Lenze PositionServo 940 User Manual

PositionServo with MVOB

Users Manual

Valid for Hardware Version 2

Copyright ©2013 - 2010 by Lenze AC Tech Corporation.

All rights reserved. No part of this manual may be reproduced or transmitted in any form without written
permission from Lenze AC Tech Corporation. The information and technical data in this manual are
subject to change without notice. Lenze 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. Lenze 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.

Windows™ and all related indicia are registered trademarks of Microsoft Corporation.

Java™ and all related indicia are registered trademarks of Sun Microsystems, Incorporated.

CANopen® is a registered trademark of ‘CAN in Automation (CiA)’.

DeviceNet™, EtherNet/IP™, and all related indicia are trademarks of ODVA (Open Device Vendors
Association).

PROFIBUS DP™ is a registered trademark of PROFIBUS International.

S94H201E_13426446_EN L 1

Contents

1 Introduction......................................................................5

1.1 Safety Information ...........................................................5

1.2 Legal Regulations............................................................ 5

1.3 General Drive Information......................................................6

1.3.1 Mains Configuration ...................................................6

1.3.2 Operating Modes...................................................... 6

1.3.3 Feedback ...........................................................7

1.3.4 Software ............................................................7

1.4 Part Number Designation ......................................................8

1.4.1 Drive Part Number..................................................... 8

1.4.2 Filter Part Number.....................................................8

1.4.3 Option Part Number.................................................... 9

2 Technical Data ..................................................................10

2.1 Electrical Characteristics .....................................................10

2.2 Power Ratings .............................................................11

2.3 Fuse Recommendations ...................................................... 12

2.4 Digital and Analog I/O Ratings .................................................12

2.5 Environment............................................................... 12

2.6 Operating Modes ...........................................................12

2.7 Connections and I/O ......................................................... 13

2.8 PositionServo Dimensions ....................................................14

2.9 Clearance for Cooling Air Circulation............................................. 15

3 Installation .....................................................................16

3.1 Wiring ...................................................................17

3.2 Shielding and Grounding .....................................................17

3.2.1 General Guidelines ...................................................17

3.2.2 EMI Protection....................................................... 18

3.2.3 Enclosure ..........................................................18

3.3 Line Filtering ..............................................................18

3.4 Heat Sinking............................................................... 19

3.5 Line (Mains) Fusing .........................................................19

4 Interface .......................................................................20

4.1 External Connectors .........................................................20

4.1.1 P1 & P7 - Input Power and Output Power Connections ........................20

4.1.2 P2 - Ethernet Communications Port....................................... 21

4.1.3 P3 - Controller I/O ....................................................22

4.1.4 P4 - Motor Feedback.................................................. 23

4.1.5 P5 - 24 VDC Back-up Power Input........................................ 24

4.1.6 P6 - Braking Resistor and DC Bus ........................................24

4.1.7 Connector and Wiring Notes ............................................25

4.1.8 P8 - ISO 13849-1 Safety Circuit (option) ...................................26

4.2 Digital I/O Details ...........................................................31

4.2.1 Step & Direction/Master Encoder Inputs (P3, pins 1-4) ........................31

4.2.2 Buffered Encoder Output (P3, pins 7-12) ...................................32

4.2.3 Digital Outputs ......................................................32

4.2.4 Digital Inputs........................................................33

4.3 Analog I/O Details........................................................... 34

4.3.1 Analog Reference Input ................................................ 34

4.3.2 Analog Output .......................................................35

4.4 Communication Interfaces ....................................................35

4.4.1 Ethernet Interface (standard) ............................................ 35

4.4.2 RS485 Interface (option) ...............................................35

4.4.3 Modbus RTU Support .................................................36

4.4.4 CANopen Interface ...................................................36

4.4.5 DeviceNet Interface...................................................36

4.4.6 PROFIBUS DP Interface ................................................37

4.5 Motor Selection ............................................................37

4.5.1 Motor Connection ....................................................37

4.5.2 Motor Over-Temperature Protection ......................................37

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Contents

5 Parameters ..................................................................... 38

5.1 Drive Identification ..........................................................39

5.1.1 Drive Name ......................................................... 39

5.1.2 Group ID ...........................................................39

5.2 Motor .................................................................... 40

5.2.1 Motor Setup ........................................................40

5.2.2 Using a Custom Motor.................................................41

5.2.3 Creating Custom Motor Parameters....................................... 41

5.2.4 Autophasing ........................................................42

5.2.5 Custom Motor Data Entry ..............................................43

5.3 Parameters ...............................................................47

5.3.1 Drive Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.3.2 Reference .......................................................... 48

5.3.3 Drive PWM Frequency ................................................. 49

5.3.4 Current Limit........................................................49

5.3.5 To Change Current Limits ..............................................49

5.3.6 Peak Current Limit (8 kHz and 16 kHz) ....................................49

5.3.7 Accel/Decel Limits (velocity mode only)....................................49

5.3.8 Fault Reset .........................................................49

5.3.9 Motor Temperature Sensor .............................................50

5.3.10 Motor PTC Cutoff Resistance ............................................ 50

5.3.11 Regen Duty Cycle ....................................................50

5.3.12 Master Encoder Input Type (position mode only) .............................51

5.3.13 Master Encoder - System to Master Ratio ..................................51

5.3.14 Autoboot ........................................................... 51

5.3.15 User Units ..........................................................51

5.3.16 Rotation Direction ....................................................51

5.3.17 Resolver Tracks......................................................51

5.4 Communication ............................................................52

5.4.1 Ethernet ...........................................................52

5.4.2 RS-485 ............................................................52

5.4.3 CAN ..............................................................52

5.4.4 PROFIBUS .......................................................... 52

5.5 Analog I/O ................................................................53

5.5.1 Analog Output .......................................................53

5.5.2 Analog Output Current Scale (Volt/Amps)................................... 53

5.5.3 Analog Output Velocity Scale (mV/RPM).................................... 53

5.5.4 Analog Input Current Scale (Amps/Volt) ....................................53

5.5.5 Analog Input Velocity Scale (RPM/Volt).....................................53

5.5.6 Analog Input Dead Band ...............................................54

5.5.7 Analog Input Offset ...................................................54

5.6 Digital I/O ................................................................. 54

5.6.1 Digital Output .......................................................54

5.6.2 Digital Input De-bounce Time ...........................................54

5.6.3 Hard Limit Switch Action ............................................... 54

5.6.4 Enable Switch Function ................................................ 54

5.6.5 Brake Release Delay ..................................................55

5.7 Velocity Limits .............................................................55

5.7.1 Zero Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.7.2 Speed Window ......................................................55

