C to +40 °C
See Electrical data
-20 °C to +40 °C
-40 °C to +50 °C
See Electrical data
-20 °C to +50 °C
-40 °C to +70 °C
See Electrical data
-20 °C to +70 °C
-40 °C to +80 °C
See Electrical data
-20 °C to +80 °C
[13] Schedule
For G496 motors:
-40 °C to +40 °C
See Electrical data
-20 °C to +40 °C
-40 °C to +50 °C
See Electrical data
-20 °C to +50 °C
-40 °C to +70 °C
See Electrical data
-20 °C to +70 °C
-40 °C to +80 °C
See Electrical data
-20 °C to +80 °C
-40 °C to +90 °C
See Electrical data
-20 °C to +90 °C
-40 °C to +100 °C
See Electrical data
-20 °C to +100 °C
Electrical data
For G493:
0 0 0.52 1.6
L05
359 7800 0.44 1.6 -40 to +40
T4/T135°C
0 0 3.26 13.2 -20 to +40
L40
1117 3800 2.82 13.2
0 0 0.5 1.6
L05
341 7800 0.42 1.6 -40 to +50
T4/T135°C
0 0 3.13 13.2 -20 to + 50
L40
1059 3800 2.66 13.2
0 0 0.46 1.6
L05
304 7800 0.37 1.6 -40 to +60
T4/T135°C
0 0 2.88 13.2 -20 to +60
L40
942 3800 2.37 13.2
0 0 0.41 1.6
L05
253 7800 0.31 1.6 -40 to +70
T4/T135°C
0 0 2.56 13.2 -20 to +70
L40
786 3800 1.97 13.2
0 0 0.34 1.6
L05
177 7800 0.22 1.6 -40 to +80
T4/T135°C
0 0 2.14 13.2 -20 to +80
L40
552 3800 1.38 13.2
0 0 0.43 1.6
L05
273 7800 0.33 1.6 -40 to +40
T5/T100°C
0 0 2.74 13.2 -20 to +40
L40
847 3800 2.12 13.2
0 0 0.32 1.6
L05
118 7800 0.14 1.6 -40 to +40
T6/T85°C
0 0 1.99 13.2 -20 to +40
L40
364 3800 0.91 13.2
[13] Schedule
For G495:
L10 0 0 5.79 12.2
2173 4800 4.32 12.2 -40 to +40
T4/T135°C
L50 0 0 25.39 61.2 -20 to +40
4388 2000 20.95 61.2
L10 0 0 5.47 12.2
1969 4800 3.92 12.2 -40 to +50
T4/T135°C
L50 0 0 24 61.2 -20 to +50
4046 2000 19.32 61.2
L10 0 0 5.15 12.2
1746 4800 3.47 12.2 -40 to +60
T4/T135°C
L50 0 0 22.6 61.2 -20 to +60
3682 2000 17.58 61.2
L10 0 0 4.81 12.2
1489 4800 2.96 12.2 -40 to +70
T4/T135°C
L50 0 0 21.14 61.2 -20 to +70
3283 2000 15.67 61.2
L10 0 0 4.3 12.2
1035 4800 2.06 12.2 -40 to +80
T4/T135°C
L50 0 0 18.87 61.2 -20 to +80
2604 2000 12.43 61.2
L10 0 0 5.09 12.2
1581 4800 3.15 12.2 -40 to +40
T5/T100°C
L50 0 0 22.35 61.2 -20 to +40
3474 2000 16.6 61.2
L10 0 0 4.03 12.2
645 4800 1.47 12.2 -40 to +40
T6/T85°C
L50 0 0 17.68 61.2 -20 to +40
1640 2000 7.83 61.2
For G496:
Nm
L15 0 0 13 40
3464 4000 8 40 -40 to +40
T3/T200°C
L90 0 0 70 240 -20 to +40
8378 2000 40 240
L15 0 0 13 40
3179 4000 8 40 -40 to +50
T3/T200°C
L90 0 0 66 240 -20 to +50
8378 2000 40 240
L15 0 0 12 40
2886 4000 7 40 -40 to +60
T3/T200°C
L90 0 0 64 240 -20 to +60
8378 2000 40 240
L15 0 0 11 40
2346 3200 7 40 -40 to +70
T3/T200°C
L90 0 0 58 240 -20 to +70
6053 1700 34 240
L15 0 0 10 40
1926 2800 7 40 -40 to +80
T3/T200°C
L90 0 0 53 240 -20 to +80
5027 1500 32 240
L15 0 0 9 40
1330 2300 6 40 -40 to +90
T3/T200°C
L90 0 0 46 240 -20 to +90
4241 1500 27 240
L15 0 0 8 40
928 2000 4 40 -40 to +100
T3/T200°C
L90 0 0 40 240 -20 to +100
3142 1250 24 240
[13] Schedule

L15 0 0 13 40
3464 4000 8 40 -40 to +40
T4/T135°C
L90 0 0 70 240 -20 to +40
8378 2000 40 240
L15 0 0 13 40
3179 4000 8 40 -40 to +50
T4/T135°C
L90 0 0 66 240 -20 to +50
8378 2000 40 240
L15 0 0 12 40
2622 4000 6 40 -40 to +60
T4/T135°C
L90 0 0 62 240 -20 to +60
7459 1800 39 240
L15 0 0 11 40
2346 3200 7 40 -40 to +70
T4/T135°C
L90 0 0 58 240 -20 to +70
6053 1700 34 240
L15 0 0 10 40
1926 2800 7 40 -40 to +80
T4/T135°C
L90 0 0 53 240 -20 to +80
5027 1500 32 240
L15 0 0 10 40
1875 2700 7 40 -40 to +40
T5/T100°C
L90 0 0 55 240 -20 to +40
4765 1300 35 240
L15 0 0 9 40
1256 2100 6 40 -40 to +40
T6/T85°C
L90 0 0 47 240 -20 to +40
3110 1100 27 240

25% 85%
40% 50%
60% 25%
temperature.
Routine tests
required.
[13] Schedule
[16] Report No.
Documents:
Warning Label C88053 0 2004-04-27

temperature.
50495 standard.

EMA ACTUATOR
L875-603
ATTACHMENT 6 – BRUSHLESS SERVOMOTOR – Product
Quality Assesment Notification 09 ATEX Q148848



Directive 94/9/EC
principles:

India

India

Directive.
12CA54355, Dated 2012-10-29

been given.

2015-10-27


Jan-Erik
Jan
a Erik k Storgaard
S
Sto
t ga rd any change
Tel. +45 44 85 65 65, info.dk@ul.com
www.ul-europe.com

EMA ACTUATOR
L875-603
ATTACHMENT 7 – ACTUATOR – Declaration of
Conformity

ELECTRO MECHANICAL
ACTUATOR FOR IGV
L081-601
ATTACHMENT 3 – SERVO DRIVE – Model Operations
Manual

Codice IGV 3-4-273
DSG2010 HV (400V)
M Drive Wire List
Rev.
Data
01
29-01-13
IECEx Certification Schedule Document

Preparato da Emesso da
UTC R6D
Firma Claudio Repetto Pag. 1 of 1
Data 29-01-13
ELECTRO MECHANICAL
ACTUATOR FOR IGV
L081-601
ATTACHMENT 4 – POWER CABLE DATA SHEET

4x4mm2 + 1x2x1mm2
Application :
1 6
2 BU 7
BN GNYE
4 8
WH
BK
5 BN
9
3
10
2. 4 Cores 4.0 mm2 Conductor: stranded tin plated copper 56 x 0.30 mmD
Colours: black, brown, blue, green--yellow
3. 1 Pair 2x1.0 mm2 Conductor: stranded tin plated copper 32 x 0.20 mmD
Colours: brown, white
4. Wrapping Tape
6. Wrapping Tape
9. Wrapping Tape
Printing on sheath : HUBER+SUHNER SWITZERLAND RADOX 155 85006411--zzzzzzz

+41 (0)44 952 22 11
writing. FAX +41 (0)44 952 26 40
www.hubersuhner.com
14.11.2012 / 2447 2339 Page 1/2 85 006 411 A (e)
4x4mm2 + 1x2x1mm2
Technical data:
Voltage rating U0/U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 / 1000 . . . . . . V

