Lenze AC Tech PositionServo 940, AC Tech PositionServo 941 User Manual

S955

USERS MANUAL

S94P01C -e1

All rights reserved. No part of this manual may be reproduced or transmitted in any form without written permission from AC Technology Corporation. The information and technical data in this manual are subject to change without notice. AC Tech makes no warranty of any kind with respect to this material, including, but not limited to, the implied warranties of its merchantability and ﬁtness for a given purpose. AC Tech assumes no responsibility for any errors that may appear in this manual and makes no commitment to update or to keep current the information in this manual.

MotionView®, Positionservo®, and all related indicia are either registered trademarks or trademarks of Lenze AG in the United States and other countries.

This document printed in the United States of America

Table of Contents

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 About these Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.2 Scope of Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.3 Legal Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2 Speciﬁcations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.2 Power Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

2.3

Fuse Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

2.4

Digital I/O Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.5

Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.6

Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.7

Connections and I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

3 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.1 PositionServo Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3.2 Clearance for Cooling Air Circulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.1 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

4.2 Shielding and Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

4.2.1

GeneralGuidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

EMIProtection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

4.2.2

4.2.3 Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

4.3 Line Filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

4.4

Heat Sinking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

4.5

Line (Mains) Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

5 PositionServo Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5.1 External Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

5.1.1 P1&P7-InputPowerandOutputPowerConnections . . . . . . . . . . . . . .17

5.1.2 P2-EthernetCommunicationsPort. . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

5.1.3 P3-ControllerInterface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

5.1.4 P4-MotorFeedback/SecondLoopEncoderInput. . . . . . . . . . . . . . . .20

5.1.5 P5-24VDCBack-upPowerInput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

5.1.6 P6-BrakingResistorandDCBus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

5.1.7 ConnectorsandWiringNotes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

5.1.8 P11-ResolverInterfaceModule(optionmodule). . . . . . . . . . . . . . . . . .22

5.1.9 P12-SecondEncoderInterfaceModule(optionbay2). . . . . . . . . . . . .24

5.2 Digital I/O Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

5.2.1

Step&Direction/MasterEncoderInputs(P3,pins1-4) . . . . . . . . . . . . .25

5.2.2 BufferedEncoderOutput(P3,pins7-12). . . . . . . . . . . . . . . . . . . . . . . . .26

5.2.3 DigitalOutputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

5.2.4 DigitalInputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

5.3 Analog I/O Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

5.3.1

AnalogReferenceInput. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

5.3.2 AnalogOutput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

5.4 Communication Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

5.4.1

EthernetInterface(standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

5.4.2 RS485Interfaces(optionmodule). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

5.4.3 RS485CommunicationSetup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

5.4.4 MODBUSRTUSupport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

5.5 Motor Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

5.5.1

MotorConnection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

5.5.2 MotorOver-temperatureProtection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

5.5.3 MotorSet-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

S94P01C -e1

5.6 Using a Custom Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

5.6.1 CreatingCustomMotorParameters. . . . . . . . . . . . . . . . . . . . . . . . . . . .32

5.6.2

Autophasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

5.6.3 CustomMotorDataEntry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

6 Programmable Features and Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.1 Parameter Storage and EPM Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

6.1.1 ParameterStorage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

6.1.2 EPMOperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

6.1.3 EPMFault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

6.2 Motor Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

6.3

Parameters Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

6.3.1

DriveOperatingModes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

6.3.2 DrivePWMfrequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

6.3.3 CurrentLimit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

6.3.4 8kHzPeakCurrentLimitand16kHzPeakCurrentLimit . . . . . . . . . . . .40

6.3.5 AnalogInputScale(currentscale). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

6.3.6 AnalogInputScale(velocityscale). . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

6.3.7 ACCEL/DECELLimits(velocitymodeonly). . . . . . . . . . . . . . . . . . . . . . .41

6.3.8 Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

6.3.9 StepInputType(positionmodeonly) . . . . . . . . . . . . . . . . . . . . . . . . . . .41

6.3.10FaultResetOption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

6.3.11MotorTemperatureSensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

6.3.12MotorPTCCut-offResistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

6.3.13SecondEncoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

6.3.14RegenerationDutyCycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

6.3.15EncoderRepeatSource . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

6.3.16SystemtoMasterRatio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

6.3.17SecondtoPrimeEncoderRatio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

6.3.18Autoboot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

6.3.19GroupID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

6.3.20EnableSwitchFunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

6.3.21UserUnits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

6.3.22ResolverTrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

6.3.23CurrentLimitMaxOverwrite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

6.4 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

6.4.1

EthernetInterface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

6.4.2 RS-485Conguration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

6.4.3 ModbusBaudRate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

6.4.4 ModbusReplyDelay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

6.5 Analog I/O Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

6.5.1

AnalogOutput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

6.5.2 AnalogOutputCurrentScale(Volt/amps) . . . . . . . . . . . . . . . . . . . . . . . .48

6.5.3 AnalogOutputCurrentScale(mV/RPM) . . . . . . . . . . . . . . . . . . . . . . . . .48

6.5.4 AnalogInputDeadBand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

6.5.5 AnalogInputOffsetParameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

6.5.6 AdjustAnalogVoltageOffset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

6.6 Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

6.6.1

DigitalInputDe-bounceTime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

6.6.2 HardLimitSwitchAction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

6.7 Velocity Limits Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

6.7.1

ZeroSpeed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

6.7.2 SpeedWindow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

6.7.3 AtSpeed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

6.8 Position Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

6.8.1

PositionError . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

6.8.2 MaxErrorTime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

6.8.3 SecondEncoderPositionError . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

6.8.4 SecondEncoderMaxErrorTime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

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6.9 Compensation Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

