Lenze S94P01B2 User Manual

S929

PositionServo with RS-232

Users Manual

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

Contents

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

1.1 About These Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

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

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

2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.1 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.2 Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.3 Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.4 Connections and I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.5 Digital I/O Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.6 Power Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

2.7 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

2.8 Clearance for Cooling Air Circulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.1 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

3.2 Shielding and Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

3.2.1 General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

3.2.2 EMI Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

3.2.3 Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

3.3 Line Filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

3.4 Heat Sinking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

3.5 Line (Mains) Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

3.6 Fuse Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

4 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.1 External Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

4.1.1 P1 & P7 - Input Power and Output Power Connections. . . . . . . . . . . . .15

4.1.2 P2 - Serial Communications Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

4.1.3 P3 - Controller Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

4.1.4 P4 - Motor Feedback / Second Loop Encoder Input . . . . . . . . . . . . . . .17

4.1.5 P5 - 24 VDC Back-up Power Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

4.1.6 P6 - Braking Resistor and DC Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

4.1.7 Connector and Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

4.1.8 P11 - Resolver Interface Module (option) . . . . . . . . . . . . . . . . . . . . . . .20

4.1.9 P12 - Second Encoder Interface Module (option) . . . . . . . . . . . . . . . . .21

4.2 Digital I/O Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

4.2.1 Step & Direction / Master Encoder Inputs (P3, pins 1-4). . . . . . . . . . . .22

4.2.2 Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

4.2.3 Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

4.3 Analog I/O Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

4.3.1 Analog Reference Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

4.3.2 Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

4.4 Communication Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

4.4.1 RS232 Interface (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

4.4.2 RS485 Interface (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

4.4.3 Using RS232 and RS485 Interfaces Simultaneously . . . . . . . . . . . . . . .26

4.4.4 MODBUS RTU Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

4.5 Motor Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

4.5.1 Motor Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

4.5.2 Motor Over-Temperature Protection . . . . . . . . . . . . . . . . . . . . . . . . . . .27

4.5.3 Motor Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

4.6 Using a Custom Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

4.6.1 Creating Custom Motor Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . .29

4.6.2 Autophasing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

4.6.3 Custom Motor Data Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

S94P01B2

Contents

5 Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.1 Parameter Storage and EPM Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