Cable weight per 100 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 64 . . . . . kg

14.11.2012 / 2447 2339 Page 2/2 85 006 411 A (e)
ELECTRO MECHANICAL
ACTUATOR FOR IGV
L081-601
ATTACHMENT 5 – SIGNAL CABLE DATA SHEET

5 x 2 x 0.25 mm2
Application :
1
1 6
1
2 5 2 7
2
5
3 8
3
4
4
4 3
9

2. 5 Pairs 2x0.25 mm2 Conductor: stranded tin plated copper 19 x 0.13 mmD
Two cores twisted D: 2.9 mm
Colours: brown, white, each pair numbred 1/1; 2/2; 3/3; 4/4; 5/5
3. Wrapping Tape
5. Wrapping Tape
8. Wrapping Tape
Printing on sheath : HUBER+SUHNER SWITZERLAND RADOX 155 RADOX 85006392--zzzzzzz

+41 (0)44 952 22 11
writing. FAX +41 (0)44 952 26 40
1006243 www.hubersuhner.com
15.11.2012 / 2447 2339 Page 1/1 85 006 392 A (e)
5 x 2 x 0.25 mm2
Technical data:
Conductor resistance at 20 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 88.5 . . . . . . . . .  / km
Voltage rating U0/U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 / 750 . . . . . . . V
Cable weight per 100 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 21.7 . . . kg

15.11.2012 / 2447 2339 Page 2/1 85 006 392 A (e)
PROCEDURA DI PROVA
D’ACCETTAZIONE
ATP L107
GE10-2 Attuatore elettromeccanico e unità di controllo per IGV
GE Oil & Gas P/N:
RAO 21174 – Attuatore
RAO 20259 – Unità di controllo
RAO4758037 – Power cables
RAO4758038 – Resolver cables
Version B
May 2013
MOOG | ATP L107 – REV. B – MAY 2013 | PAGE 2
INDICE
1. A proposito di Moog ............................................................................................................................................3
2. Lista delle Revisioni .............................................................................................................................................4
3. Scopo ...................................................................................................................................................................5
4. Documenti Applicabili .........................................................................................................................................6
5. Strumentatione e Attrezzatura di Prova .............................................................................................................7
6. L10 – Verifica Valore PTC .....................................................................................................................................8
7. L20 – Controllo Dimensionale ............................................................................................................................9
8. L30 – Controllo della Corsa ................................................................................................................................10
9. Predisposizione del banco per Prove Dinamiche ..............................................................................................11
10. Predisposizione Sistema COntrollo per Test .....................................................................................................20
11. METTERE IN TENSIONE IL SISTEMA ...................................................................................................................22
12. Verifica corsa, homing attuatorE, Calibrazione Analogiche di Comando e Lettura Posizione Attuatore ..........23
13. L40 – Burn in test ...............................................................................................................................................28
14. L50 – Quasi-static friction torque and No load current tests ............................................................................29
15. L60 – Current consumption at no load test .......................................................................................................30
16. L70 & L80 – Max Speed Extend/Retract Test ....................................................................................................31
17. – Backlash Test ..................................................................................................................................................32
18. L100 – Accuracy, Repeatability, Hysteresis Tests ..............................................................................................36
19. Predisposizione Banco per Prove di Forza .........................................................................................................37
20. L110 – Continuous Stall Current and Conituous Stall Force Tests .....................................................................38
21. L120 – Peak Current and Peak Force Tests ........................................................................................................39
22. L130 – Temperature Increase at Continuous Stall Force Test verificare ...........................................................40
23. L140 – Forza di Reversibilità ..............................................................................................................................41
24. Fault Conditions Check ......................................................................................................................................42
1. A PROPOSITO DI MOOG
Moog Industrial Group progetta e costruisce soluzioni ad alte prestazioni di controllo del movimento utilizzando
tecnologie elettriche, idrauliche e ibride e fornisce una consulenza di esperti in una vasta gamma di applicazioni, tra
cui test, simulazione, plastica, lavorazione dei metalli e produzione di energia.
scuderie automobilistiche globali.
Collaboriamo con le aziende più dinamiche alla progettazione e allo sviluppo di macchinari di ultima generazione.
Moog Industrial Group fa parte di Moog Inc.
Per maggiori informazioni si prega di visitare il sito www.moog.com/industrial.
Info Descrizione
Moog Moog Italiana S.r.l.
Indirizzo Via Pastore 4, 21046 Malnate (VA) - Italia
Tel + 39 0332 421 111
Fax +39 0332 429 233

2. LISTA DELLE REVISIONI

La seguente tabella mostra la lista delle revisioni:
Preparato Revisionato Approvato

Revisione Descrizione Data
da da da
A First issue AIG FAP LOF 02/13
B Modifica cap. 22 (L130) e cap. 24 BEB FAP LOF 05/13

3. SCOPO
Le prove intendono verificare la funzionalità e le prestazioni del sistema di attuazione dello NGV.
Sistema Codice Cliente Codice Moog
IGV electrical actuator system RAO 21173 L081-601 – L081-602
La seguente tabella mostra i componenti del sistema:
Componente Codice Cliente Codice Moog
Attuatore electro-meccanico RAO 21174 L875-603
Unità di controllo e posizionamento

RAO 20259 CZ 140100
per motori senza spazzole
RAO 4758037
Cavo di potenza CB 54994-1500
Cavo di segnale RAO 4758038 CB 54995-1500
Power cable Not Armored Used For the test CB57098-2000
Signal cable Not Armored Used For the test CB57097-2000

4. DOCUMENTI APPLICABILI
La seguente tabella mostra i documenti applicabili:
Documento Revisione Descrizione
EIL-133 EMA L875-603 Rev. 0 Istruzioni di Lavoro – Montaggio EMA L875-603

5. STRUMENTATIONE E ATTREZZATURA DI PROVA

La seguente tabella mostra la strumentazione e l’attrezzatura necessarie:
Item # Strumento/Attrezzatura Caratteristiche

Imm. 263-xxx
AAA Multimetro Digitale Campo misura 0…20mA
Risoluzione 0,001mA
Imm. 263-xxx
BBB Multimetro Digitale Campo misura 0…20mA
Risoluzione 0,001mA
Imm. 310-xxx
CCC Pinza amperometrica A effetto di Hall
Risoluzione 2V/20A
Imm. L291-xxx
DDD Sonda temperatura Sensore di temperatura (0÷150°) C
Precisione ± 0.1° C
Imm. 046-xxx
200 kN FS
Cella di carico HBM
EEE accuracy 0.1 % Fondo Scala
Mod. U5
(Condizionatore/ amplificatore cella di carico HBM
Mod. n. MVD2555)
sensore di posizione magnetostrittivo
Trasduttore Lineare MTS
FFF Scala (0-300) mm
Mod. RH
Risoluzione 0,002 mm
GGG Calibro Apertura > 400 mm
25 mm Fondo Scala
HHH Micrometro 1 mm/turn
0.01 mm/div
III Bilancia Precisione ± 0.5 kg
JJJ Cavo Ethernet Incrociato
6. L10 – VERIFICA VALORE PTC

Dal documento EI-L133:
Item # Attività Riferimento Strumento/Attrezzatura Requisito Notes

Verifica valore
L10 TOOL AAA  750 W @ 25°C
PTC
Misurare la resistenza con il multimetro digitale tra i cavi 9 e 10, nel Drive con morsetti (7 e 8 scollegati)
Parametro Valore
Resistenza  750 W @ 25°C
La seguente immagine mostra i morsetti dei cavi 9 e 10:
Strumento:

Imm. 263-xxx
AAA Multimetro Digitale Campo misura 0…1 KOhm
Risoluzione 0,1 Ohm
7. L20 – CONTROLLO DIMENSIONALE