6.9.1 VelocityP-gain(proportional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

6.9.2

VelocityI-gain(integral). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

6.9.3 PositionP-gain(proportional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

6.9.4 PositionI-gain(integral). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

6.9.5 PositionD-gain(differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

6.9.6 PositionI-limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

6.9.7 GainScalingWindow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

6.10 Tools Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

6.10.1

OscilloscopeTool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

6.10.2RunPanels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

6.11 Faults Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

7 Display and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

7.1 Diagnostic Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

7.2 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

7.3

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

7.3.1

FAULTCODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

7.3.2 FaultEvent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

7.3.3 FaultReset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

8.1 Minimum Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

8.2 Conﬁguration of the PositionServo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

8.3

Position Mode Operation (gearing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

8.4

Dual-loop Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

8.5

Enabling the PositionServo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

8.6

Tuning in Velocity Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

8.7

Tuning in Position Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

9 Sample Motor Responses to Gain Settings . . . . . . . . . . . . . . . . . . . . . . . . 62

9.1 Motor Response to Gain Settings (velocity mode). . . . . . . . . . . . . . . . . . . . . . . .62

9.1.1 P-gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

9.1.2 I-gain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

9.1.3 AbnormalGains(velocitymode). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

9.2 Motor Response to Gain Settings (position mode) . . . . . . . . . . . . . . . . . . . . . . .66

9.2.1

P-gainselection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

9.2.2 OptimalP-gain/D-gainSettings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

S94P01C -e1

Safety Information

All safety information given in these Operating Instructions have the same layout:

Signal Word! (Characteristics the severity of the danger)

Note (describes the danger and informs on how to proceed)

Icon

Warning of hazardous electrical voltage

Warning of a general danger

Warning of damage to equipment

Information

Signal Words

DANGER!

WARNING!

STOP!

Note

Warns of impending danger.

Consequences if disregarded: Death or severe injuries.

Warns of potential, very hazardous situations.

Consequences if disregarded: Death or severe injuries.

Warns of potential damage to material and equipment.

Consequences if disregarded: Damage to the controller/drive or its environment.

Designates a general, useful note.

If you observe it, handling the controller/ drive system is made easier.

S94P01C -e1

1 General Information

The PositionServo line of advanced general purpose servo drives utilizes the latest technology in power semiconductors and packaging. The PositionServo uses Field Oriented control to enable high quality motion.

The PositionServo is available in four mains (input power) conﬁgurations:

400/480V (nominal) three phase input. An external input mains (line) available. Actual voltage can range from 320 - 528 VAC.

2. 120/240V (nominal) Single Phase input with integrated input mains (line) ﬁlter, Actual input voltage can range from 80VAC to 264VAC. The maximum output voltage is approximately equal to the input voltage.

3. 120V or 240V (nominal) Single or Three Phase input. Actual input voltage can range from 80VAC to 264VAC. The maximum output voltage is approximately equal to the input voltage. An external input mains (line) ﬁlter is available.

120V or 240V (nominal) single phase input. When wired for Doubler mode

4. (L1-N), the input is for 120V nominal only and can range from 45VAC to 132 VAC and the maximum output voltage is double the input voltage. When wired to terminals L1-L2/N, the input can range from 80 VAC to 264 VAC and the maximum output voltage is equal to the input voltage.

The PositionServo drive can operate in one of three mode settings, torque (current), velocity, or position (step & direction or master encoder). The drives command or reference signal can come from one of three choices. The ﬁrst is an external reference. An external reference can be an analog input signal, a step and direction input or an input from a master encoder. The second reference is an internal reference. An internal reference is when the commanded move is derived from the drives users program. The third reference is when the commanded move is done via a host device over a communications network. This Host device can be an external motion controller, PLC, HMI or PC. The communication network can be over, RS485 (Point-to-Point or Modbus RTU), Ethernet (using MotionView DLL’s), Modbus over TCP/IP, or CANopen (DS301 and DS402).

Depending on the primary feedback, there are two types of drives: the Model 940 PositionServo encoder-based drive which accepts an incremental encoder with Hall channels inputs and the Model 941 PositionServo resolver-based drive which accepts resolver inputs. The feedback signal is brought back to the P4 connector on the drive. This connector will be a 15 pin D-sub for the encoder version and a 9 pin D-sub for the resolver version. A second encoder can be used in position and velocity modes.

The MotionView software is the setup and management tool for PositionServo drives. All parameters can be set and monitored via this user-friendly tool. It has a real-time oscilloscope tool for analysis and optimum tuning. The users program written with SimpleMotion Programming Language (SML) can be utilized to command motion and handle the drive’s inputs/outputs (I/O). The programming language is designed to be very user friendly and easy to implement. For programming details, refer to PositionServo Programming Manual. Note that all PositionServo related manuals can be found under MotionView “Help” – “Product Manuals”.

On each PositionServo drive, there is an Electronic Programming Module (EPM), which stores all drive setup and tuning information. This module can be removed from the drive and reinstalled into another drive, making the ﬁeld replacement of the drive extremely easy. Also this makes it easy to duplicate the settings for several drives.