5.1.1 Parameter Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

5.1.2 EPM Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

5.1.3 EPM Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

5.2 Motor Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

5.3 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

5.3.1 Drive Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

5.3.2 Drive PWM Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

5.3.3 Current Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

5.3.4 Peak Current Limit (8kHz and 16 kHz). . . . . . . . . . . . . . . . . . . . . . . . . .37

5.3.5 Analog Input Scale (Current) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

5.3.6 Analog Input Scale (Velocity). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

5.3.7 ACCEL/DECEL Limits (Velocity Mode Only) . . . . . . . . . . . . . . . . . . . . .38

5.3.8 Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

5.3.9 Step Input Type (Position Mode Only) . . . . . . . . . . . . . . . . . . . . . . . . . .38

5.3.10 Fault Reset Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

5.3.11 Motor Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

5.3.12 Motor PTC Cut-off Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

5.3.13 Second Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

5.3.14 Regen Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

5.3.15 Encoder Repeat Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

5.3.16 System to Master Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

5.3.17 Second to Prime Encoder Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

5.3.18 Autoboot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

5.3.19 Group ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

5.3.20 Enable Switch Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

5.3.21 User Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

5.4 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

5.4.1 IP Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

5.4.2 RS-485 Conﬁguration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

5.4.3 Modbus Baud Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

5.4.4 Modbus Reply Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

5.5 Analog I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

5.5.1 Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

5.5.2 Analog Output Current Scale (Volt / amps) . . . . . . . . . . . . . . . . . . . . . .41

5.5.3 Analog Output Velocity Scale (mV/RPM) . . . . . . . . . . . . . . . . . . . . . . . .41

5.5.4 Analog Input Dead Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

5.5.5 Analog Input Offset Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

5.5.6 Adjust Analog Voltage Offset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

5.6 Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

5.6.1 Digital Input De-bounce Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

5.6.2 Hard Limit Switch Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

5.7 Velocity Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

5.7.1 Zero Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

5.7.2 Speed Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

5.7.3 At Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

5.8 Position Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

5.8.1 Position Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

5.8.2 Max Error Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

5.8.3 Second Encoder Position Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

5.8.4 Second Encoder Max Error Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

S94P01B2

Contents

5.9 Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

5.9.1 Velocity P-gain (Proportional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

5.9.2 Velocity I-gain (Integral). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

5.9.3 Position P-gain (Proportional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

5.9.4 Position I-gain (Integral). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

5.9.5 Position D-gain (Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

5.9.6 Position I-limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

5.9.7 Gain Scaling Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

5.10 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

5.10.1 Oscilloscope Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

5.10.2 Run Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

5.11 Faults Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

6.1 Minimum Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

6.2 Conﬁguration of the PositionServo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

6.3 Position Mode Operation (gearing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

6.4 Dual-loop Feedback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

6.5 Enabling the PositionServo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

6.6 Drive Tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

6.6.1 Tuning the Drive in Velocity Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

6.6.2 Tuning the Drive in Position Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

7 Quick Start Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

7.1 Quick Start - External Torque Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

7.2 Quick Start - External Velocity Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

7.3 Quick Start - External Positioning Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

8 Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

8.1 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

8.2 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

8.3 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

8.3.1 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

8.3.2 Fault Event . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

8.3.3 Fault Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

8.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

S94P01B2

Safety Information

All safety information given in these Operating Instruction has a similar layout:

Signal Word! (Characteristics the severity of the danger)

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

Pictographs used in these instructions:

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.

S94P01B2

Introduction

1 Introduction

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 Model 940 is available in four mains (input power) conﬁgurations:

1. 400/480V (nominal) three phase input. An external input mains (line) ﬁlter is available. These drives have the sufﬁx “T4N”. 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. These drives have the sufﬁx “S2F”.

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. These drives have the sufﬁx “Y2N”.

4. 120V or 240V (nominal) single phase input. When wired for Doubler mode (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. These drives have the sufﬁx “S1N”.

The PositionServo 940 will accept feedback from an incremental encoder (that includes Hall channel information) or from a resolver. It accepts commands from a variety of sources, including analog voltage, RS485 interface (PPP and Modbus RTU), Ethernet interface, CANopen interface, digital pulse train, and master encoder reference. The control will operate in current (torque), velocity, or position (step and direction / master encoder) modes.

The 940 utilizes a software package called MotionView. MotionView provides a window into the drive allowing the user to check and set parameter. It has a real-time oscilloscope tool, for analyses and optimum tuning, as well as a User Program. This User Program can be utilized to command motion and handle the drives I/O. The MotionView programming language is designed to be very user friendly and easy to implement.

The EPM (Electronic Programming Module) stores all drive setup and tuning information. This module can be removed from the drive and reinstalled into another PositionServo 940, making ﬁeld replacement of the PositionServo 940 extremely easy.

The PositionServo 940 controls supports Point-to-Point (PPP) and Modbus RTU over RS485, Ethernet TCPIP and CANopen (DS301, DS402) communication protocols.

The PositionServo 940 supports incremental quadrature encoder or resolver feedback devices. A second encoder can also be supported during position and velocity modes.

1.1 About These Instructions

• These Operating Instructions are provided to assist the user in connecting and commissioning the PositionServo drive equipped with an RS232 interface in P2. Observe all safety instructions contained in this document.

• 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.

• Read these Operating Instructions in their entirety before operating the drive.

S94P01B2

Introduction

1.2 Scope of Supply

Scope of Supply Important

•1Model940ServotypeE94P...

•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deciencies/ incompleteness immediatelyto

your Lenze representative.

1.3 Legal Regulations

Identiﬁcation Nameplate CE Identiﬁcation Manufacturer

Application as directed

Liability

Warranty

Disposal

Lenze controllers are unambiguously designated by the contents of the nameplate

E94P... 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... 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 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 conditions: see Sales and Delivery Conditions of Lenze Drive Systems GmbH.

• Warranty claims must be made to Lenze immediately after detecting the deciency or fault.

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

Material Recycle Dispose

Metal

Plastic

Assembled PCB’s

In compliance with the EC Low-Voltage Directive

•

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

•

S94P01B2

Technical Data

2 Technical Data

2.1 Electrical Characteristics

Single-Phase Models

1~ Mains

Current

(2)

or 240V

(1)

(doubler)

(3)

Type Mains Voltage

E94P020S1N

E94P040S1N 15 8.6 4.0 12

E94P020S2F

E94P040S2F -- 8.6 4.0 12

E94P080S2F -- 15.0 8.0 24

E94P100S2F -- 18.8 10.0 30

120V

120 / 240V

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

Single/Three-Phase Models

1~ Mains

Type Mains Voltage

E94P020Y2N

E94P040Y2N 8.6 5.0 4.0 12

E94P080Y2N 15.0 8.7 8.0 24

E94P100Y2N 18.8 10.9 10.0 30

E94P120Y2N 24.0 13.9 12.0 36

E94P020T4N

E94P040T4N -- 5.5 4.0 12

E94P050T4N -- 6.9 5.0 15

E94P060T4N -- 7.9 6.0 18

(1)

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

(2)

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.