Controllo Tolleranze a Verifica misure
L20 Disegno CB53763 TOOL BBB
dimensionale disegno con check list
Verificare che le dimensioni e le masse dell’attuatore e dell’unità di controllo siano in accordo con i relativi disegni:
Valore
Parametro
L875-603
Attuatore CB53763
Unità di controllo CZ140100
Verificare la rispondenza dei cavi di potenza e di segnale ai disegni:
Valore
Parametro
L875-603
Cavo di potenza CB54994-1500
Cavo di segnale CB54995-1500
Power cable Not Armored Used For the test CB57098-2000
Signal cable Not Armored Used For the test CB57097-2000

8. L30 – CONTROLLO DELLA CORSA

Controllo della TOOL FFF

L30 95+4/-0 mm
corsa TOOL GGG
Ruotare manualmente lo stelo dell’attuatore, dalla posizione tutta retratta contro il fine corsa interno, a quella tutta
estesa contro il fine corsa interno.
Misurare la corsa con il calibro:
Parametro Valore
Corsa 95+4/-0 mm
Strumento:

GGG Calibro Apertura > 400 mm
La corsa deve essere poi verificata anche sul banco di prova mediante slitta, trasduttore MTS esterno ed encoder
(simulato da resolver motore).
9. PREDISPOSIZIONE DEL BANCO PER PROVE DINAMICHE

La seguente tabella mostra quale banco e quali equipaggiamenti sono necessari per fissare l’attuatore al banco
stesso:
Elemento Codice
Assieme attrezzatura prova scorrimento libero
CB57495
servoattuatore
Assieme attrezzatura prova in forza per servoattuatore CB57591
Posizionare l’attuatore sul banco prova, come da figura seguente:
Predisporre il pin attautore

tutto rientrato avvitando lo
stelo a mano.
MOOG | ATP L107 – REV. A – FEBRUARY 2013 | PAGE 12
Connessioni Elettriche
Cablaggio Motore
Effettuare il collegamento del motore ai cavi di potenza come da figura seguente
Effettuare il collegamento del motore ai cavi di resolver come da figura seguente

Cablaggio Driver
CZ 140100 Internal Layout

CZ 140100 Internal Layout

CZ 140100 Connections Wirings

Effettuare il collegamento del sistema di comando test (Ref. 5), come come indicato:
Signal Cable
Nel Drive Effettuare il collegamento del cavo di alimentazione 400 Vac e del cavo di potenza del motore come
indicato:
Pos.2
Moog Motor Cable

Pos. 1
Power Supply Cable

Nel Drive Effettuare il collegamento del cavo Resolver come indicato:
Moog Resolver Cable

10. PREDISPOSIZIONE SISTEMA CONTROLLO PER TEST

Utilizzare i seguenti elementi:
Elemento Riferimento Azione

Selettore abilitazione Pos. 9 Posizionare fu OFF
Magnetotermico Pos. 15 Alimentare sistema di controllo test: armare magnetotermico
Cavo ethernet incrociato N.A. Connettere PC del Laboratorio Motori al sistema di comando
La seguente immagine mostra gli elementi precedenti:
Pos. 9
Pos. 15
Connettore e cavo Ethernet incrociato

Una volta collegato il PC del Laboratorio Motori al sistema di comando, eseguire le seguenti operazioni:
Operazione Riferimento
Attivare l’interfaccia MACSHMI avviando runtime con link su desktopPC Lab. Motori :
N.A.
TestNuovo_Pignone
Indirizzo IP 192.101.32.5 N.A.
La seguente immagine mostra la pagina di comando (i parametri in giallo sono modificabili):
Ref. 20 Ref. 21
Ref. 17
Ref. 13
Ref. 11
Ref. 12
Ref. 10
11. METTERE IN TENSIONE IL SISTEMA

Mettere in tensione il driver azionando l’interruttore di potenza
Verificare il valore visto dall’azionamento entrando nel menu Visualizza Variabili ,tramite tastierino DS2000XP e
scorrere i campi visualizzati sino a VBUS: 565 Vdc con Vac 400 di tensione in ingresso (Vdc Bus = Vac x 1,41).
La seguente tabella mostra lo status dell’azionamento, post messa in tensione:
Led Status Riferimento

Led di DRIVE STATUS OFF Pos. 13
Led di DRIVE _OK ON Pos. 14
Led di SYSTEM _ENABLE OFF Pos. 14
BRAKE ENABLE OFF Pos.14
La seguente misura mostra gli status dei led precedenti:
Convertitori mA/V con

isolamento galvanico
Pos. 13
Pos.14
12. VERIFICA CORSA, HOMING ATTUATORE, CALIBRAZIONE ANALOGICHE DI COMANDO E LETTURA

POSIZIONE ATTUATORE
Parametro Valore
Corsa 95 +4/-0 mm
La corsa è verificata al banco con slitta e trasduttore MTS esterno .

METODO: Durante esecuzione procedura di Homing, il sistema cerca la battuta meccanica in estensione e poi resta
in posizione per 10 secondi; durante questa pausa premere pulsante di HOME su interfaccia MACSHMI : la lettura
dei trasduttori si azzera. Attendere completamento procedura di HOME : attuatore retrae del valore dichiarato nel
parametro driver Usable Stroke e se il valore del parametro drive Home Offset è diverso da zero retrae
ulteriormente del valore di HomeOffset . Tramite interfaccia drive DS2000XP_GUI ridotta modificare i parametri:
UsableStroke e HomeOffset per aderire alla corsa meccanica massima teorica.
I due parametri interagiscono tra loro secondo lo schema seguente
Start of Usable Stroke at the end
of homing procedure
Mechanicall
End Stroke
Homing total Retract
Declared
Usable Stroke
Mechanical
End Stroke
Extend
Post Home Additional

If enabled , check extra stroke behind
HomeOffset+UsableStroke and then go
back to HomeOffset+UsableStroke
Home Offset
Valori di riferimento per attuatore IGV
Parametro MACSHMI DRVER
Usable Stroke - 95mm
Home Offset - 10mm
UsableStroke Normalmente usiamo una corsa di test di 95mm.
Home Offset poiché corsa meccanica teorica massima è di 99mm impostiamo 10mm ; in questo modo la corsa
percorsa sarà pari a quella teorica e il trasduttore MTS ritornerà il valore effettivo della corsa meccanica attuatore.
Questa è l’interfaccia DS2000XP_GUI ridotta

semplificata da cui è possibile modificare i due
parametri citati.
ATTENZIONE: predisporre collegamento con cavo

95
seriale tra PC e driver al connettore J1/XP (Rs 232)
Predisponiamo l’interfaccia MACSHMI per aderire alla procedura

La quota impostata come UsableStroke deve corrispondere all’impostazione dei parametri di controllo del sistema
comando MaxPosSet(Ref_20) e MaxStroke(Ref_21) nella pagina interfaccia sistema comando MACSHMI
TestNuovo_Pignone. Ad ogni modifica dell’ UsableStroke ricordarsi di aggiornare MaxPosSet e MaxStroke
nell’interfaccia MACSHMI con il medesimo valore. In caso contrario la corsa non sarà scalata correttamente col
comando creando un disallineamento progressivo tra comando e corsa effettivamente percorsa.
Assicuriamoci che il valore di comando posizione sia a zero mm in ManPosSet cioè RampOut=0 che dovrebbe
corrispondere a un valore teorico in mA di 4 in Ao2(mA) . Questo in realtà dovrà essere diverso e maggiore di 4mA
per compensare gli offset delle varie porte analogiche di ingresso e uscita coinvolte nel trasferimento del comando
da sistema controllo test ad azionamento: Usare Ao2_Offset per ottenere quanto sopra.
AZIONI: Attiviamo procedura di Homing:
NOTA: La procedura di HOMING viene eseguita solo alla prima abilitazione azionamento dopo che questo è stato
spento completamente e riacceso.
1. Posizionare selettore ENABLE nella posizione di ON