5.7.3 At Speed ........................................................... 55

5.8 Position Limits .............................................................56

5.8.1 Position Error .......................................................56

5.8.2 Max Error Time ......................................................56

5.8.3 Soft Limits.......................................................... 56

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Contents

5.9 Compensation .............................................................56

5.9.1 Velocity P-gain (proportional)............................................ 56

5.9.2 Velocity I-gain (integral)................................................ 56

5.9.3 Position P-gain (proportional) ...........................................57

5.9.4 Position I-gain (integral) ...............................................57

5.9.5 Position D-gain (differential) ............................................57

5.9.6 Position I-limit.......................................................57

5.9.7 Gain Scaling Window.................................................. 57

5.9.8 Disable High Performance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

5.9.9 Auto Tuning.........................................................57

5.9.10 Set Default Gains.....................................................58

5.9.11 Feedback and Loop Filters..............................................58

5.10 Tools ....................................................................59

5.10.1 Oscilloscope ........................................................59

5.10.2 Parameter & I/O View .................................................60

5.11 Faults....................................................................61

5.12 Monitor ..................................................................62

6 Operation ......................................................................63

6.1 Minimum Connections .......................................................63

6.2 Ethernet Connection ......................................................... 63

6.2.1 PositionServo Ethernet Port Configuration ..................................64

6.2.2 Configuring the PC IP Address (Windows XP) ................................ 66

6.2.3 Initial Connection to the Drive ...........................................69

6.2.4 Launching MotionView & Communicating to the PS Drive ......................70

6.3 Parameter Storage and EPM Operation........................................... 73

6.3.1 Parameter Storage ...................................................73

6.3.2 EPM Operation ......................................................73

6.3.3 EPM Fault ..........................................................73

6.4 Configuration of the PositionServo ..............................................74

6.5 Position Mode Operation (gearing) ..............................................75

6.6 Enabling the PositionServo ....................................................75

6.7 Drive Tuning............................................................... 76

6.7.1 Auto Tuning the Drive .................................................76

6.7.2 Manually Tuning the Drive in Velocity Mode................................. 77

6.7.3 Manually Tuning the Drive in Position Mode ................................82

6.8 Upgrading Firmware......................................................... 87

7 Quick Start Reference ............................................................. 88

7.1 Quick Start - External Torque Mode .............................................88

7.2 Quick Start - External Velocity Mode............................................. 89

7.3 Quick Start - External Positioning Mode ..........................................91

8 Diagnostics.....................................................................93

8.1 Diagnostic Display ..........................................................93

8.2 Diagnostic LEDs ............................................................ 94

8.3 Stop/Reset ................................................................ 94

8.4 Faults....................................................................95

8.4.1 Fault Codes.........................................................95

8.4.2 Fault Event .........................................................97

8.4.3 Fault Reset .........................................................97

8.4 Troubleshooting ............................................................ 97

4 L S94H201E_13426446_EN

About These Instructions

This documentation pertains to the PositionServo drive with Hardware Version 2. This documentation contains
important technical data regarding the installation, operation and commissioning of the drive. Observe all
safety instructions. Read this document in its entirety before operating or servicing a PositionServo drive.

Drive Hardware Version

For hardware version 2, the drive dataplate (identification label) displays “2” in the fourth to last digit of the
drive indentification number. Refer to “E” designation in the drive identification label. Upon power-up the
drive LED display will read “9402” to indicate 940 PositionServo, hardware version 2.

If upon power-up the drive LED reads “940”, the drive has hardware version 1. Refer to User Manual
S94PM01 for hardware version 1 drives.

Drive Identification Label

C A B D E F

Type:
E94P120Y2NES

ID-No: 13014745

INPUT:

1(3)/PE
120/240 V

24.0 (13.9) A
50-60 HZ

OUTPUT:

3/PE
0 - 230 V

12.0 A

For detailed information

refer to instruction

Manual: S94H201

SN: 13014745012345678

E94P120Y2NES0XX2###

Made in USA

Model 940

13014745012345678

A B C D E F

Certifications Model

Number

Input
Ratings

Output
Ratings

Hardware
Version

Software
Version

Package Contents

Scope of Supply Important

1 Model PositionServo:

Type E94P or E94R
1 Mounting Instructions (English)
1 MotionView CD ROM including:

- configuration software

- documentation

After reception of the delivery, immediately check whether the scope
of supply matches the accompanying papers. Lenze- AC Tech 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.

Related Documents

The documentation listed herein contains information relevant to the operation of the PositionServo and
MotionView OnBoard. To obtain the latest documentation, visit the Technical Documentation section of
http://www.lenze.com.

Table 1: Reference Documentation

Document # Description

P94MI01 PositionServo (with MVOB) Mounting Instructions

PM94H201 PositionServo (with MVOB) Programming Manual

P94MOD01 Position Servo ModBus RTU over RS485 ; Modbus TCP/IP

P94CAN01 PositionServo CANopen Communications Reference Guide

P94DVN01 PositionServo DeviceNet Communications Reference Guide

P94ETH01 PositionServo EtherNet/IP Communications Reference Guide

P94PFB01 PositionServo PROFIBUS Communications Reference Guide

S94H201E_13426446_EN L 5

Introduction

1 Introduction

1.1 Safety Information

The safety information provided in this documentation has the layout shown herein.