The PositionServo drive supports a variety of communication protocols, including Pointto-Point (PPP), Modbus RTU over RS485, Ethernet TCP/IP, Modbus over TCP/IP and CANopen (DS301 and DS402).

ﬁlter is

S94P01C -e1

1.1 About these Operating Instructions

• These Operating Instructions are provided to assist the user in connecting and commissioning the PositionServo drive. Important safety instructions are contained in this document which must be observed carefully.

• All persons working on and with the controller must have the Operating Instructions available and must observe the information and notes relevant for their work.

• The Operating Instructions must always be in a complete and perfectly readable state.

1.2 Scope of Supply

Scope of Supply Important

• 1 Model PositionServo type E94P or E94R.

• 1 Users Manual (English)

• 1 MotionView CD ROM including

- conﬁguration software

- documentation (Adobe Acrobat)

After reception of the delivery, check immediately whether the scope of supply matches the accompanying papers. Lenze does not accept any liability for deﬁciencies claimed subsequently.

Claim

• visible transport damage immediately to the forwarder

• visible deﬁciencies / incompleteness immediately to your Lenze representative.

1.3 Legal Regulations

Identication Nameplate CE Identication Manufacturer

Application as directed

Liability

Lenze controllers are unambiguously designated by the contents of the nameplate

E94P or E94R servo controller

• must only be operated under the conditions prescribed in these Instructions.

• are components

- for closed loop control of variable speed and torque applications with PM synchronous motors

- for installation in a machine.

- for assembly with other components to form a machine.

• are electric units for the installation into control cabinets or similar enclosed operating housing.

• comply with the requirements of the Low-Voltage Directive.

• are not machines for the purpose of the Machinery Directive.

• are not to be used as domestic appliances, but only for industrial purposes.

Drive systems with E94P or E94R servo inverters

• comply with the EMC Directive if they are installed according to the guidelines of CE-typical drive systems.

• can be used

- for operation on public and non-public mains

- for operation in industrial premises and residential areas.

• The user is responsible for the compliance of his application with the EC directives.

Any other use shall be deemed as inappropriate!

• The information, data, and notes in these instructions met the state of the art at the time of publication. Claims on modiﬁcations referring to controllers which have already been supplied cannot be derived from the information, illustrations, and descriptions.

• The speciﬁcations, processes and circuitry described in these instructions are for guidance only and must be adapted to your own speciﬁc application. Lenze does not take responsibility for the suitability of the process and circuit proposals.

• The speciﬁcations in these Instructions describe the product features without guaranteeing them.

• Lenze does not accept any liability for damage and operating interference caused by:

- Disregarding the operating instructions

- Unauthorized modiﬁcations to the controller

- Operating errors

- Improper working on and with the controller

In compliance with the EC Low-Voltage Directive

AC Technology Corp. member of the Lenze Group 630 Douglas Street Uxbridge, MA 01569 USA

S94P01C -e1

Warranty

Disposal

• Warranty conditions: see Sales and Delivery Conditions of Lenze Drive Systems GmbH.

• Warranty claims must be made to Lenze immediately after detecting the deﬁciency or fault.

• The warranty is void in all cases where liability claims cannot be made.

Material Recycle Dispose

Metal

Plastic

Assembled PCB’s

•

S94P01C -e1

2 Specications

2.1 Electrical Characteristics

Single-Phase Models

1~ Mains

(1)

Type

E94_020S1N_X

E94_040S1N_X 16.8 8.6 4.0 12

Mains Voltage

(3)

or 240V

120V

E94_020S2F_X

E94_040S2F_X -- 8.6 4.0 12

E94_080S2F_X -- 15.0 8.0 24

120 / 240V

(80 V -0%...264 V +0%)

E94_100S2F_X -- 18.8 10.0 30

E94_120S2F_X -- 24.0 12.0 36

Current

(2)

(doubler)

(4)

Single/Three-Phase Models

1~ Mains

Current

(Std.)

Rated Output

Current

9.7 5.0 2.0 6

-- 5.0 2.0 6

Peak Output

(5)

Current

(6)

Type

(1)

Mains Voltage

(2)

1~ Mains

Current

E94_020Y2N_X

E94_040Y2N_X 8.6 5.0 4.0 12

E94_080Y2N_X 15.0 8.7 8.0 24

120 / 240V

(80 V -0%...264 V +0%)

(4)

1~ or 3~

3~ Mains

Current

Rated Output

Current

(5)

Peak Output

Current

5.0 3.0 2.0 6

E94_120Y2N_X 24.0 13.9 12.0 36

E94_180T2N_X

240V 3~

(180 V -0%...264 V +0%)

E94_020T4N_X

E94_040T4N_X -- 5.5 4.0 12

E94_050T4N_X -- 6.9 5.0 15

E94_060T4N_X -- 7.9 6.0 18

400 / 480V

(320 V -0%...528 V +0%)

-- 19.6 18.0 54

-- 2.7 2.0 6

E94_090T4N_X -- 12.0 9.0 27

(1)

The ﬁrst “_” equals either “P” for the Model 940 encoder based drive OR an “R” for the Model 941 resolver

based drive.

(2)

The second “_” equals either “E” for incremental encoder (must have E94P drive) OR an “R” for the standard

resolver (must have E94R drive).

(3)

Mains voltage for operation on 50/60 Hz AC supplies (48 Hz -0% … 62Hz +0%).