2. Attivare pulsante ritentivo su interfaccia MACSHMI <Drive Enable> Ref _10
3. Il led del relè SYSTEM_ENABLE e BRAKE_ENABLE(Ref_14) si deve accendere e la procedura di HOMING
deve iniziare con un movimento in estensione a cercare la battuta meccanica esterna
4. Quando raggiunta verrà mantenuta per 10 secondi; durante questo tempo premere pulsante <HOMED >
sull’interfaccia MACSHMI
5. Attendere che l’attuatore si retrae della corsa dichiarata in UsableStroke più quella dichiarata in
HomeOffset
6. L’attuatore deve raggiungere la battuta meccanica indietro e la posizione visualizzata dal trasduttore MTS
rappresenta la corsa meccanica a meno del segno negativo
HOMING
Procediamo ora a eseguire la Homing effettiva che ci servirà nei test successivi.
Tramite interfaccia DS2000XP_GUI ridotta riportiamo il parametro drive HomeOffset al valore zero
Predisponiamo l’interfaccia MACSHMI per aderire

alla procedura
La quota impostata come UsableStroke deve
95 corrispondere all’impostazione dei parametri di
controllo del sistema comando MaxPosSet(Ref_20)
1 e MaxStroke(Ref_21) nella pagina interfaccia
sistema comando MACSHMI
TestNuovo_Pignone. Ad ogni modifica dell’
UsableStroke ricordarsi di aggiornare MaxPosSet e
MaxStroke nell’interfaccia MACSHMI con il
medesimo valore. In caso contrario la corsa non
sarà scalata correttamente col comando creando
un disallineamento progressivo tra comando e
corsa effettivamente percorsa.
Assicuriamoci che il valore di comando posizione sia a zero mm in ManPosSet cioè RampOut=0 che dovrebbe
corrispondere a un valore teorico in mA di 4 in Ao2(mA) . Questo in realtà dovrà essere diverso e maggiore di 4mA
per compensare gli offset delle varie porte analogiche di ingresso e uscita coinvolte nel trasferimento del comando
da sistema controllo test ad azionamento: Usare Ao2_Offset per ottenere quanto sopra.
AZIONI: Attiviamo procedura di Homing:
NOTA: La procedura di HOMING viene eseguita solo alla prima abilitazione azionamento dopo che questo è stato
spento completamente e riacceso. Ogni volta che si esegue una modifica all’installazione sulla slitta di test la
procedura di Homing deve essere ripetuta.
1. rilasciare pulsante HOMED su interfaccia MACSHMI

2. posizionare selettore ENABLE nella posizione di ON
3. attivare pulsante ritentivo su interfaccia MACSHMI <Drive Enable> Ref _10
4. il led del relè SYSTEM_ENABLE e BRAKE_ENABLE(Ref_14) si deve accendere e la procedura di HOMING
deve iniziare con un movimento in estensione a cercare la battuta meccanica esterna
5. Quando raggiunta verrà mantenuta per 10 secondi
6. Attendere che l’attuatore si retrae della corsa dichiarata in UsableStroke
7. La posizione in cui si arresta diventa posizione di parcheggio utilizzata ad ogni evenienza di guasti, secondo
specifica FAULT CONDITION CHECK presente al termine di questo documento
Confermiamo quindi che l’asse ha completato l’HOMING forzando a ON il pulsante sw HOMED nell’interfaccia
MACSHMI
Con L’attuatore in posizione di parcheggio/Home:

misurare il valore effettivo della corrente erogata sia dal comando di posizione che dal monitor di posizione attuale
con tester in serie: campo di escursione 4÷20 mA
NOTA: se il led di DRIVE_OK non si accende pur avendo i leds di STATUS (Pos_13) del driver spenti è probabile che il
valore in mA del comando di posizione, letto anche dal multimetro digitale, risulta inferiore ai 4 mA all’ingresso
azionamento;
È necessario calibrare le analogiche In (Ref_17) e Out (Ref_13) perché i valori letti siano allineati con i valori di
posizione SSI (Ref_11) e ENC (Ref_12) che ora sono a zero mm.
Si deve agire su Offset e valori Max e Min (Ref_13) dell’uscita analogica perché il valore dell’uscita resti superiore a
4mA e inferiore a 20mA (come lettura su multimetro digitale Comando Posizione) quando attuatore è
rispettivamente retratto a zero(posizione parcheggio) ed esteso alla corsa massima dichiarata nel parametro
UsableStroke .
13. L40 – BURN IN TEST


100 cycles 0-
(pos. loop-delay
Drive CZ140100+ slitta 1.680-0 RPM in
L40 Burn in test Δt 1 s)
per prove dinamiche 95 mm stroke
Posizionare l’attuatore a centro corsa (55 mm), impostando il valore ManPosSet a 55.
Impostare il Generatore di Forme d’onda come segue:
Parametro Valore
ONDA 2 = quadra (equivalente a 70 mm/s)
FRQ 0,2 Hz = garantisce 10 s di corsa alla massima velocità
OFFSET 47,5 mm
AMP 47,5 mm
Impostare il trigger Data Logger come Trigger_UP e settare la soglia a 94,5, essendo la corsa massima attuata
95 mm.
Nel data Logger impostare il tempo di registrazione a 25 s. (plot speed and position Vs. time)
Abilitare il generatore d’onda dopo essersi assicurati che .b_SMTH_Enb sia abilitato: 1, r_SM_Rate=0,5
mm/periodo_onda questo assicurerà una rampa sulla variazione di ampiezza all’uscita generatore rendendo privo di
contraccolpi l’inizio del moto.
ATTENZIONE: l’attuatore si muove alla sua velocità massima operativa ”PERICOLO” eseguendo tutta la corsa
impostata. Questo permette di portare la temperatura del sistema a un valore tale da ridurre gli attriti dovuti alla
viscosità del grasso di lubrificazione. La temperatura di circa (40÷45)° C, consente di procedere al rilievo delle
correnti e forze di attrito dinamiche con attuatore a 50 rpm = 2mm/s.
Al termine, disabilitare il generatore.
14. L50 – QUASI-STATIC FRICTION TORQUE AND NO LOAD CURRENT TESTS


along the
Quasi-static Quasi-static friction
entire stroke
friction torque torque  3,52 Nm
L50 Tool CCC @ 50 RPM
and No load No load current  2
(motor
current tests ARMS
speed)
Parametro Valore
ONDA 1 triangolare rampa posizione costante
FRQ 0,011 Hz = 2mm/s => 50rpm
OFFSET 47,5 mm
AMP 47,5 mm
95 mm.
Nel data Logger impostare il tempo di registrazione a 100 s.
Abilitare il generatore onda dopo essersi assicurati che .b_SMTH_Enb sia abilitato: 1, r_SM_Rate=0,5
mm/periodo_onda questo assicura una rampa sulla variazione di ampiezza all’uscita generatore, rendendo privo di
contraccolpi l’inizio del moto. Salvare registrazione DataLogger in un file con nome secondo il formato a seguire:
“L875-603_snL101_NoLoad@50rpm”
15. L60 – CURRENT CONSUMPTION AT NO LOAD TEST


Current
L60 consumption at Tool CCC  2,5 ARMS 70 mm/s
no load test
Parametro Valore
FRQ 0,370 Hz = 70mm/s => 1680rpm
OFFSET 47,5 mm
AMP 47,5 mm
Impostare il trigger Data Logger come Trigger_UP e settare la soglia a 94,5 mm, essendo la corsa massima attuata
95 mm.
Abilitare il generatore onda dopo essersi assicurati che .b_SMTH_Enb sia abilitato: 1, r_SM_Rate = 0,5
16. L70 & L80 – MAX SPEED EXTEND/RETRACT TEST


Max speed Max speed (U
L70 TOOL AAA  70 mm/s
extend test 400 Vac  5%)
Max speed Max speed (U

L80 TOOL AAA  70 mm/s
retract test 400 Vac  5%)
Posizionare l’attuatore a centro corsa (47,5 mm), impostando il valore ManPosSet a 47,5.
Parametro Valore
FRQ 0,370 Hz = 70mm/s => 1680rpm
OFFSET 47,5 mm
AMP 47,5 mm
95 mm.
Abilitare il generatore onda dopo essersi assicurati che .b_SMTH_Enb sia abilitato: 1, r_SM_Rate = 0,5
NOTA: Clarification of Vac supply voltage detection