Signal Word! (Characteristics the severity of the danger)

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

Table 2: Pictographs used in these Instructions

Icon Signal Words

Warning of
hazardous
electrical voltage

DANGER!

Warns of impending danger.
Consequences if disregarded:
Death or severe injuries.

Warning of a
general danger

WARNING!

Warns of potential, very hazardous situations.
Consequences if disregarded:
Death or severe injuries.

Warning of
damage to
equipment

STOP!

Warns of potential damage to material and
equipment.
Consequences if disregarded:
Damage to the controller/drive or its environment.

Information

NOTE

Designates a general, useful note.
If you observe it, handling the controller/drive system is
made easier.

1.2 Legal Regulations

Table 2 lists the identification, application, liability, warranty and disposal information for the PositionServo
drive.

Table 3: Legal Disclaimers

Claim Description

Identification

Nameplate CE Identification Manufacturer

Lenze controllers are unambiguously
designated by the contents of the
nameplate

In compliance with the EC
Low-Voltage Directive

Lenze AC Tech Corporation
630 Douglas Street
Uxbridge, MA 01569 USA

Application
as directed

E94P or E94R servo controller

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

• are components for:

- Closed loop control of Velocity, Torque, or Positioning applications with AC synchronous motors.

- installation in a machine.

- assembly with other components to form a machine.

• are electric units for installation in control cabinets or similarly enclosed 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.

Application
as directed

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:

- 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!

Note: Table 3 continued on next page.

6 L S94H201E_13426446_EN

Introduction

Claim Description

Liability

•Theinformation,data,andnotesintheseinstructionsmetthelatestdesignandimplementationofthe

drive at the time of publication. Claims on modifications referring to controllers that have already been
supplied cannot be derived from the information, illustrations, and descriptions.

•Thespecications,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specications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

Warranty

•Warrantyconditions:refertoLenzeACTechTermsandConditionsofSale,documentTD03.

Disposal Material Recycle Dispose

Metal • -

Plastic • -

Assembled PCB’s - •

1.3 General Drive Information

1.3.1 Mains Configuration

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

1. 120/240V Single Phase (Voltage Doubler) Units

When wired for Doubler mode (L1-N), the input is for 120V nominal only and can range from 70 VAC 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.

2. 120/240V Single Phase (Filtered) Units

120/240V (nominal) single phase input with integrated input mains (line) filter. Actual input voltage range:

80VAC to 264VAC. The maximum output voltage is approximately equal to the input voltage.

3. 120/240V Single or Three Phase Units

120V or 240V (nominal) single or three phase input. Actual input voltage range: 80VAC to 264VAC. The

maximum output voltage is approximately equal to the input voltage. An external input mains (line) filter is
available.

4. 400/480V Three phase Units

400/480V (nominal) three phase input. An external input mains (line) filter is available. Actual voltage

range: 320 - 528 VAC.

1.3.2 Operating Modes

The PositionServo drive can operate in one of three mode settings, torque (current), velocity, or positioning. The
drive’s command or reference signal can come from one of three sources. 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 reference is
derived from the drive’s user program. The third reference is when the commanded reference is given by 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), Modbus over TCP/IP,
CANopen (DS301), EtherNet/IP, DeviceNet or PROFIBUS DP.

S94H201E_13426446_EN L 7

Introduction

1.3.3 Feedback

Depending on the primary feedback, there are two types of drives: the Model 940 PositionServo encoder­based drive which accepts an incremental encoder with Hall channel 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.

1.3.4 Software

MotionView software is the setup and management tool for the PositionServo drive. All parameters can be
set and monitored via this software 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 analog and digital I/O (inputs and outputs). The programming language is a
Basic-like language designed to be very intuitive and easy to implement. For programming details, refer to the
PositionServo Programming Manual. All PositionServo related manuals can be downloaded from the Technical
Documentation section on the Lenze website (http://www.lenze.com).

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

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

8 L S94H201E_13426446_EN

Introduction

1.4 Part Number Designation

The table herein describes the part number designation for the PositionServo drive. The available filter and
communication options are detailed in separate tables.

1.4.1 Drive Part Number

E94

P 020 S 1 N E M

Electrical Products in the 94x Series

P = PositionServo Model 940 with Encoder Feedback
R = PositionServo Model 941 with Resolver Feedback

Drive Rating in Amps:

020 = 2 Amps 090 = 9 Amps
040 = 4 Amps 100 = 10 Amps
060 = 6 Amps 120 = 12 Amps
080 = 8 Amps 180 = 18 Amps

Input Phase:

S = Single Phase Input only
Y = Single or Three Phase Input
T = Three Phase Input only

Input Voltage:

1 = 120 VAC Doubler (120V, 1~ in/ 240V, 3~ out)
2 = 200/240 VAC
4 = 400/480 VAC

Line Filter:

N = No Line Filter*
F = Integrated Line Filter

Secondary Feedback:

E = Incremental Encoder
R = Standard Resolver

Safety Option:

M = MotionView OnBoard, no ISO 13849-1 safety compliance
S = MotionView OnBoard, with ISO 13849-1 safety compliance

* For 3-phase EMC installation, model 940 EMC footprint/side mount filters are required.

1.4.2 Filter Part Number

E94Z

F 4 T 4

A1

Electrical Option in the 94x Series

F = EMC Filter

Filter Current Rating in Amps:

04 = 4.4 Amps 12 = 12 Amps
07 = 6.9 Amps 15 = 15 Amps
10 = 10 Amps 24 = 24 Amps

Input Phase:

S = Single Phase
T = Three Phase

Max Voltage:

2 = 240 VAC
4 = 400/480 VAC

Degree of Filtering/Variation

A1 = Industrial/1st Variation
A2 = Industrial/2nd Variation

S94H201E_13426446_EN L 9

Introduction

1.4.3 Option Part Number

E94Z A

CAN 1

Electrical Option in the 94x Series

A = Communication or Breakout Module

Module Type:

Communication: Breakout:
CAN = CANopen COMM Module HBK = Motor Brake Terminal Module
RS4 = RS485 COMM Module TBO = Terminal Block I/O Module
DVN = DeviceNet COMM Module SCA = Panel Saver I/O Module
PFB = PROFIBUS COMM Module

Variations

1 = 1st Variation
2 = 2nd Variation
3 = 3rd Variation

10 L S94H201E_13426446_EN

Technical Data

2 Technical Data

2.1 Electrical Characteristics

Single-Phase Models

Type

(1)

Mains Voltage

(2)

1~ Mains

Current

(doubler)

1~ Mains

Current

(Std.)