(3)

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.

(4)

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

(5)

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

120 / 240V

1~ or 3~

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

400 / 480V

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

(1)

Current

(3)

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-) 47k Ω 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)

1~ Mains

Current

(Std.)

9.7 5.0 2.0 6

-- 5.0 2.0 6

3~ Mains

Current

5.0 3.0 2.0 6

-- 2.7 2.0 6

Rated Output

(4)

Current

Rated Output

(4)

Current

Peak Output

Current

Peak Output

Current

(5)

2.2 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)]

S94P01B2

Technical Data

2.3 Operating Modes

Torque Reference ± 10 VDC 16-bit; scalable

Torque Range 100:1 Current-Loop Bandwidth Up to 1.5 kHz* Velocity Reference ± 10 VDC or 0…10 VDC; 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 and Direction or 2 channels quadrature input; scalable Minimum Pulse Width 500 nanoseconds Loop Bandwidth Up to 200 Hz* Accuracy ±1 encoder count

* = motor and application dependent

2.4 Connections and I/O

Mains Power 4-pin removable terminal block (P1) RS232 Port Standard 9-pin D-shell (DCE) Connector (P2) I/O Connector Standard 50-pin SCSI. (P3)

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

- Digital Inputs 12 programmable, 1 dedicated (5-24V) (P3)

- Digital Outputs 4 programmable, 1 dedicated(5-24V @ 15mA) (P3)

- Analog Input 1 differential; ±10 VDC (16 bit) (P3)

- Analog Output 1 single ended; ±10 VDC (10-bit) (P3) Encoder Feedback (primary) Standard 15-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) 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) Comm Option Bay Optional Comm Modules (CAN, Ethernet, RS485) (P21) Windows® Software: MotionView (Windows 98, NT, 2000, XP)

2.5 Digital I/O Ratings

Scan

Linearity Temperature Drift Offset Current

Units ms % % % mA Ohm VDC

Digital Inputs

Digital Outputs 512 15 max N/A 30 max

Analog Inputs 512 ± 0.013 0.1% per °C rise ± 0 adjustable Depend on load 47 k ± 18

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.

Times

(1)

512 Depend on load 2.2 k 5-24

Notes for Power Ratings Table in section 2.6:

(1) 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 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 runs 50-70% of the kVA ratings listed. (2) At 16 kHz, de-rate continuous current by 17% (3) Leakage Current is typically >3.5mA. Contact factory for applications requiring <3.5mA

S94P01B2

rated

] /1000

Input

Impedance

Voltage

Range

Technical Data

2.6 Power Ratings

Type

Units kVA

E94P020S1N 0.8 19 21

E94P040S1N 1.7 29 30

E94P020S2F 0.8

E94P040S2F 1.7 29 30

E94P080S2F 3.3 61 63

E94P100S2F 4.2 80 85

E94P020Y2N 0.8

E94P040Y2N 1.7 29 30

E94P080Y2N 3.3 61 63

E94P100Y2N 4.2 80 85

E94P120Y2N 5.0 114 129

E94P020T4N 1.7

E94P040T4N 3.3 50 73

E94P050T4N 4.2 70 90

E94P060T4N 5.0 93 122

Refer to Notes that precede this table.

Output Current (8kHz)

Output kVA at Rated

(1)

Leakage

Current

Typical:

>3.5mA*

Typical:

>3.5mA*

Typical:

>3.5mA*

Typical:

>3.5mA*

Power Loss at Rated

(3)

Output Current (8kHz)

Watts Watts

Power Loss at Rated

Output Current (16 kHz)

19 21

31 41

2.7 Dimensions

(2)

182 B

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

E94P020S1N 68 190 190 1.1

E94P040S1N 69 190 190 1.2

E94P020S2F 68 190 235 1.3

E94P040S2F 69 190 235 1.5

E94P080S2F 87 190 235 1.9

E94P100S2F 102 190 235 2.2

E94P020Y2N 68 190 190 1.3

E94P040Y2N 69 190 190 1.5

E94P080Y2N 95 190 190 1.9

E94P100Y2N 114 190 190 2.2

E94P120Y2N 68 190 235 1.5

E94P020T4N 68 190 190 1.5

E94P040T4N 95 190 190 1.9

E94P050T4N 114 190 190 2.2

E94P060T4N 68 190 235 1.4

S94P01B2

S923

Technical Data

2.8 Clearance for Cooling Air Circulation

>25mm

>3mm

S94P01B2

Installation

3 Installation

Perform the minimum system connection. Please 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 940 must be mounted vertically for safe operation and enough cooling air circulation.