Driver doesn’t detect directly the supply voltage for threshold value check operations.
The driver detects the DC Bus voltage on Motor control line.
The relation between DC Bus Voltage and VAC line is VAC Line * 1,41 = VDC Bus with a tolerance of +/- 5%
For example:
360 VAC * 1,41 = 507,6 VDC Bus +/- 5%
17. – BACKLASH TEST


TOOL AAA + Resolver
L90 Backlash test  0,2 mm
motore
Portare l’attuatore alla corsa: ManPosSet = 55 mm
La verifica del gioco attuatore viene eseguita utilizzando il comando manuale di posizione ManPosSet e impostando
degli step di posizione tali da incrementare la posizione e generando un precarico del cinematismo tale da
recuperare eventuali giochi.
Successivamente, si eseguono gli stessi step, ma in decremento ritornando alla posizione di partenza.
Durante questi step, si devono registrare i valori della posizione sia del trasduttore esterno di posizione MTS SSI che
dell’encoder motore.
Per ottenere un movimento morbido e stabile privo di overshoot, portare il valore delle rampe di accelerazione e
decelerazione a valori bassi RiseRamp(mm/s) e FallRamp(mm/s) = 0,5 mm/s
La seguente tabella mostra i dati ricavati per step di 0,05 mm:
Item # SSI [mm] ENC [mm] CMD [mm] SSI-ENC [mm] Max-Min [mm]
1 55.073 55.03 55.05 0.043 Min
2 55.127 55.083 55.1 0.044
3 55.184 55.137 55.15 0.047
4 55.247 55.197 55.2 0.050
5 55.193 55.137 55.15 0.056 Max
6 55.134 55.081 55.05 0.053
7 55.81 55.036 55.0 0.045
Questi valori vengono poi inseriti nel foglio di calcolo, di seguito descritto, nelle colonne P,Q,R,S e nelle colonne
T,U,V vengono rispettivamente calcolati i valori di Diff.Max e Diff.Min e Backlash
Backlash = SSI-ENCMax – SSI-ENCMin = (0,056 – 0,043) mm = 0,013 mm
Confrontarlo con il valore massimo ammissibile:
Backlash  0,4 mm
FOGLIO DI CALCOLO
Per i test di Backlash , Isteresi e ripetibilità è necessario l’utilizzo di un modello di foglio di calcolo. Questo è
attivabile tramite collegamento su desktop PC lab. Motori : CollegamentoPlotIsteresi.XLS.
Al suo interno troviamo dei fogli calcolo , uno per ogni attuatore. Facendo click col tasto dx mouse sulla linguetta
dell’ultimo foglio si apre un menu che permette di selezionare la voce InserisciFoglio; Selezioniamola e si aprirà una
finestra di impostazione :
Impostiamo:
 Dopo Foglio Corrente
 Da File
Questa ultima selezione aprirà una ulteriore finestra di impostazione per la selezione del file dati da usare.
Il file dati sarà un file formato ASCII salvato come risultato del plot rilevamento corsa fatto da DataLogger con profilo
posizione forma triangolare e velocità 2mm/s come descritto al punto L100.
Selezionato il file e inserito , comparirà una finestra per specificare il formato del file selezionato e permettere una
importazione dati appropriata.
In questo caso la formattazione specificata dovrebbe dare come risultato una visualizzazione campi come in figura
qui accanto.
Confermare con OK
Il foglio viene creato come Foglio1; quindi procediamo a rinominarlo

18. L100 – ACCURACY, REPEATABILITY, HYSTERESIS TESTS


Accuracy,
2 cycles full
L100 repeatability, TOOL AAA  1,0 mm
stroke
hysteresis tests
Per eseguire il grafico dell’isteresi dell’attuatore (intesa come differenza tra Comando posizione e Posizione reale
rilevata con trasduttore lineare MTS SSI), è necessario rilevare i dati delle due grandezze lungo tutta la corsa
dell’attuatore; la corsa viene eseguita alternativamente in estensione e retrazione.
Parametro Valore
Velocità massima 50 rpm
L’escursione della corsa deve essere eseguita a una velocità di 2 mm/s, pari a 50 rpm motore.
Il Datalogger deve essere impostato con tempo totale di acquisizione pari a 100 s e il trigger è TriggerUp = 94,5mm.
Posizionare l’attuatore a centro corsa (47,5 mm), impostando il valore ManPosSet a 47,5.
Parametro Valore
ONDA 1 triangolare
FRQ 0,009 Hz
OFFSET 47,5 mm
AMP 47,5 mm
Abilitare il generatore onda dopo essersi assicurati che .b_SMTH_Enb sia abilitato: 1,
r_SM_Rate = 0,5 mm/periodo_onda questo assicura una rampa sulla variazione di ampiezza all’uscita generatore,
rendendo privo di contraccolpi l’inizio del moto. Salvare registrazione DataLogger in un file con nome secondo il
formato a seguire:
“L875-603_snL101_Isteresi.asc”
Formato ASCII necessario all’importazione in foglio Excel, per tracciamento isteresi.
19. PREDISPOSIZIONE BANCO PER PROVE DI FORZA

L’attuatore deve essere montato sulla struttura a castello con cella di carico.
Deve essere smontato dalla slitta senza spegnerlo, solo disabilitato, in modo che non perda l’homing.
La seguente immagine mostra il collegamento necessario (vedere disegno n° CB57591):
Avvitare forchetta con occhiello sulla cella fino in fondo e posizionare il taglio come in figura, puntare le viti delle
spallette senza tirarle in modo che si possa allineare l’occhiello nel taglio e tenerlo equidistante.
Abilitare drive e muovere di 5mm in estensione poi a piccoli step rientrare fino ad ottenere l’allineamento
necessario ad infilare la spina di accoppiamento(normalmente il rientro è di 2,5mm circa).
Per compensare le quote agire sullo stelo avvitandolo e contemporaneamente svitando la forchetta sulla cella:
poiché i due hanno filetti con passi diversi si centrano automaticamente. Ricordarsi che non possiamo lavorare con
lo stello sullo zero perché dobbiamo sviluppare una forza in tiro e spinta e ci serve della corsa anche in tiro.
Assicurarsi che il fissaggio sia appropiato: tutte le viti dell’insieme struttura ben tirate, altrimenti si generano delle
elesticità che creano problemi nella ricerca simmetrica dei valori di forza in tiro e spinta.
Inizialmente si dovrà annullare la lettura della cella agendo sul comando manuale. Per orientare la forza in positivo e
negativo agire sul comando manuale di posizione in modo da modulare il comando 4÷20 mA opportunamente:
estensione carica cella in positivo; retrazione carica cella in negativo.
20. L110 – CONTINUOUS STALL CURRENT AND CONITUOUS STALL FORCE TESTS

Continuous stall
TOOL CCC 6,8  0,2 ARMS
current set and Extend and
L110
Continuous stall TOOL EEE  + 18,6kN, retract
force tests  -18,6kN
Scopo del test: generare una forza di spinta e tiro tale da sviluppare un valore di corrente massimo di 6,8  0,2 ARMS.
A questa corrente deve corrispondere un valore letto della cella di carico di 18,6 kN, sia in tiro, sia in spinta.
La misura della corrente deve essere fatta con sonda di corrente a effetto Hall, con lo strumento a seguire:

Imm. 310-xxx
CCC Current probe/Pinza amperometrica A effetto di Hall
Risoluzione 2V/20A
Per impostare il generatore d’onda, trovare la posizione per lettura quasi nulla della cella e impostare il valore come
offset del generatore d’onda.
Selezionare una forma d’onda quadra con periodo di 20 s, tale da permettere alla cella di carico di stabilizzare la
lettura.
Parametro Valore
ONDA 2 quadrata
FRQ 0,05 Hz
OFFSET ManPosSet
AMP 0 mm
Abilitare il generatore onda dopo essersi assicurati che .b_SMTH_Enb sia disabilitato: 0.; e che rWGOnHysteresys
=120;
Incrementare l’ampiezza dell’onda a step di 0,1 mm e trovare il valore tale per cui la cella sviluppa 18,6 kN.
Calibrare il valore di offset per ottenere una lettura simmetrica (l’offset permette di compensare l’isteresi della cella
di carico e centrare lo sviluppo della forza in spinta e tiro).
Raggiunto il valore di forza a specifica (18,6 kN), misurare le correnti nelle tre fasi del motore, in corrispondenza di
una periodo di tiro e di spinta.
Essendo in condizioni statiche, le correnti nelle fasi del motore si suddividono in modo che la somma dei valori
positivi e negativi si equivale e corrispondono a 6,8 ARMS. La corrente misurata con sonda non ha una forma
sinusoidale a causa della condizione di staticità, ma ha una forma continua. Quindi il valore letto deve essere riferito
al valore equivalente di corrente di picco (Multimetro Digitale impostato per misure Vdc con sonda 2V/20A):
[6,8 ARMS * 1,41 = 9,59 APK]
21. L120 – PEAK CURRENT AND PEAK FORCE TESTS