Rated

Output

Current

(5)

Peak

Output

Current

(6)

E94_020S1N_~

120V

(3)

or 240V

(4)

9.7 5.0 2.0 6

E94_040S1N_~ 15 8.6 4.0 12

E94_020S2F_~

120 / 240V

(4)

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

-- 5.0 2.0 6

E94_040S2F_~ -- 8.6 4.0 12

E94_080S2F_~ -- 15.0 8.0 24

E94_100S2F_~ -- 18.8 10.0 30

Single/Three-Phase Models

Type

(1)

Mains Voltage

(2)

1~

Mains

Current

3~

Mains

Current

Rated

Output

Current

(5)

Peak

Output

Current

(6)

E94_020Y2N_~

120 / 240V

(4)

1~ or 3~

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

5.0 3.0 2.0 6

E94_040Y2N_~ 8.6 5.0 4.0 12

E94_080Y2N_~ 15.0 8.7 8.0 24

E94_100Y2N_~ 18.8 10.9 10.0 30

E94_120Y2N_~ 24.0 13.9 12.0 36

E94_180T2N_~

240V 3~

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

-- 19.6 18.0 54

E94_020T4N_~

400 / 480V

3~

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

-- 2.7 2.0 6

E94_040T4N_~ -- 5.5 4.0 12

E94_060T4N_~ -- 7.9 6.0 18

E94_090T4N_~ -- 12.0 9.0 27

(1) The first “_” equals “P” for the 940 encoder based drive or “R” for the 941 resolver based drive.

The second “_” equals “E” for incremental encoder (must have E94P drive) or “R” for the standard resolver (must have E94R drive).
The last digit “~” equals “M” for MV OnBoard and no ISO 13849-1 circuit or “S” for MV OnBoard plus the ISO 13849-1 circuit.

(2)

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

(3) Connection of 120VAC (70 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.

(4)

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.

(5)

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

(6)

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

(7)

Derate rated output current and peak output current by 2.5% for every ºC above 40ºC up to 55ºC maximum.

S94H201E_13426446_EN L 11

Technical Data

Electrical Specifications applicable to all models:

Acceleration Time Range (Zero to Max Speed) 0.1 … 5x10

6

RPM/sec

Deceleration Time Range (Max Speed to Zero) 0.1 … 5x10

6

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

Power Supply (max) +5 VDC @ 300 mA

Maximum Encoder Feedback Frequency 2.1 MHz (per channel)

Maximum Output Frequency (to motor) 400 Hz

Resolver Carrier Frequency 4.5 - 5.5kHz (5kHz nom)

Resolver Turns Ratio: Reference to SIN/COS signal 2:1

Resolver Voltage 10V peak to peak

Maximum Resolver Feedback Speed 6500 rpm

2.2 Power Ratings

Type

(1)

Output Power

at Rated Output

Current (8kHz)

(2)

Leakage Current

Power Loss at

Rated Output

Current

(8kHz)

Power Loss at

Rated Output

Current

(16 kHz)

(3)

Units kVA mA Watts Watts

E94_020S1N_~ 0.8

Typically >3.5 mA.

Consult factory for

applications requiring

<3.5 mA.

19 21

E94_040S1N_~ 1.7 29 30

E94_020S2F_~ 0.8 19 21

E94_040S2F_~ 1.7 29 30

E94_080S2F_~ 3.3 61 63

E94_100S2F_~ 4.2 80 85

E94_020Y2N_~ 0.8 19 21

E94_040Y2N_~ 1.7 29 30

E94_080Y2N_~ 3.3 61 63

E94_120Y2N_~ 5.0 114 129

E94_180T2N_~ 7.5 171 195

E94_020T4N_~ 1.7 31 41

E94_040T4N_~ 3.3 50 73

E94_060T4N_~ 5.0 93 122

E94_090T4N_~ 7.5 138 182

(1) The first “_” equals “P” for the Model 940 encoder based drive or “R” for the Model 941 resolver based drive.

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

The last digit “~” equals “M” for MV OnBoard and no ISO 13849-1 circuit or “S” for MV OnBoard plus the ISO 13849-1 circuit.

(2) 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 kVA = [(3) x ULL x I

rated

] / 1000

b. The actual output power (kW) depends on the motor in use due to variations in motor rated voltage, rated speed and power factor, as well as actual max

operating speed and desired overload capacity.

c. Typical max continuous power (kW) for PM servo motors run 50-70% of the kVA ratings listed.

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

12 L S94H201E_13426446_EN

Technical Data

2.3 Fuse Recommendations

Type

(1)

AC Line

Input Fuse

(1ø/3ø)

Miniature

Circuit Breaker

(4)

(1ø/3ø)

AC Line Input Fuse

or Breaker

(5) (6)

(N. America)

DC Bus Input

Fuse

(7)

Amp Ratings
E94_020S1N_~ M20/M10 C20/C10 20/10 10
E94_040S1N_~ M32/M20 C32/C20 30/20 20

E94_020S2F_~ M20 C20 20 15
E94_040S2F_~ M20 C20 20 20
E94_080S2F_~ M32 C32 32 40
E94_100S2F_~ M40 C40 40 45

E94_020Y2N_~ M20/M16 C20/C16 20/15 15
E94_040Y2N_~ M20/M16 C20/C16 20/15 20
E94_080Y2N_~ M32/M20 C32/C20 30/20 40
E94_120Y2N_~ M50/M32 C50/C32 50/30 55
E94_180T2N_~ M40 C40 40 80

E94_020T4N_~ M10 C10 10 10
E94_040T4N_~ M10 C10 10 20
E94_060T4N_~ M20 C20 20 30
E94_090T4N_~ M25 C25 25 40

(1) The first “_” equals “P” for the Model 940 encoder based drive or “R” for the Model 941 resolver based drive.