(4)

Connection of 120VAC (45 V … 132 V) to input power terminals L1 and N on these models doubles the voltage on motor output terminals U-V-W for use with 230VAC motors.

(5)

Connection of 240VAC or 120VAC to input power terminals L1 and L2 on these models delivers an equal voltage as maximum to motor output terminals U-V-W allowing operation with either 120VAC or 230VAC motors.

(6)

Drive rated at 8kHz Carrier Frequency. Derate Continuous current by 17% at 16kHz.

(7)

Peak RMS current allowed for up to 2 seconds. Peak current rated at 8kHz. Derate by 17% at 16kHz.

Applies to all models:

Acceleration Time Range (Zero to Max Speed) 0.1 … 5x106 RPM/sec Deceleration Time Range (Max Speed to Zero) 0.1 … 5x106 RPM/sec Speed Regulation (typical) ± 1 RPM Input Impedance (AIN+ to COM and AIN+ to AIN-) 47 kΩ Power Device Carrier Frequency (sinusoidal commutation) 8,16 kHz Encoder Power Supply (max) +5 VDC @ 300 mA Maximum Encoder Feedback Frequency 2.1 MHz (per channel) Maximum Output Frequency (to motor) 400Hz

(6)

S94P01C -e1

2.2 Power Ratings

Power Loss at

Rated Output

Current

(8KHz)

Type

(1)

Output Power

at Rated Output

Current (8kHz)

(2)

Leakage Current

Units kVA mA Watts Watts

E94_020S1N_X 0.8

19 21

E94_040S1N_X 1.7 29 30

E94_020S2F_X 0.8 19 21

E94_040S2F_X 1.7 29 30

E94_080S2F_X 3.3 61 63

E94_100S2F_X 4.2 80 85

E94_020Y2N_X 0.8 19 21

E94_040Y2N_X 1.7 29 30

E94_080Y2N_X 3.3 61 63

E94_120Y2N_X 5.0 114 129

Typically >3.5 mA. Consult factory for

applications requiring

<3.5 mA.

E94_180T2N_X 7.5 171 195

E94_020T4N_X 1.7 31 41

E94_040T4N_X 3.3 50 73

E94_050T4N_X 4.2 70 90

E94_060T4N_X 5.0 93 122

E94_090T4N_X 7.5 138 182

Power Loss at

Rated Output

2.3 Fuse Recommendations

rated

(6)

AC Line Input

(4)

Fuse

(5)

Breaker

(N. America)

DC Bus Input

Type

(1)

AC Line

Input Fuse

(1ø/3ø)

Miniature

Circuit Breaker

(1ø/3ø)

Amp Ratings E94_020S1N_X M20/M10 C20/C10 20/10 10

E94_040S1N_X M32/M20 C32/C20 30/20 20

E94_020S2F_X M20 C20 20 15

E94_040S2F_X M20 C20 20 20

E94_080S2F_X M32 C32 32 40

E94_100S2F_X M40 C40 40 45

E94_020Y2N_X M20/M16 C20/C16 20/15 15

E94_040Y2N_X M20/M16 C20/C16 20/15 20

E94_080Y2N_X M32/M20 C32/C20 30/20 40

E94_120Y2N_X M50/M32 C50/C32 50/30 55

E94_180T2N_X M40 C40 40 80

E94_020T4N_X M10 C10 10 10

E94_040T4N_X M10 C10 10 20

E94_050T4N_X M16 C16 15 25

E94_060T4N_X M20 C20 20 30

E94_090T4N_X M25 C25 25 40

(1)

The ﬁrst “_” equals either “P” for the Model 940 encoder based drive OR an “R” for the Model 941 resolver based drive.

(2)

The second “_” equals either “E” for incremental encoder (must have E94P drive) OR an “R” for the standard resolver (must have E94R drive).

(3) At 240 VAC line input for drives with sufﬁxes “S1N”, “S2F”, “Y2N”. At 480 VAC line input for drives with sufﬁxes “T4N”.

a. The output power is calculated from the formula: output power (kVA)

b. The actual output power depends on the motor in use due to variations in power factor.

(4) At 16 kHz, de-rate continuous current by 17%

(5) Installations with high fault current due to large supply mains may require a type D circuit breaker.

(6) UL Class CC or T fast-acting current-limiting type fuses, 200,000 AIC, preferred. Bussman KTK-R, JJN, JJS or equivalent.

(7) Thermal-magnetic type breakers preferred.

(8) DC-rated fuses, rated for the applied voltage. Examples Bussman KTM or JJN as appropriate.

=sqrt(3) x ULL x I

Current

(16 kHz)

Fuse

(3)

(7)

S94P01C -e1

2.4 Digital I/O Ratings

Scan

Linearity Temperature Drift Offset Current

Times

Units ms % % % mA Ohm VDC

Digital Inputs

Digital Outputs 0.052

Analog Inputs 0.052 ± 0.013 0.1% per °C rise ± 0 adjustable Depend on load 47 k ± 18

Analog Outputs 0.052 0.1% per °C rise ± 0 adjustable 10 max N/A ± 10

(1) Inputs do not have scan time. Their values are read directly by indexer program statement. De-bounce time is programmable and can be set as low as 0. Propagation delay is typical 20 us (2) Time when output has an assigned function.