Peak current set
and Peak force TOOL CCC 7,2  0,2 ARMS Extend and
L120
at peak current retract
TOOL EEE  20 KN,  -20 kN
tests
Ampliando il valore di ampiezza dell’onda quadra, si cerca il valore di Forza Picco a specifica (20 kN), e si eseguono le
misure di corrente come per la prova di forza continuativa, avendo come riferimento i seguenti valori:
7,2 ARMS
[7,2 ARMS * 1,41 = 10,2 APK.]
22. L130 – TEMPERATURE INCREASE AT CONTINUOUS STALL FORCE TEST

TOOL AAA
Temperature
increase at TOOL CCC Tmotor rises on
L130 240 min
continuous stall TOOL DDD Tamp < 30° C
force test
TOOL EEE
Comandare l’attuatore in modo che sviluppi il massimo carico di compressione (stelo in estensione).
Mantenere il comando e rilevare la temperatura del motore, la temperatura del paramentro DRIVE:
“IGBT_Temperatur” e la temperatura ambiente a intervalli di 15 min.
Mettere a grafico i valori e verificare che, trascorsi 135 min, l’incremento di temperatura del motore rispetto
all’ambiente sia minore di 30 ° C.
Si ritorna alle stesse condizioni della prova di forza continuativa: disabilitare il generatore d’onda.
Riportare il valore di ManPosSet al valore di offset impostato nel generatore onda, aumentato del valore impostato
nell’ampiezza dell’onda quadra.
Questo genera un valore di forza di 18,6 kN e una corrente corrispondente di 6,8 ARMS ( 9,59 APK)
Le correnti nelle tre fasi si suddividono in positive e negative e la somma delle positive deve eguagliare la somme
delle negative.
In queste condizioni, devono essere rilevate le temperature iniziali del motore (se necessario dovrà essere
raffreddato o lasciato raffreddare per soddisfare le condizioni iniziali del test specificate sopra).
23. L140 – FORZA DI REVERSIBILITÀ


Back driving
L140 TOOL EEE > 500 N Force tension
force test
Disabilitare driver e allentare completamente le viti fissaggio spallette.

Abilitare drive con comando per estensione a una quota di 8÷10 mm.
In questo modo si crea una distanza tra la flangia e le spallette.
Spegnere completamente l’azionamento senza disabilitarlo: si evita che l’attuatore venga riportato in parcheggio (ci
sarà comunque un piccolo ritorno prima che si spenga completamente).
In assenza di coppia motore, tirare le viti di fissaggio spallette in croce e monitorare la forza sulla cella di carico.
La lettura della forza parte da un minimo determinato dal peso dell’attuatore e aumenta gradualmente
all’aumentare del tiro viti fino a un valore massimo dopo il quale cedono le forze di reversibilità e questa diminuisce.
Il valore massimo letto diminuito del valore iniziale determinato dal peso attuatore è la forza di reversibilità.
La misura attesa è pari a:
Parametro Valore
Forza di reversibilità > 500 N

24. FAULT CONDITIONS CHECK

Parametri impostati e collaudati di fabbrica sul Drive CZ140100
Funzione collaudata (a cura Moog Italiana - sede di Casella) e Valori

Parametro Drive CZ140100
rilevati per CZ140100
Bassa tensione d’alimentazione - Drive holds current position

- The drive will be disabled and brake activated
Input Power is in the range between < 340 VAC - Drive OK signal disabled
and >320 VAC - When a new Drive Enable command is supplied the Homing
Tolerance applied +/- 5% VAC procedure will start
Bassa tensione d’alimentazione - Drive holds current position

- The drive will be disabled and brake activated
Input Power is under a minimum threshold value
- Drive OK signal disabled
<320 VAC
- When a new Drive Enable command is supplied the Homing
Tolerance applied +/- 5% VAC procedure will start
Sovratemperatura Drive
La temepratura esterna supera I 55° C - Il paramentro “Warning di temperature IGBT” è impostato a
97° C, corrispondente a una temepratura esterna di 56° C
Il drive mantiere la posizione corrente e aziona il
freno
Simulare le avarie elencate e verificare il conseguente comportamento del sistema:
N° Avaria Simulata Metodo di Simulazione Comportamento in Avaria
Applicare corrente di comando

Loss of position command
< 4 mA and > 20 mA - Actuator holds current position
Comando analogico fuori
- The drive will be disabled and brake
M10 campo (4-20 mA) Comandare in manuale una
activated
posizione oltre quella massima e
Analog command signal out - Drive OK signal disabled
modificare il limite massimo
of range
dell’uscita analogica
- Actuator holds current position
Motor overtemperature activated
Apertura contatto termo-
M20 - Drive OK signal disabled
Sovratemperatura motore resistenza PTC motore (n°7o8)
When the Reset the Homing procedure
will start
Drive overtemperature activated
Funzione collaudata (a cura Moog
Sovratemperatura Drive Italiana - sede di Casella)
- When a new Drive Enable command
is supplied the Homing procedure will
start
-
N° Avaria Simulata Metodo di Simulazione Comportamento in Avaria
Ruotare 1,5 giri antiorario lo stelo - Actuator holds current position

dopo procedura di zero (-15 mm di - The drive will be disabled and brake
Extension stroke lower
riposizionamento) activated
than assigned value
M40 Factory Position Error Thresholds: - Drive OK signal disabled
Corsa in estensione minore - When a new Drive Enable command
di quella rilevata Fault 2mm @ 10s is supplied the Homing procedure will
Warning 1mm @ 10s start

Ruotare 1,5 giri orario lo stelo dopo - The drive will be disabled and brake
Retraction stroke lower procedura di zero (+15 mm di
than assigned value activated
M50 riposizionamento) - Drive OK signal disabled
Corsa in retrazione minore Factory Position Error Thresholds: - When a new Drive Enable command
di quella rilevata Fault 2mm @ 10s is supplied the Homing procedure will
Power Low Voltage - Actuator holds current position
Bassa tensione
activated
d’alimentazione Funzione collaudata (a cura Moog
Italiana - sede di Casella)
When the Input Power is - When a new Drive Enable command
out of range but still over a is supplied the Homing procedure will
minimum threshold value start
Power Critical Low Voltage - Actuator holds current position

Bassa tensione
activated
d’alimentazione Funzione collaudata (a cura Moog
Italiana - sede di Casella)
When the Input Power is - When a new Drive Enable command
out of range and under a is supplied the Homing procedure will
minimum threshold value start
IGBT Fault activated
M80 Avaria stadio di potenza Corto circuito tra due fasi - Drive OK signal disabled
(IGBT) - When a new Drive Enable command
start
M90
Sconnessione cavo segnale; - Actuator holds current position

Actuator Fault sconnessione di un qualunque - The drive will be disabled and brake
contatto di resolver (pin1 resolver activated
M100 Loss of actuator enable/trip motore) - Drive OK signal disabled
command (also Position - When a new Drive Enable command
and Fault Feedback error) Factory Position Error Thresholds:
Fault 2mm @ 10s
PROCEDURA DI
COLLEGAMENTO
ELETTRICO
L081-601/L081-602
Originale
Rev.1, Aprile 2013
QUESTO DOCUMENTO DESCRIVE LE PROCEDURA DI COLLEGAMENTO ELETTRICO DEL PRODOTTO MOOG

L081-601/L081-602.
( English version CDP37913)