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

The last digit “~” equals M” for MV OnBoard and no ISO 13849-1 circuit or “S” for MV OnBoard plus the ISO 13849-1 circuit.

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

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

(6) Thermal-magnetic type breakers preferred.

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

2.4 Digital and Analog I/O Ratings

I/O Scan

Times

Linearity Temperature Drift Offset Current Input

Impedance

Voltage

Range

Units

ms % % % mA Ohm VDC

Digital Inputs

(1)

512 Depend on load 2.4 k

(2)

5-24

Digital Outputs

512 100 max N/A 30 max

Analog Inputs

512 ± 0.013 0.1% per °C rise ± 0 adjustable Depend on load 47 k ± 10

Analog Outputs

512 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) Input Impedance is 1.2kΩ for drive with Hardware Revision 2A.

2.5 Environment

Vibration 2 g (10 - 2000 Hz)
Ambient Operating Temperature Range 0 to 40ºC (Derate rated output current and peak output current by 2.5% for

every ºC above 40ºC up to 55ºC)
Ambient Storage Temperature Range -10 to 70ºC
Temperature Drift 0.1% per ºC rise
Humidity 5 - 90% non-condensing
Altitude 1500m/5000ft [derate by 1% per 300m (1000 ft) above 1500m (5000 ft)]

2.6 Operating Modes

Torque

Reference ± 10 VDC 12-bit; scalable
Torque Range 100:1
Current-Loop Bandwidth Up to 1.5 kHz*

S94H201E_13426446_EN L 13

Technical Data

Velocity

Reference ± 10 VDC or 0…10 VDC; 12-bit; scalable
Regulation ± 1 RPM
Velocity-Loop Bandwidth Up to 200 Hz*
Speed Range 5000:1 with 5000 ppr encoder

Position

Reference 0…2 MHz Step & Direction or 2 channels quadrature input; scalable
Minimum Pulse Width 500 nanoseconds
Loop Bandwidth Up to 150 Hz*
Accuracy ±1 encoder count for encoder feedabck
±1.32 arc-minutes for resolver feedback (14-bit resolution)

* = motor and application dependent

2.7 Connections and I/O

Mains Power 3-pin or 4-pin removable terminal block (P1)
Ethernet Port Standard RJ45 Connector (P2)
I/O Connector Standard 50-pin SCSI (P3)

- Buffered Encoder Output A, B, & Z channels with compliments (5V @ 20mA) (P3)

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

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

- Analog Input 2 differential; ±10 VDC (12-bits each) (P3)

- Analog Output 1 single ended; ±10 VDC (10-bit) (P3)

- Position Reference Input Step & Direction or Master Encoder (TTL) (P3)
Encoder Feedback (E94P drive) Feedback connector, 15-pin D-shell (P4)
Resolver Feedback (E94R drive) Feedback connector, 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)
ISO 13849-1 Safety Circuit (option) 6-pin quick connect terminal block (P8)
RS485 Option Module 3-pin terminal block (installed in Option Bay 1) (P21)
CAN Option Module 3-pin terminal block (installed in Option Bay 1) (P21)
DeviceNet Option Module 5-pin terminal block (installed in Option Bay 1) (P23)
PROFIBUS Option Module 9-pin D-shell connector (installed in Option Bay 1) (P24)
MotionView OnBoard Embedded Software (Java-based)
Maximum Servo Cable Length 20 meters (10m if EN55011 compliance required, see 3.2.1)

P2

P3

P1

P4

P5

P6

P7

EPM

W

V

U

T2

T1

9

4

0

2

8

d

i

S

P8

Ground Lug

Ground Lug

L3

L2

L1

1

2

3

4

5

6

14 L S94H201E_13426446_EN

Technical Data

2.8 PositionServo Dimensions

C

15

12

12

A

38

D B

34

dia = 4.57

4.57

Dimensions in mm

S923

Type

(1)

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

E94_020S1N_~ 68 190 190 182 1.1

E94_040S1N_~ 69 190 190 182 1.2

E94_020S2F_~ 68 190 235 182 1.3

E94_040S2F_~ 69 190 235 182 1.5

E94_080S2F_~ 87 190 235 182 1.9

E94_100S2F_~ 102 190 235 182 2.2

E94_020Y2N_~ 68 190 190 182 1.3

E94_040Y2N_~ 69 190 190 182 1.5

E94_080Y2N_~ 95 190 190 182 1.9

E94_100Y2N_~ 114 190 190 182 2.2

E94_120Y2N_~ 68 190 235 182 1.5

E94_180T2N_~ 68 242 235 233 2.0

E94_020T4N_~ 68 190 190 182 1.5

E94_040T4N_~ 95 190 190 182 1.9

E94_060T4N_~ 68 190 235 182 1.4

E94_090T4N_~ 68 242 235 233 2.0

(1) The first “_” equals “P” for the Model 940 encoder based drive or “R” for the Model 941 resolver based drive.

The second “_” equals “E” for incremental encoder (must have E94P drive) or “R” for the standard resolver (must have E94R drive).
The last digit “~” equals M” for MV OnBoard and no ISO 13849-1 circuit or “S” for MV OnBoard plus the ISO 13849-1 circuit.

S94H201E_13426446_EN L 15

Technical Data

2.9 Clearance for Cooling Air Circulation

>25mm

>3mm

>25mm

S924

16 L S94H201E_13426446_EN

Installation

3 Installation

Perform the minimum system connection. Refer to section 6.1 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 required 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 61800-5-1). 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.

• The PositionServo does not provide motor over-temperature protection. The

user may connect a KTY motor thermal sensor to the drive as detailed in
section 4.1.1 and 4.5.2 if necessary to satisfy NEC requirements.