• Printed circuit board components are sensitive to electrostatic ﬁelds. Avoid contact with the printed circuit board directly. Hold the PositionServo 940 by it’s 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 940 drive unless (mains) power is removed. Opening any one motor lead may cause failure.

• Control Terminals provide basic isolation (insulation per EN618005-1). Protection against contact can only be ensured by additional measures, e.g., supplemental insulation.

WARNING!

For compliance with EN61800-5-1, 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.

S94P01B2

Installation

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.

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.

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 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 940 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 940 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 must

S94P01B2

Installation

EMC

Compliance with EN 61800-3/A11 This is a product of the restricted sales distribution class according to IEC 61800-3. 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 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)

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.

Installation according to EMC Requirements

EDB C

S930

3.2.3 Enclosure

The panel in which the PositionServo 940 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 2.6 suggested cooling air clearance.

3.3 Line Filtering

In addition to EMI/RFI safeguards inherent in the PositionServo 940 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, 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 940 drive.

S94P01B2

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 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 940 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 940 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.

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.

3.6 Fuse Recommendations

(1)

Type

E94P020S1N M20/M10 C20/C10 20/10 10

E94P040S1N M32/M20 C32/C20 30/20 20

E94P020S2F M20 C20 20 15

E94P040S2F M20 C20 20 20

E94P080S2F M32 C32 32 40

E94P100S2F M40 C40 40 45

E94P020Y2N M20/M16 C20/C16 20/15 15

E94P040Y2N M20/M16 C20/C16 20/15 20

E94P080Y2N M32/M20 C32/C20 30/20 40

E94P100Y2N M40/M25 C40/C25 40/25 45

E94P120Y2N M50/M32 C50/C32 50/30 55

E94P020T4N M10 C10 10 10

E94P040T4N M10 C10 10 20

E94P050T4N M16 C16 15 25

E94P060T4N M20 C20 20 30

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

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

(3) Thermal-magnetic type breakers preferred.

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

AC Line

Input Fuse

(1ø/3ø)

Miniature

Circuit Breaker

(1ø/3ø)

Amp Ratings

(1)

AC Line

Input Fuse or

(2) (3)

Breaker (N. America)

DC Bus Input

(4)

Fuse

S94P01B2

Interface

4 Interface

The standard PositionServo 940 drive contains seven connectors: four quick-connect terminal blocks, one SCSI connector and two 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.

4.1 External Connectors

4.1.1 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.

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 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 (Arms) 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)

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 (120V Doubler only)

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)

S94P01B2

Interface

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)

4.1.2 P2 - Serial Communications Port

P2 is a 9-pin D-sub connector that is used to communicate with a host computer via standard RS-232 interface using a proprietary Point-to-Point Protocol (PPP). This port is present on all Model 94 and 940 RS-232-based drives. All levels must be RS-232C compliant.

P2 PIN ASSIGNMENTS (COMMUNICATIONS)

Pin Name Function RS-232 Connector

1 Reserved

2 TX RS-232 (transmit)

3 RX RS-232 (receive)

4 Reserved

5 GND Common

6 Reserved

7 Reserved

8 Reserved

9 Reserved

RS-232

STOP!

Do not make any connection to Reserved pins!

NOTE

If you purchase serial cables from a third party, you must use a passthrough cable, not Null-Modem (not crossover)

4.1.3 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+

S94P01B2

(2)

(1)

Interface

Pin Name Function

10 BB- Buffered Encoder Output: Channel B-

11 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

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 4.1.7 - Connector and Wiring Notes

(2)

See Note 2, Section 4.1.7 - Connector and Wiring Notes

See Note 3, Section 4.1.7 - Connector and Wiring Notes

50 OUT4-E Programmable output #4 Emitter

(1)

(3)

4.1.4 P4 - Motor Feedback / Second Loop Encoder Input

P4 is a 15-pin DB connector that contains connections for Hall Effect sensors and incremental encoder feedback. Refer to the P4 pin assignments table for the connector pin assignments. 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.

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.

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The PositionServo 940 buffers encoder feedback from P4 to P3. Encoder Feedback channel A on P4, for example, is Buffered Encoder Output channel A on P3. The Hall sensors from the motor must be wired to the 15-pin connector (P4).

STOP!