INDICE REVISIONI
La seguente tabella mostra l’indice di revisione:
Revisione Descrizione Preparato Controllato Approvato Data
0 Versione iniziale FAP BEB LOF Marzo 2013
Aggiunta di
1 FAP BEB LOF Aprile 2013
informazioni
SOMMARIO
Indice revisioni................................................................................................................................................... 2
Sommario .......................................................................................................................................................... 3
1. Scopo ......................................................................................................................................................... 4
2. Riferimenti ................................................................................................................................................. 5
3. Responsabilità ........................................................................................................................................... 6
4. Connessioni elettriche ............................................................................................................................... 7
4.1. Cablaggio completo ........................................................................................................................... 7
4.2. Cablaggio motore .............................................................................................................................. 8
4.3. Cablaggio Resolver&PTC .................................................................................................................. 11
4.4. Cablaggio morsetto PE Motore ....................................................................................................... 14
4.5. Cablaggio Driver .............................................................................................................................. 15
5. Allegati ..................................................................................................................................................... 20
1. SCOPO
La presente specifica descrive il processo di collegamento elettrico tra Drive CZ140100 e attuatore L875-603,
mediante cavi di potenza e di segnale.
Il sistema oggetto della specifica è il seguente:
Sistema Codice Cliente Codice Moog
IGV electrical actuator system RAO 21173 – RAO 21196 L081-601/L081-602
La seguente tabella mostra i componenti del sistema:
Componente Codice Cliente Codice Moog
Attuatore electro-meccanico RAO 21174 L875-603
Unità di controllo e posizionamento

RAO 20259 CZ 140100
per motori senza spazzole
Cavo di potenza RAO 4758037 CB 54994-1500
Cavo di segnale RAO 4758038 CB 54995-1500
Cavo di potenza non armato Utilizzato per test CB57098-2000
Cavo di segnal non armato Utilizzato per test CB57097-2000

2. RIFERIMENTI
La seguente tabella mostra i documenti applicabili:
Documento Revisione Descrizione
ServoMotors_InstallInstr_RevG.pdf G Manuale servo motore
CDS37112_L081-601_IM-Drive.pdf 1 Manuale servo drive
CDS37897_L875-603_MIM.pdf 0 Manuale servo attuatore
DOC-0000413342 power.pdf - Data sheet cavo potenza
CB54994.pdf Disegno cavo potenza
DOC-0000413459 signal.pdf - Data sheet cavo segnale
CB54995.pdf Disegno cavo segnale

3. RESPONSABILITÀ
È responsabilità del personale incaricato di applicare i contenuti della presente specifica.
Il personale addetto al cablaggio deve essere in possesso dei requisiti e delle informazioni tecniche necessari allo
svolgimento al’operazione e deve essere a conoscenza delle disposizioni in materia di pericoli e rischi.
Il personale deve essere in grado di prendere contromisure in caso di incidente.
Il personale deve indossare gli opportuni DPI (Dispositivi di Protezione Individuale).
Il personale non autorizzato non deve avvicinarsi al gruppo di potenza durante le operazioni di funzionamento e
gestione del sistema.
4. CONNESSIONI ELETTRICHE
4.1. Cablaggio completo

Per il cablaggio completo del sistema, fare riferimento all’Allegato 1:
Allegato Documento Revisione Descrizione
1 CB62738.pdf rev.A Electrical connections for L081-601 and L081-602
Il sistema è schematizzabile come a seguire:

4.2. Cablaggio motore
Il seguente schema mostra gli elementi (A) del sistema sottoposti a cablaggio:
La seguente figura mostra la necessaria apertura del motore per effettuare il cablaggio:
EMA L875-603_MOTORE – Apertura Cover

La seguente immagine mostra lo schema dei Terminal blocks del motore:
EMA L875-603_MOTORE – Terminal blocks (schema)

La seguente immagine mostra i terminal blocks del motore:
EMA L875-603_MOTORE – Terminal blocks

La seguente immagine mostra il collegamento del motore ai cavi di potenza:
EMA L875-603_MOTORE – Collegamento cavi di potenza CB 54994-1500 (RAO 4758037)

4.3. Cablaggio Resolver&PTC
Il seguente schema mostra gli elementi del sistema (B) sottoposti a cablaggio:
La seguente figura mostra la necessaria apertura del motore per effettuare il cablaggio:
EMA L875-603_MOTORE – Apertura cover

La seguente immagine mostra lo schema dei Terminal blocks del resolver&PTC:
EMA L875-603_RESOLVER&PTC – Terminal blocks (schema)

La seguente immagine mostra i terminal blocks di Resolver&PTC:
EMA L875-603_RESOLVER&PTC – Terminal blocks

La seguente immagine mostra il collegamento di Resolver&PTC ai cavi disegnale:
EMA L875-603_RESOLVER & PTC – Collegamento cavi di segnale CB 54995-1500 (RAO 4758038)
4.4. Cablaggio morsetto PE Motore
La seguente figura mostra come effettuare il collegamento con il morsetto PE:
EMA L875-603_PE - Posizione del morsetto di PROTECTIVE EARTH
Posizione del morsetto di PROTECTIVE EARTH esterno

4.5. Cablaggio Driver
Il seguente schema mostra gli elementi del sistema (C, D, E, F) sottoposti a cablaggio:
La seguente figura mostra il layout interno del drive:
DRIVE CZ 140100 – Layout interno

La seguente figura mostra la connessione dei cavi:
DRIVE CZ 140100 – Connessione ai cavi di potenza e di segnale

La seguente figura mostra il collegamento del cavo di potenza del motore e freno:
DRIVE CZ 140100 –- Collegamento cavo di potenza MOTOR/BRAKE CB 54994-1500 (RAO 4758037)

(cavo non armato per test CB57098)
La seguente figura mostra il collegamento del cavo di segnale con RESOLVER&PTC:
DRIVE CZ 140100 –- Collegamento cavo di segnale RESOLVER&PTC CB 54995-1500 (RAO 4758038)

(cavo non armato per test CB57097)
La seguente figura mostra i collegamenti da utilizzarsi per connettere il ENGINE CONTROLLER (escluso dalla
fornitura):
DRIVE CZ 140100 –- Connessione con ENGINE CONTROLLER (cavi esclusi dalla fornitura)
La seguente figura mostra il collegamento con il POWER SUPPLY a 400 V AC (escluso dalla fornitura):
DRIVE CZ 140100 –- Connessione con POWER SUPPLY (cavo escluso dalla fornitura)
Posizionare il terminale della connessione PROTECTIVE EARTH esterno in uno dei quattro punti di fissaggio del
contenitore metallico del Drive.
La seguente figura mostra un esempio di possibile connessione:
Terminale connessione PROTECTIVE EARTH esterno: fissaggio al contenitore metallico del Drive
.
5. ALLEGATI
2 MRE37113_L081-601_602_ECS.pdf Drive Electrical connections Scheme
3 MRE37114_L081-601_602_TBDCD.pdf Drive Terminal Blocks Drive Connections Diagram
4 MRE37118_L081-601_602_WD.pdf Drive Wiring Diagram
10
11
12
13
TAKE A CLOSER LOOK

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+61 3 9561 6044 +39 0332 421 111 +41 71 394 5010

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+86 21 5854 1411 +352 40 46 401 +1 734 887 4250
Finland Norway
+358 9 2517 2730 +47 224 32927
France Russia
+33 1 4560 7000 +7 831 713 1811
Germany Singapore
+49 7031 622 0 +65 677 36238

+852 2 635 3200 +27 11 655 7030
India Spain
+91 80 4120 8785 +34 902 133 240
PRODOTTO
Rev. , Documento nr.
ELECTRICAL CONNECTIONS
PROCEDURE
L081-601/L081-602
Translation
Rev.0, April 2013
THIS DOCUMENT DESCRIBES THE DESCRIVE LE ELECTRICAL CONNECTIONS PROCEDURE OF THE MOOG PRODUCT
L081-601/L081-602.
(Italian version CDP37912)

REVISION INDEX
The following table lists the revision index:
Revision Description Preparared Checked Approved Date
0 First issue FAP BEB LOF April 2013