S94H201E_13426446_EN L 17

Installation

3.1 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.

WARNING!

The PositionServo drive runs on phase-to-phase voltage. For the standard drive, either a
delta or wye transformer may be used for 3-phase input. However, for reinforced insulation
of user accessible I/O circuits, each phase voltage to ground must be less than or equal to
300VAC rms. This means that the power system must use center grounded wye secondary
configuration for 400/480VAC mains.

Refer to section 4.1.1 for Power wiring specifications.

3.2 Shielding and Grounding

3.2.1 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

2

) or larger
wire to join the enclosure to earth ground. A lock washer 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 the drive and servo motor).

18 L S94H201E_13426446_EN

Installation

EMC

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

Noise emission

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

Installation according to EMC
Requirements

E

D

B C

A

F

S930

A

Screen clamps

B

Control cable

C

Low-capacitance motor cable

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

D

Earth grounded conductive mounting plate

E

Encoder/Resolver Feedback Cable

F

Footprint or Sidemount Filter (optional)

3.2.2 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.

3.2.3 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 3.2.1.

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 2.9
suggested cooling air clearance.

3.3 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 IEC 61800­3:2004, 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.

S94H201E_13426446_EN L 19

Installation

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 feedback cables (maximum cable length of 10m), 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.

3.4 Heat Sinking

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

3.5 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.

20 L S94H201E_13426446_EN

Interface

4 Interface

The standard PositionServo drive is equipped with seven connectors including: four quick-connect terminal
blocks, one SCSI connector, one subminiature type “D” connector and one ethernet RJ45 connector. 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, the convention PX.Y is used, where
X is the connector number and Y is the pin number.

4.1 External Connectors

4.1.1 P1 & P7 - Input Power and Output Power Connections

Located on the top of the drive, P1 is a 3 or 4-pin quick-connect terminal block used for input (mains) power.
Located on the bottom of the drive, 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 (refer to paragraph 4.5.2).
The P1 and P7 connector pin assignments are listed in the tables herein.

P1 Pin Assignments (Input Power)

Standard Models

1

2

3

4

L3

L2

L1

PE

Pin Name Function

1 PE Protective Earth (Ground)
2 L1 AC Power in
3 L2 AC Power in
4 L3 AC Power in (3~ models only)

Doubler Models

1

2

3

4

L2/N

L1

N

PE

Pin Name Function

1 PE Protective Earth (Ground)
2 N AC Power Neutral (120V Doubler only)
3 L1 AC Power in
4 L2/N AC Power in (non-doubler operation)

P7 Pin Assignments (Output Power)

Pin Terminal Function

1

2

3

4

5

W

V

U

6

T2

T1

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)

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!

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 miswired, severe damage
to the PositionServo will result.

S94H201E_13426446_EN L 21

Interface

All conductors must be enclosed in one shield with a 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 3.2. 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
A (rms)

Terminal

Torque (lb-in)

Wire Size

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)

4.1.2 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

ETHERNET

1

8

P2

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 recommended. If
using a hub or switch, use a regular patch cable.

22 L S94H201E_13426446_EN

Interface

4.1.3 P3 - Controller I/O

P3 is a 50-pin SCSI connector to interface with the front-end of the controller. It is strongly recommended
that OEM cables be used to aid in satisfying CE requirements. Contact your Lenze representative for
assistance.

P3 Pin Assignments (Controller Interface)

Pin Name Function

CONTROLLER I/O

1

25

P3

50

26

1 MA+ Master Encoder A+ / Step+ input

(2)

2 MA- Master Encoder A- / Step- input

(2)

3 MB+ Master Encoder B+ / Direction+ input

(2)

4 MB- Master Encoder B- / Direction- input

(2)

5 GND Drive Logic Common
6 5+ +5V output (max 100mA)
7 BA+ Buffered Encoder Output: Channel A+

(1)

8 BA- Buffered Encoder Output: Channel A-

(1)

9 BB+ Buffered Encoder Output: Channel B+

(1)

10 BB- Buffered Encoder Output: Channel B-

(1)

11 BZ+ Buffered Encoder Output: Channel Z+

(1)

12 BZ- Buffered Encoder Output: Channel Z-

(1)

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

(3)

27 IN_A1 Digital input A1
28 IN_A2 Digital input A2
29 IN_A3 Digital input A3

(3)

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
50 OUT4-E Programmable output #4 Emitter

(1) Refer to Note 1, Section 4.1.7 - Connector and Wiring Notes
(2) Refer to Note 2, Section 4.1.7 - Connector and Wiring Notes
(3) Refer to Note 3, Section 4.1.7 - Connector and Wiring Notes

S94H201E_13426446_EN L 23

Interface

4.1.4 P4 - Motor Feedback

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, Hall sensors or Hall
emulation tracks are necessary for commutation. 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. The resolver feedback is translated to 65,536 counts
per revolution.

All conductors must be enclosed in one shield with a 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 4.2.2 “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 front-end 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. The user does
not need to supply pull-up resistors for open-collector hall sensors. The necessary pull­up circuits are already provided.

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

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

P4A Pin Assignments (Encoder Feedback - E94P Drives)

Pin Name Function

ENCODER

1

8

P4

15

9

1 EA+ Encoder Channel A+ Input

(1)

2 EA- Encoder Channel A- Input

(1)

3 EB+ Encoder Channel B+ Input

(1)

4 EB- Encoder Channel B- Input

(1)

5 EZ+ Encoder Channel Z+ Input

(1)

6 EZ- Encoder Channel Z- Input

(1)

7 GND Drive Logic Common/Encoder Ground
8 SHLD Shield
9 PWR Encoder supply (+5VDC)
10 HA- Hall Sensor A- Input

(2)

11 HA+ Hall Sensor A+ Input

(2)

12 HB+ Hall Sensor B+ Input

(2)

13 HC+ Hall Sensor C+ Input

(2)

14 HB- Hall Sensor B- Input

(2)

15 HC- Hall Sensor C- Input

(2)

(1) Refer to Note 1, Section 4.1.7 - Connector and Wiring Notes

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

24 L S94H201E_13426446_EN

Interface

P4B Pin Assignments (Resolver Feedback - E94R Drives)

Pin Name Function

RESOLVER

1

5

P4

9

6

1 Ref +

Resolver reference connection

2 Ref -

3 N/C No Connection

4 Cos+

Resolver Cosine connections

5 Cos-

6 Sin+

Resolver Sine connections

7 Sin-

8 PTC+

Motor PTC Temperature Sensor

9 PTC-

STOP!