(2)

(1)

0.02

(2)

Depend on load 2.2 k 5-24

100 max N/A 30 max

Input

Impedance

Voltage

Range

2.5 Environment

Vibration 2 g (10 - 2000 Hz) Ambient Operating Temperature Range 0 to 40ºC Ambient Storage Temperature Range -10 to 70ºC Temperature Drift 0.1% per ºC rise Humidity 5 - 90% non-condensing Altitude 1500 m/5000 ft [derate by 1% per 300m (1000 ft) above 1500m (5000 ft)]

2.6 Operating Modes

Torque

Reference ± 10 VDC 16-bit; scalable Torque Range 100:1 Current-Loop Bandwidth Up to 3 kHz

Velocity

Reference ± 10 VDC or 0…10 VDC; scalable Regulation ± 1 RPM Velocity-Loop Bandwidth Up to 400 Hz Speed Range 5000:1 with 5000 ppr encoder

Position

Reference 0…2 MHz Step and Direction or 2 channels quadrature input; scalable Minimum Pulse Width 500 nanoseconds Loop Bandwidth Up to 200 Hz Accuracy ±1 encoder count for encoder feedabck ±1.32 arc-minutes for resolver feedback (14-bit resolution)

2.7 Connections and I/O

Mains Power 4-pin removable terminal block (P1) Ethernet Port Standard RJ45 Connector (P2) I/O Connector Standard 50-pin SCSI. (P3)

- Buffered Encoder Output In 50-pin SCSI controller connector (P3)

- Digital Inputs 11 programmable, 1 dedicated (5-24V) (P3)

- Digital Outputs 4 programmable, 1 dedicated(5-24V @ 100mA) (P3)

- Analog Input 2 differential; ±10 VDC (one16 bit, one 10 bit) (P3)

- Analog Output 1 single ended; ±10 VDC (10-bit) (P3) Encoder Feedback (E94P drive) Feedback connector is a 15-pin D-shell (P4) Resolver Feedback (E94R drive) Feedback connector is a 9-pin D-shell (P4) 24VDC Power “Keep Alive” 2-pin removable terminal block (P5) Regen and Bus Power 5-pin removable terminal block (P6) Motor Power 6-pin pin removable terminal block (P7) Comm Option Bay Optional Comm Modules (CAN, RS485) (P21) Resolver feedback (option bay) Option module with standard 9-pin D-shell (P11) Encoder Feedback (option bay) Option module with standard 9-pin D-shell (P12) Windows® Software: MotionView (Windows 98, NT, 2000, XP)

S94P01C -e1

3 Dimensions

9 7

()

3.1 PositionServo Dimensions

(1)

Type

E94_020S1N_X 67 190 190 182 1.1

E94_040S1N_X 69 190 190 182 1.2

E94_020S2F_X 67 190 235 182 1.3

E94_040S2F_X 69 190 235 182 1.5

E94_080S2F_X 88 190 235 182 1.9

E94_100S2F_X 103 190 235 182 2.2

E94_020Y2N_X 67 190 190 182 1.3

E94_040Y2N_X 69 190 190 182 1.5

E94_080Y2N_X 95 190 190 182 1.9

E94_120Y2N_X 67 190 235 182 1.5

E94_180T2N_X 67 242 235 233 2.0

E94_020T4N_X 69 190 190 182 1.5

E94_040T4N_X 95 190 190 182 1.9

E94_050T4N_X 115 190 190 182 2.2

E94_060T4N_X 67 190 235 182 1.4

E94_090T4N_X 67 242 235 233 2.0

(1)

The ﬁrst “_” equals either “P” for the Model 940 encoder based drive OR an “R” for the Model 941 resolver

based drive.

(2)

The second “_” equals either “E” for incremental encoder (must have E94P drive) OR an “R” for the standard

resolver (must have E94R drive).

A (mm) B (mm) C (mm) D (mm) Weight (kg)

S923

S94P01C -e1

3.2 Clearance for Cooling Air Circulation

3'*bb

3(bb

3'*bb

S924

S94P01C -e1

4 Installation

Perform the minimum system connection. Please refer to section 8.1 for minimum connection requirements. Observe the rules and warnings below carefully:

DANGER!

Hazard of electrical shock! Circuit potentials are up to 480 VAC above earth ground. Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injury or fatality. Disconnect incoming power and wait 60 seconds before servicing drive. Capacitors retain charge after power is removed.

STOP!

• The PositionServo must be mounted vertically for safe operation and to ensure enough cooling air circulation.

• Printed circuit board components are sensitive to electrostatic ﬁelds. Avoid contact with the printed circuit board directly. Hold the PositionServo by its case only.

• Protect the drive from dirt, ﬁlings, airborne particles, moisture, and accidental contact. Provide sufﬁcient room for access to the terminal block.

• Mount the drive away from any and all heat sources. Operate within the speciﬁed ambient operating temperature range. Additional cooling with an external fan may be recommended in certain applications.

• Avoid excessive vibration to prevent intermittent connections

• DO NOT connect incoming (mains) power to the output motor terminals (U, V, W)! Severe damage to the drive will result.

• Do not disconnect any of the motor leads from the PositionServo drive unless (mains) power is removed. Opening any one motor lead may cause failure.

• Control Terminals provide basic isolation (insulation per EN 618005-1). Protection against contact can only be ensured by additional measures, e.g., supplemental insulation.

• Do not cycle mains power more than once every 2 minutes. Otherwise damage to the drive may result.