Use only +5 VDC encoders. Do not connect any other type of encoder to the PositionServo 940 reference voltage terminals. When using a front-end controller, it is critical that the +5 VDC supply on the frontend controller NOT be connected to the PositionServo 940’s +5 VDC supply, as this will result in damage to the PositionServo 940.

NOTE

• The PositionServo 940 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. Refer to “Dual-loop Feedback Operation” for details (Section 6.4).

P4 PIN ASSIGNMENTS (ENCODER)

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 4.1.7 - Connector and Wiring Notes

15 HC- Hall Sensor C- Input

(1)

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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

1 +24 VDC Positive 24 VDC Input

2 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.

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 940 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

1 B+

2 B+

3 BR Brake Resistor

4 B-

5 B-

Positive DC Bus / Brake Resistor

Negative DC Bus

4.1.7 Connector and Wiring Notes

Note 1 - Encoder Inputs

Each of the encoder output pins on P3 is a buffered pass-through of the corresponding input signal on P4. This can be either from a motor mounted (primary feedback) encoder or from an auxiliary encoder when a resolver is the primary feedback device on the motor.

Via software, these pins can be re-programmed to be a buffered pass through of the signals from a feedback option card. This can be either the second encoder option module (E94ZAENC1) or an encoder emulation of the resolver connected to the resolver option module (E94ZARSV1, E94ZARSV2 or E94ZARSV3).

Note 2 - Encoder Outputs

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 940 determines the position of the servomotor. “DIR” input controls direction of the motion.

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Note 3 - Digital Input A3

The ENABLE pin (IN_A3, P3.29) must be wired through a switch or an output on a front-end controller to digital input common (IN_ACOM, P3.26). If a controller is present, it should supervise the PositionServo 940’s enable function. The ENABLE circuit will accept 5-24V control voltage.

Wiring the ENABLE Switch:

CONTROLLER /O

Pn 26 N A COM

Pn 5 GND

Pin 26 IN A COM

Pin 29 IN A3

Pin 6 +5V

Power Supply

4.1.8 P11 - Resolver Interface Module (option)

PositionServo drives can operate motors equipped with resolvers. Resolver connections are made to a 9 pin D-shell female connector (P11) on the resolver option module E94ZARSV2 (scalable) or E94ZARSV3 (standard). When the motor proﬁle is loaded from the motor database or from a custom motor ﬁle, the drive will select the primary feedback source based on the motor data entry.

When using a Lenze motor with resolver feedback and a Lenze resolver cable, the pins are already conﬁgured for operation. If a non-Lenze motor is used, the resolver connections are made as follows:

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P11 PIN ASSIGNMENTS (Resolver Feedback)

Pin Name Function

1 Ref +

2 Ref -

3 N/C No Connection

4 Cos+

5 Cos-

6 Sin+

7 Sin-

8 PTC+

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 resolver option module.

4.1.9 P12 - Second Encoder Interface Module (option)

PositionServo drives can support a second incremental encoder interface for dual-loop systems. Depending on the motor’s primary feedback type (encoder or resolver) a second encoder can be connected as follows:

• If the primary motor feedback is an encoder (connected to P4), the second

encoder interfaces through the encoder option module (E94ZAENC1) at P12 on Option Bay 2.

• If the motor primary feedback is a resolver connected to the resolver option

module (E94ZARSV1) at P11 on Option Bay 2, the second encoder connects to the P4 connector on the drive. In this case, the hall inputs on P4 are not used.

The 2nd Encoder Option Module includes a 9 pin D-shell male connector. When using a Lenze motor with encoder feedback and a Lenze encoder cable, the pins are already conﬁgured for operation. If a non-Lenze motor is used, the encoder connections are made as follows:

P12 PIN ASSIGNMENTS (Second Encoder Feedback)

Pin Name Function

1 E2B+ Second Encoder Channel B+ Input

2 E2A- Second Encoder Channel A- Input

3 E2A+ Second Encoder Channel A+ Input

4 +5v Supply voltage for Second Encoder

5 COM Supply common

6 E2Z- Second Encoder Channel Z- Input

7 E2Z+ Second Encoder Channel Z+ Input

8 N/C No Connection

9 E2B- Second Encoder Channel B- Input

The second encoder needs to be enabled using MotionView software. Refer to “Dualloop Feedback” (Section 6.4) for details.

Resolver reference connection

Resolver Cosine connections

Resolver Sine connections

Thermal sensor

STOP!

Use only +5 VDC encoders. Do not connect any other type of encoder to the option module otherwise damage to drive’s circuitry may result.

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