Use only 10 V (peak to peak) or less resolvers. Use of higher voltage resolvers may result
in feedback failure and damage to the drive.

4.1.5 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

+

-

+

-

24

1 +24 VDC Positive 24 VDC Input

2 Return 24V power supply return

WARNING!

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

4.1.6 P6 - Braking Resistor and DC Bus

P6 is a 5-pin quick-connect terminal block that can be used with an external braking resistor (the
PositionServo has the regen circuitry built-in). The Brake Resistor connects between the Positive DC Bus
(either P6.1 or 2) and P6.3.

P6 Terminal Assignments (Brake Resistor and DC Bus)

Pin Terminal Function

B+

B-

BR

B-

B+

1 B+

Positive DC Bus / Brake Resistor

2 B+

3 BR Brake Resistor

4 B-

Negative DC Bus

5 B-

DANGER!

Hazard of electrical shock! Voltage up to 480 VAC above earth ground is possible. Avoid direct contact
with live terminals and circuit elements. Disconnect incoming power and wait 60 seconds before
opening or servicing the drive. Capacitors retain charge after power is removed.

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4.1.7 Connector and Wiring Notes

Note 1 - Buffered Encoder Outputs

Each of the encoder output pins on P3 is a buffered pass-through of the corresponding input signal on P4,
Refer to section 4.2.2 “Buffered Encoder Outputs”. This can be either from a motor mounted encoder or
an encoder emulation of the resolver. The parameter “Resolver Tracks” configures the resolution of the
encoder emulation (refer to 5.3.17).

Note 2 - Master Encoder Inputs or Step/Direction Inputs

An external pulse train signal (“step”) supplied by an external device, such as a PLC or stepper indexer, can
control the speed and position of the servomotor. The speed of the motor is controlled by the frequency of
the “step” signal, while the number of pulses that are supplied to the PositionServo determines the position
of the servomotor. Direction input controls direction of the motion.

Note 3 - Digital Input A3

For the drive to function, an ENABLE input must be wired to the drive, and should be connected to IN_A3,
(P3.29), which is, by the default the ENABLE input on the drive. This triggering mechanism can either be
a switch or an input from an external PLC or motion controller. The input can be wired either sinking or
sourcing (section 4.2.3). The Enable circuit will accept 5-24V control voltage.

Wiring the ENABLE Switch:

Pin 6 +5V

Pin 5 GND

Pin 26 IN_A_COM

Pin 29 IN-A3

CONTROLLER I/O

1

25

P3

50

26

Power Supply

Pin 26 IN_A_COM

Pin 29 IN-A3

-

+

CONTROLLER I/O

1

25

P3

50

26

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4.1.8 P8 - ISO 13849-1 Safety Circuit (option)

If installed, the ISO 13849-1 Safety Circuit connector, P8, is located on the bottom of the PositionServo. P8,
a 6-pin quick-connect terminal block.

P8 Pin Assignments (ISO 13849-1 Safety Function)

Pin Name Function

1

4

3

1

5

2

2

3

4

5

6

6

1 Bypass Voltage ISO 13849-1Bypass Voltage (+24VDC)

2 Bypass COM ISO 13849-1 Bypass Common

3 Safety Status ISO 13849-1 Safety Status

4 Safety Input1 ISO 13849-1 Safety Input 1 (+24VDC to Enable)

5 Safety COM ISO 13849-1 Safety Common

6 Safety Input2 ISO 13849-1 Safety Input 2 (+24VDC to Enable)

WARNING!

The drive is supplied from the factory with the ISO 13849-1 safety circuit enabled. The drive is not operational until +24V
is present at terminals 4 and 6. For the proper safety connections, refer to the “Connection of Two Safety Circuits with
External +24V Supply” diagram. Under certain applications when safety connections are not required the drive may be
operated with the safety circuit disabled. The diagram below illustrates how to bypass the safety circuit.

Wiring Diagram to Bypass ISO 13849-1 Safety Circuit

Pin Name Function

P1

P2

P3

P4

P5

P6

1 Bypass Voltage ISO 13849-1 Bypass Voltage (+24VDC)

*1

2 Bypass COM ISO 13849-1 Bypass Common

*1

3 Safety Status ISO 13849-1 Safety Status

4 Safety Input1 ISO 13849-1 Safety Input 1 (+24VDC to Enable)

*2, *3

5 Safety COM ISO 13849-1 Safety Common

*2, *3

6 Safety Input2 ISO 13849-1 Safety Input 2 (+24VDC to Enable)

*2, *3

*1 – This voltage must under no circumstances be used to supply the ISO 13849-1 Safety circuits (terminals 3 to 6). This voltage is intended only for use

in bypassing (disabling) the ISO 13849-1 circuits should they not be required.

*2 – A Separate +24VDC supply providing reinforced isolation (SELV or PELV), must be supplied to operate these inputs. This supply should not be floating

but should be referenced within 20V peak of PE at the drive.

*3 – Unsnubbed inductive loads must NOT be used on the 24VDC safety circuit wiring.

PositionServo drives with the following “S” designation in the model number have been fitted with the
optional ISO 13849-1 Safe Torque Off function.

Drive Model Number: E94 P 020 S 1 N E

S

The last “S” denotes ISO 13849-1
option fitted to drive at manufacturer.

This option can only be fitted at the factory at the time of unit manufacturer.