WARNING!

For compliance with EN 61800-5-1, the following warning applies.

This product can cause a d.c. current in the protective earthing conductor. Where a residual current-operated protective (RCD) or monitoring (RCM) device is used for protection in case of direct or indirect contact, only an RCD or RCM of Type B is allowed on the supply side of this product.

UL INSTALLATION INFORMATION

• Suitable for use on a circuit capable of delivering not more than 200,000 rms symmetrical amperes, at the maximum voltage rating marked on the drive.

• Use Class 1 wiring with minimum of 75ºC copper wire only.

• Shall be installed in a pollution degree 2 macro-environment.

S94P01C -e1

4.1 Wiring

DANGER!

Hazard of electrical shock! Circuit potentials are up to 480 VAC above earth ground. Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injury or fatality. Disconnect incoming power and wait 60 seconds before servicing the drive. Capacitors retain charge after power is removed.

WARNING!

Leakage current may exceed 3.5mA AC. Minimum size of the protective earth conductor shall comply with local safety regulations for high leakage current equipment.

STOP!

Under no circumstances should power and control wiring be bundled together. Induced voltage can cause unpredictable behavior in any electronic device, including motor controls.

Refer to section 5.1.1 for Power wiring speciﬁcations.

4.2 Shielding and Grounding

4.2.1 General Guidelines

Lenze recommends the use of single-point grounding (SPG) for panel-mounted controls. Serial grounding (a “daisy chain”) is not recommended. The SPG for all enclosures must be tied to earth ground at the same point. The system ground and equipment grounds for all panel-mounted enclosures must be individually connected to the SPG for that panel using 14 AWG (2.5 mm2) or larger wire.

In order to minimize EMI, the chassis must be grounded to the mounting. Use 14 AWG (2.5 mm must be installed between the enclosure and ground terminal. To ensure maximum contact between the terminal and enclosure, remove paint in a minimum radius of 0.25 in (6 mm) around the screw hole of the enclosure.

Lenze recommends the use of the special PositionServo drive cables provided by Lenze. If you specify cables other than those provided by Lenze, please make certain all cables are shielded and properly grounded.

It may be necessary to earth ground the shielded cable. Ground the shield at both the drive end and at the motor end.

If the PositionServo drive continues to pick up noise after grounding the shield, it may be necessary to add an AC line ﬁltering device and/or an output ﬁlter (between drive and servo motor).

) or larger wire to join the enclosure to earth ground. A lock washer

S94P01C -e1

EMC

Compliance with EN 61800-3:2004 In a domestic environment this product may cause radio interference in which the user may be required to take adequate measures

Noise emission

Drive Models ending in the sufﬁx “2F” are in

Installation according to EMC Requirements

compliance with class A limits according to EN 55011 if installed in a control cabinet and the motor cable length does not exceed 10m. Models ending in “N” will require an appropriate line ﬁlter.

Screen clamps

Control cable

Low-capacitance motor cable

(core/core < 75 pF/m, core/screen < 150 pF/m)

Earth grounded conductive mounting plate

Encoder Feedback Cable

Footprint or Sidemount Filter (optional)

EDB C

S930

4.2.2 EMI Protection

Electromagnetic interference (EMI) is an important concern for users of digital servo control systems. EMI will cause control systems to behave in unexpected and sometimes dangerous ways. Therefore, reducing EMI is of primary concern not only for servo control manufacturers such as Lenze, but the user as well. Proper shielding, grounding and installation practices are critical to EMI reduction.

4.2.3 Enclosure

The panel in which the PositionServo is mounted must be made of metal, and must be grounded using the SPG method outlined in section 4.2.1.

Proper wire routing inside the panel is critical; power and logic leads must be routed in different avenues inside the panel.

You must ensure that the panel contains sufﬁcient clearance around the drive. Refer to Section 3.2 suggested cooling air clearance.

S94P01C -e1

4.3 Line Filtering

In addition to EMI/RFI safeguards inherent in the PositionServo design, external ﬁltering may be required. High frequency energy can be coupled between the circuits via radiation or conduction. The AC power wiring is one of the most important paths for both types of coupling mechanisms. In order to comply with IEC61800-3:2004, an appropriate ﬁlter must be installed within 20cm of the drive power inputs.

Line ﬁlters should be placed inside the shielded panel. Connect the ﬁlter to the incoming power lines immediately after the safety mains and before any critical control components. Wire the AC line ﬁlter as close as possible to the PositionServo drive.

Note

The ground connection from the ﬁlter must be wired to solid earth ground, not machine ground.

If the end-user is using a CE-approved motor, the AC ﬁlter combined with the recommended motor and encoder cables, is all that is necessary to meet the EMC directives listed herein. The end user must use the compatible ﬁlter to comply with CE speciﬁcations. The OEM may choose to provide alternative ﬁltering that encompasses the PositionServo drive and other electronics within the same panel. The OEM has this liberty because CE requirements are for the total system.

4.4 Heat Sinking

The PositionServo drive contains sufﬁcient heat sinking within the speciﬁed ambient operating temperature in their basic conﬁguration. There is no need for additional heat sinking. However, you must ensure that there is sufﬁcient clearance for proper air circulation. As a minimum, you must allow an air gap of 25 mm above and below the drive.