SUMMARY
Revision index .................................................................................................................................................... 2
Summary............................................................................................................................................................ 3
1. Purpose ...................................................................................................................................................... 4
2. References ................................................................................................................................................. 5
3. Responisibility ............................................................................................................................................ 6
4. Electrical connections ................................................................................................................................ 7
4.1. Complete wiring ................................................................................................................................ 7
4.2. Motor wiring ...................................................................................................................................... 8
4.3. Resolver&PTC wiring ....................................................................................................................... 11
4.4. Motor PE terminal ........................................................................................................................... 14
4.5. Driver wiring .................................................................................................................................... 15
5. Attachments ............................................................................................................................................ 20
1. PURPOSE
The above procedure describes the electrical connections procedure between the Drive CZ140100 and the
actuator L875-603 (using power and signal cables).
The system in object is the following:
System Customer Code Moog Code
IGV electrical actuator system RAO 21173 – RAO 21196 L081-601/L081-602
The following table lists the components of the system:
Component Customer Code Moog Code
Eletro Mechanical Actuator RAO 21174 L875-603
Control unit and positioning for

RAO 20259 CZ 140100
brushless motors
Power cable RAO 4758037 CB 54994-1500
Signal cable RAO 4758038 CB 54995-1500
Power cable not armoured Used only for test CB57098-2000
Signal cable not armoured Used only for test CB57097-2000

2. REFERENCES
The following table lists the applicable documents:
Document Revision Description
ServoMotors_InstallInstr_RevG.pdf G Serv o motor manual
CDS37112_L081-601_IM-Drive.pdf 1 Servo drive manual
CDS37897_L875-603_MIM.pdf 0 Servo actuator manual
DOC-0000413342 power.pdf - Power cable data sheet
CB54994.pdf Power cable drawing
DOC-0000413459 signal.pdf - Signal cable data sheet
CB54995.pdf Signal cable drawing

3. RESPONISIBILITY
It is the responsibility of the assigned staff to apply the contents of this specification.
The staff at the wiring must have the requirements and technical information necessary for the performance and
must be aware of the provisions of the dangers and risks.
The staff must be able to take countermeasures in case of accident.
Personnel should wear appropriate PPE (Personal Protective Equipment).
The unauthorized personnel should not approach the power unit during operation and management of the system.
4. ELECTRICAL CONNECTIONS
4.1. Complete wiring

For the complete wiring of the system, please refer to the Attachment 1:
Attachment Document Revision Description
The following scheme hexibits the system:

4.2. Motor wiring
The following scheme hexibitis the elements (A) of the system included in the wiring:
The following image hexibits the opening of the motor for the wiring:
EMA L875-603_MOTOR – Cover opening

The following image hexibits the terminal bliocks schme of the motor:
EMA L875-603_MOTOR – Terminal blocks (scheme)

The folloiwng image hexibits the terminal blocks of the motor:
EMA L875-603_MOTOR – Terminal blocks

The following image hexibits the connection between the motor and the power cable:
EMA L875-603_MOTOR – Connectionwith power cable CB 54994-1500 (RAO 4758037)

4.3. Resolver&PTC wiring
The following scheme hexibitis the elements (B) of the system included in the wiring:
The following image hexibits the opening of the motor for the wiring:
EMA L875-603_MOTOR –Cover opening

The following image hexibits the schem of the terminal blocks of the resolver&PTC:
EMA L875-603_RESOLVER&PTC – Terminal blocks (scheme)

The following image hexibits the terminal blocks of the Resolver&PTC:
EMA L875-603_RESOLVER&PTC – Terminal blocks

The following image hexibits the connections between Resolver&PTC and signal cable:
EMA L875-603_RESOLVER & PTC – Connection of signal cable CB 54995-1500 (RAO 4758038)
4.4. Motor PE terminal
The following image hexibits how to make the connection with the PE terminal:
EMA L875-603_PE - PROTECTIVE EARTH terminal position
External position of the PROTECTIVE EARTH terminal

4.5. Driver wiring
The following scheme hexibitis the elements (C, D, E, F) of the system included in the wiring::
The following image hexibits the interla layout of the drive:
DRIVE CZ 140100 – Internal layout

The following image hexibits the wiring cables:
DRIVE CZ 140100 – Power and signal cables connections

The following image hexibits the connection between power cable and motor/brake:
DRIVE CZ 140100 –- Connection power cable-MOTOR/BRAKE CB 54994-1500 (RAO 4758037)

(cable not armoured for testing CB57098)
The following image hexibits the connection between signal cable and RESOLVER&PTC:
DRIVE CZ 140100 –- connection signal cable-RESOLVER&PTC CB 54995-1500 (RAO 4758038)

(cable not armoured for testing CB57097)
The following image hexibits the connections for the ENGINE CONTROLLER (excluded from the supply):
DRIVE CZ 140100 –-ENGINE CONTROLLER connection (cables excluded from the supply)
The following image hexibits the POWER SUPPLY 400 V AC connection (excluded from the supply):
DRIVE CZ 140100 –-POWER SUPPLY connection (cable excluded from the supply)
Put the external PROTECTIVE EARTH terminal in one of the fours fixing points of the Drive metal housing.
The following image hexibits an example of possible connection:
External PROTECTIVE EARTH terminal: fixing to the Drive metal housing
.
5. ATTACHMENTS
2 MRE37113_L081-601_602_ECS.pdf Drive Electrical connections Scheme
3 MRE37114_L081-601_602_TBDCD.pdf Drive Terminal Blocks Drive Connections Diagram
4 MRE37118_L081-601_602_WD.pdf Drive Wiring Diagram
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PRODUCT
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CDS38231 - L081-602 Igv Moog

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PARTLY COMPLETED

Rev. 0, April 2013

Moog Company Moog Italiana S.r.l. (Malnate)

Tel +39 0332 421 111

Fax +39 0332 429 233

Web Site www.moog.com

Revision Description Prepared Checked Approved Date

0 First issue BEB CAR, FAP LOF April 2013

EMA Electro Mechanical Actuator

EH Electro Hydraulic Actuator

EHA Electro Hydrostatic Actuator

MSD Moog Servo Drive

The following table shows the symbols adopted in Moog documents:

ATTENTION: Danger to persons, including death

1.1. Nameplate and type designation

Characteristic Description Value

Mod: Model L875-603

S/N Serial Number See on the nameplate

Date Manufacturing date (month/year) See on the nameplate

NP Purchasing Code Nuovo Pignone Purchasing Code RAO21196

Characteristic Description Value

Model Motor Model G495L1007

Serial Serial Number See on the nameplate

Mfg.Date Manufacturing date (year/month) See on the nameplate

PN [kW] Nominal Power 2,451

Ud [V] Voltage 565

Mo [Nm] Nominal Torque 18,39

Io [Arms] Current 10,43

Temp. class Temperature class T4

Am. Temp. Ambient temperature -40° C/ +80° C

Weight [kg] Weight 22

Brake [Nm] Brake torque 22

Type Motor Type G-5LV8-020-02-99-01-00-000

Mmax [Nm] Maximum Torque 61,26

Fsw [kHz] Switching Frequency 4

Characteristic Description Value

IECEx BKI 10.0001X

Code Model code CZ140100

S/N Serial Number See on the nameplate

Vin Voltage 400 Vac +/-10%

Iin In current 6 Arms

Iout Out current 6 Arms 22 Apeak

- ATEX Certification II 3GD

1.2. Manufacturer name and address

Moog Company Moog Italiana S.r.l. (Malnate)

Tel +39 0332 421 111

Fax +39 0332 429 233

Web Site www.moog.com

1.3. Warranty and Liability

1.5. Applicable standards

2006/95/EC Low Voltage Directive

2004/108/EC EMC Directive

94/9/EC ATEX Directive

L875-603 Servo Actuator

CZ140100 Servo Driver

CB54994 Power cable

CB54995 Signal cable

2.1. Intended use

2.4. Energy consumption and conditions

2.5.1. Noise, gases, water

2.7. Electromagnetic compatibility

2.9. Reasonably foreseeable misuse

3.1. General warnings