This option provides additional methods (Inputs) to disable the drive output so that the drive cannot cause
torque to be generated in the motor. This safety function is often referred to as the “Safe Torque Off”
function and meets the requirements of the following standard: ISO 13849-1 Safety of Machinery, Safety­related Parts of Control Systems, Category (Cat.) 3, Performance Level (PL) d and Safety Integrity Level (SIL)
2, per EN 61800-5-2 2007.

WARNING!

It is required that all information contained within this ISO 13849-1 standard be observed
when implementing any part of this safety circuit functionality with the PositionServo drive.

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Operation of the ISO 13849-1 Safety Circuit

ISO 13849-1 Cat 3, PL d designates that the enable function of the drive be designed in such a way that
a single fault in any of the parts of this enable circuit cannot lead to a loss of this safety function. The ISO
13849-1 safe torque off function has been designed and certified as meeting the requirements of this
standard.

PositionServo drives equipped with the ISO 13849-1 safety circuit option can be used in application
requiring conformance to this standard, and also in safety-related applications or in other applications
where the integrity of the enable / disable function is paramount to the safety of personnel and machinery.

The ISO 13849-1 safety circuit can interrupt the power supply to the motor without the AC line input to the
drive being removed. However, for the purposes of maintenance and mechanical work on the drive system
it is recommended that the AC (work swap) Line input be removed and the drives internal bus voltages
allowed to discharge before any such work is attempted. The ISO 13849-1 category 3 standard does not
provide for electrical safety of all components within the drive system.

For normal operation (enable) of the PositionServo drive, both the Safety Input 1 and Safety Input 2 are
required to be active. These inputs act as a Inhibit function, preventing the drive from being enabled until
both are active, and causing the drive to disable once either one or both of the inputs are removed. The
activation of both inputs will not automatically cause the drive to enable but will allow enable through the
standard methods provided for enable of the drive.

If an attempt is made to enable the drive by executing the program statement “ENABLE” or from activating
the input IN_A3 with the ISO 13849-1 safety inputs not being present then the drive will generate an ISO
13849-1 Safety Fault (F_EF).

When the drive is disabled through the ISO 13849-1 safety inputs (by removing the +24VDC assertion
level to either Safety Input 1 or Safety Input 2 or both while the drive is enabled) the drive output is turned
off and further torque cannot be produced by the drive in the motor. The drive will go to the “F_EF” fault
condition to indicate disable of the drive was by means of the safety circuits. With the drive output disabled
the motor will perform an uncontrolled stop or free-wheel deceleration to stand-still (unless driven by the
load). Rotation of the motor will not stop immediately and the time to reach standstill will depend on the
inertia contained within the system.

WARNING!

Ensure motion has stopped and the machine is in a safe condition before approaching the application.

If the system is required to be brought to zero speed on loss of the safety circuit function then a motor with
a fail-safe mechanical brake should be used and the necessary mechanism implemented.

Due to ISO 13849-1 regulations, a separate +24VDC external dedicated safety power supply must be
provided to the drive Safety circuits. The bypass +24V supply is intended for bypass purposes only and
must not be used as the control voltage to these circuits.

Installation and Connection

Connection of Two Safety Circuits with External +24V Supply

Pin Name Function

+

P1

P2

P3

P4

P5

P6

-

External
+24VDC

Safety Circuit

Input 1

Safety Circuit

Input 2

1 Bypass Voltage ISO 13849-1 Bypass Voltage (+24VDC)

2 Bypass COM ISO 13849-1 Bypass Common

3 Safety Status ISO 13849-1 Safety Status * 100mA max.

4 Safety Input1 ISO 13849-1 Safety Input 1 (+24VDC to Enable)

5 Safety COM ISO 13849-1 Safety Common

6 Safety Input2 ISO 13849-1 Safety Input 2 (+24VDC to Enable)

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Evaluation and Testing of the ISO 13849-1 Safety Circuit

As part of the regulations for ISO 13849-1 safety circuit provision must be made for the user to periodically
test the safety circuits and that testing should be capable of identifying a single fault. The PositionServo
drive uses the safety status output (Pin 3) in conjunction with the display of the drive to allow the testing of
the safety circuits.

The safety status output becomes active to indicate partial or full enable of the safety input circuits 1 and

2. If safety input 1 or safety input 2 or both inputs are on then the safety status output will become active.
The safety status output must be connected to some visible indication for the operator to reference during
test of the circuit.

As well as being used to test the correct operation of the safety circuits the safety status output can be used
as an indicator that the drive has been placed in the fully shut down condition (all safety circuits off). For
example, if both Safety Inputs have been Deactivated, the Safety Status is also Deactivated. If one of the
Safety Inputs signals failed to call for a shutdown, or if one of the Safety Circuits failed to shut down, the
Safety Status signal remains Asserted to alert the operator to the problem.

The procedure for testing the ISO 13849-1 safety circuit and the identification of a single fault on the system
is given below. The safety status output should be connected to a visible indicator (such as a lamp or LED)
so the operator can interpret its condition.

NOTE

Customer must size load so as not to pull more than 100mA.

Safety Status Output Indication

Pin Name Function

P1

P2

P3

P4

P5

P6

Safety Output

Status Indication

+

-

External
+24VDC

Safety Circuit

Input 1

Safety Circuit

Input 2

1 Bypass Voltage ISO 13849-1 Bypass Voltage (+24VDC)

2 Bypass COM ISO 13849-1 Bypass Common

3 Safety Status ISO 13849-1 Safety Status *100mA max

4 Safety Input1 ISO 13849-1 Safety Input 1 (+24VDC to Enable)

5 Safety COM ISO 13849-1 Safety Common

6 Safety Input2 ISO 13849-1 Safety Input 2 (+24VDC to Enable)

Setting up the Drive in a Maintenance Mode:

WARNING!

During test of the ISO 13849-1 circuit, as laid out in this documentation the drive will
go to run (enabled) condition and motion from the motor may be generated. It is the
responsibility of the system designer to ensure the system remains in a safe condition
during the enclosed maintenance procedure.