4.5 Line (Mains) Fusing

External line fuses must be installed on all PositionServo drives. Connect the external line fuse in series with the AC line voltage input. Use fast-acting fuses rated for 250 VAC or 600 VAC (depending on model), and approximately 200% of the maximum RMS phase current. Refer to section 2.3 for fuse recommendations.

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5 PositionServo Connections

The standard PositionServo drive contains seven connectors: four quick-connect terminal blocks, one SCSI connector and one subminiature type “D” connectors. These connectors provide communications from a PLC or host controller, power to the drive, and feedback from the motor. Prefabricated cable assemblies may be purchased from Lenze to facilitate wiring the drive, motor and host computer. Contact your Lenze Sales Representative for assistance.

As this manual makes reference to speciﬁc pins on speciﬁc connectors, we will use the convention PX.Y where X is the connector number and Y is the pin number.

5.1 External Connectors

5.1.1 P1 & P7 - Input Power and Output Power Connections

P1 is a 3 or 4-pin quick-connect terminal block used for input (mains) power. P7 is a 6-pin quick-connect terminal block used for output power to the motor. P7 also has a thermistor (PTC) input for motor over-temperature protection. The tables below identify connector pin assignments.

DANGER!

STOP!

DO NOT connect incoming power to the output motor terminals (U, V, W)! Severe damage to the PositionServo will result.

Check phase wiring (U, V, W) and thermal input (T1, T2) before powering up drive. If miss wired severe damage to the PositionServo will result.

All conductors must be enclosed in one shield and jacket around them. The shield on the drive end of the motor power cable should be terminated to the conductive machine panel using screen clamps as shown in section 4.2. The other end should be properly terminated at the motor shield. Feedback cable shields should be terminated in a like manner. Lenze recommends Lenze cables for both the motor power and feedback. These are available with appropriate connectors and in various lengths. Contact your Lenze representative for assistance.

Wire Size

Current

(Arms)

I<8 4.5 16 AWG (1.5mm2) or 14 AWG (2.5mm2)

8<I<12 4.5 14 AWG (2.5mm2) or 12 AWG (4.0mm2)

12<I<15 4.5 12 AWG (4.0mm2)

15<I<20 5.0 - 7.0 10 AWG (6.0mm2)

20<I<24 11.0 - 15.0 10 AWG (6.0mm2)

Terminal

Torque (lb-in)

Wire Size

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P1 Pin Assignments (Input Power)

Standard Models Doubler Models

Pin Name Function Name Function

1 PE Protective Earth (Ground) PE Protective Earth (Ground)

2 L1 AC Power in N AC Power Neutral

3 L2 AC Power in L1 AC Power in

4 L3 AC Power in

(3~ models only) L2/N AC Power in (non-doubler operation)

(120V Doubler only)

P7 Pin Assignments (Output Power)

Pin Terminal Function

1 T1 Thermistor (PTC) Input

2 T2 Thermistor (PTC) Input

3 U Motor Power Out

4 V Motor Power Out

5 W Motor Power Out

6 PE Protective Earth (Chassis Ground)

5.1.2 P2 - Ethernet Communications Port

P2 is a RJ45 Standard Ethernet connector that is used to communicate with a host computer via Ethernet TCP/IP.

P2 Pin Assignments (Communications)

Pin Name Function

1 + TX Transmit Port (+) Data Terminal

2 - TX Transmit Port (-) Data Terminal

3 + RX Receive Port (+) Data Terminal

4 N.C.

5 N.C.

6 - RX Receive Port (-) Data Terminal

7 N.C.

8 N.C.

Note

To communicate from the PC directly to the drive a crossover cable is required. If using a Hub or Switch, a regular patch cable shall be used.

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5.1.3 P3 - Controller Interface

P3 is a 50-pin SCSI connector for interfacing to the front-end of the controllers. It is strongly recommended that you use OEM cables to aid in satisfying CE requirements. Contact your Lenze representative for assistance.

P3 Pin Assignments (Controller Interface)

Pin Name Function

1 MA+ Master Encoder A+ / Step+ input 2 MA- Master Encoder A- / Step- input 3 MB+ Master Encoder B+ / Direction+ input 4 MB- Master Encoder B- / Direction- input 5 GND Drive Logic Common 6 5+ +5V output (max 100mA) 7 BA+ Buffered Encoder Output: Channel A+ 8 BA- Buffered Encoder Output: Channel A-

9 BB+ Buffered Encoder Output: Channel B+ 10 BB- Buffered Encoder Output: Channel B11 BZ+ Buffered Encoder Output: Channel Z+ 12 BZ- Buffered Encoder Output: Channel Z-

13-19 Empty

20 AIN2+ Positive (+) of Analog signal input 21 AIN2- Negative (-) of Analog signal input 22 ACOM Analog common 23 AO Analog output (max 10 mA) 24 AIN1+ Positive (+) of Analog signal input 25 AIN1 - Negative (-) of Analog signal input 26 IN_A_COM Digital input group ACOM terminal 27 IN_A1 Digital input A1 28 IN_A2 Digital input A2 29 IN_A3 Digital input A3 30 IN_A4 Digital input A4 31 IN_B_COM Digital input group BCOM terminal 32 IN_B1 Digital input B1 33 IN_B2 Digital input B2 34 IN_B3 Digital input B3 35 IN_B4 Digital input B4 36 IN_C_COM Digital input group CCOM terminal 37 IN_C1 Digital input C1 38 IN_C2 Digital input C2 39 IN_C3 Digital input C3 40 IN_C4 Digital input C4 41 RDY+ Ready output Collector 42 RDY- Ready output Emitter 43 OUT1-C Programmable output #1 Collector 44 OUT1-E Programmable output #1 Emitter 45 OUT2-C Programmable output #2 Collector 46 OUT2-E Programmable output #2 Emitter 47 OUT3-C Programmable output #3 Collector 48 OUT3-E Programmable output #3 Emitter 49 OUT4-C Programmable output #4 Collector

(1)

See Note 1, Section 5.1.7 - Connector and Wiring Notes

(2)

See Note 2, Section 5.1.7 - Connector and Wiring Notes

See Note 3, Section 5.1.7 - Connector and Wiring Notes

50 OUT4-E Programmable output #4 Emitter

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(3)

(2)

(1)

(3)

5.1.4 P4 - Motor Feedback / Second Loop Encoder Input

For encoder-based 940 drives, P4 is a 15-pin DB connector that contains connections for an incremental encoder with Hall emulation tracks or Hall sensors. For synchronous servo motors, it is necessary to have Hall sensors or Hall emulation tracks for commutation. If an asynchronous servo motor is used, it is not necessary to connect Hall sensor inputs. For pin assignments, refer to the table P4A. Encoder inputs on P4 have 26LS32 or compatible differential receivers for increased noise immunity. Inputs have all necessary ﬁltering and line balancing components so no external noise suppression networks are needed.

For resolver-based 941 drives, P4 is a 9-pin DB connector for connecting resolver feedback and thermal sensor. For pin assignments, refer to the table P4B.

All conductors must be enclosed in one shield and jacket around them. Lenze recommends that each and every pair (for example, EA+ and EA-) be twisted. In order to satisfy CE requirements, use of an OEM cable is recommended. Contact your Lenze representative for assistance.

The PositionServo buffers encoder/resolver feedback from P4 to P3. For example, when encoder feedback is used, channel A on P4, is Buffered Encoder Output channel A on P3. For more information on this refer to section 5.2.2 “Buffered Encoder Outputs”.

STOP!

Use only +5 VDC encoders. Do not connect any other type of encoder to the PositionServo reference voltage terminals. When using a frontend controller, it is critical that the +5 VDC supply on the front-end controller NOT be connected to the PositionServo’s +5 VDC supply, as this will result in damage to the PositionServo.

Note

• The PositionServo encoder inputs are designed to accept differentially driven hall signals. Single-ended or open-collector type hall signals are also acceptable by connecting “HA+”, “HB+”, “HC+” and leaving “HA-,HB-,HC-” inputs unconnected. You do not need to supply pull-up resistors for open-collector hall sensors. The necessary pull-up circuits are already provided.

• Encoder connections (A, B, and Z) must be full differential. PositionServo doesn’t support single-ended or open-collector type outputs from the encoder.

• An encoder resolution of 2000 PPR (pre-quadrature) or higher is recommended.

Using P4 as second encoder input for dual-loop operation.

P4 can be used as a second loop encoder input in situations where the motor is equipped with a resolver as the primary feedback. If such a motor is used, the drive must have a resolver feedback option module installed. A second encoder can then be connected to the A and B lines of the P4 connector for dual loop operation. See “Dual loop feedback operation” for details (Section 8.4).

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P4A Pin Assignments (Encoder Feedback - E94P Drives)

Pin Name Function

1 EA+ Encoder Channel A+ Input

2 EA- Encoder Channel A- Input

3 EB+ Encoder Channel B+ Input

4 EB- Encoder Channel B- Input

5 EZ+ Encoder Channel Z+ Input

6 EZ- Encoder Channel Z- Input

7 GND Drive Logic Common/Encoder Ground

8 SHLD Shield

9 PWR Encoder supply (+5VDC)

10 HA- Hall Sensor A- Input

11 HA+ Hall Sensor A+ Input

12 HB+ Hall Sensor B+ Input

13 HC+ Hall Sensor C+ Input

14 HB- Hall Sensor B- Input

(1)

See Note 1, Section 5.1.7 - Connector and Wiring Notes

(2)

For asynchronous servo motor, an incremental encoder without Hall effect sensors (commutation tracks) can be used.

15 HC- Hall Sensor C- Input

(1)

(2)

P4B Pin Assignments (Resolver Feedback - E94R Drives)

Pin Name Function

1 Ref +

2 Ref -

3 N/C

4 Cos+

5 Cos-

6 Sin+

7 Sin-

8 PTC+

9 PTC-

Resolver reference connection

No Connection

Resolver Cosine connections

Resolver Sine connections

Motor PTC Temperature Sensor

5.1.5 P5 - 24 VDC Back-up Power Input

P5 is a 2-pin quick-connect terminal block that can be used with an external 24 VDC (500mA) power supply to provide “Keep Alive” capability: during a power loss, the logic and communications will remain active. Applied voltage must be greater than 20VDC.

P5 Pin Assignments (Back-up Power)

Pin Name Function

1 +24 VDC Positive 24 VDC Input

4 Return 24V power supply return

WARNING!

Hazard of unintended operation! The “Keep Alive” circuit will restart the motor upon restoration of mains power when the enable input remains asserted. If this action is not desired, then the enable input must be removed prior to re-application of input power.

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+ 52 hidden pages

Lenze AC Tech PositionServo 940, AC Tech PositionServo 941 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual