Lenze S94P01G User Manual

PositionServo (MVCD)

Users Manual

Copyright ©2005 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.

This document printed in the United States of America.

Contents

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

1.1 About These Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

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

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

1.4 Part Number Designation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

2.2 Power Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.3 Fuse Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.4 Digital I/O Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.5 Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.6 Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.7 Connections and I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.8 PositionServo Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.9 Clearance for Cooling Air Circulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.1 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

3.2 Shielding and Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

3.2.1 General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

3.2.2 EMI Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

3.2.3 Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

3.3 Line Filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

3.4 Heat Sinking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

3.5 Line (Mains) Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

4 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.1 External Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

4.1.1 P1 & P7 - Input Power and Output Power Connections . . . . . . . . . .18

4.1.2 P2 - Ethernet Communications Port . . . . . . . . . . . . . . . . . . . . . . . . .19

4.1.3 P3 - Controller Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

4.1.4 P4 - Motor Feedback / Second Loop Encoder Input . . . . . . . . . . . .21

4.1.5 P5 - 24 VDC Back-up Power Input . . . . . . . . . . . . . . . . . . . . . . . . . .22

4.1.6 P6 - Braking Resistor and DC Bus . . . . . . . . . . . . . . . . . . . . . . . . . .22

4.1.7 Connector and Wiring Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

4.1.8 P11 - Resolver Interface Module (option) . . . . . . . . . . . . . . . . . . . . .24

4.1.9 P12 - Second Encoder Interface Module (option). . . . . . . . . . . . . . .25

4.2 Digital I/O Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

4.2.1 Step & Direction / Master Encoder Inputs (P3, pins 1-4) . . . . . . . . .26

4.2.2 Buffered Encoder Output (P3, pins 7-12) . . . . . . . . . . . . . . . . . . . . .27

4.2.3 Digital Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

4.2.4 Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

4.3 Analog I/O Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

4.3.1 Analog Reference Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

4.3.2 Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

4.4 Communication Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

4.4.1 Ethernet Interface (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

4.4.2 RS485 Interface (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

4.4.3 RS485 Communication Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

4.4.4 MODBUS RTU Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

4.4.5 CAN Interface (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

4.5 Motor Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

4.5.1 Motor Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

4.5.2 Motor Over-temperature Protection. . . . . . . . . . . . . . . . . . . . . . . . . .32

4.5.3 Motor Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

S94P01G

1

Contents

4.6 Using a Custom Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

4.6.1 Creating Custom Motor Parameters . . . . . . . . . . . . . . . . . . . . . . . . .33

4.6.2 Autophasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

4.6.3 Custom Motor Data Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

5 Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.1 Parameter Storage and EPM Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

5.1.1 Parameter Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

5.1.2 EPM Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

5.1.3 EPM Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

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

5.3 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

5.3.1 Drive Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

5.3.2 Drive PWM frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

5.3.3 Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

5.3.4 Peak Current Limit (8 kHz and 16 kHz) . . . . . . . . . . . . . . . . . . . . . . .41

5.3.5 Analog Input Scale (current scale) . . . . . . . . . . . . . . . . . . . . . . . . . .41

5.3.6 Analog Input Scale (velocity scale). . . . . . . . . . . . . . . . . . . . . . . . . .41

5.3.7 ACCEL/DECEL Limits (velocity mode only) . . . . . . . . . . . . . . . . . . .42

5.3.8 Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

5.3.9 Step Input Type (position mode only) . . . . . . . . . . . . . . . . . . . . . . . .42

5.3.10 Fault Reset Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

5.3.11 Motor Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

5.3.12 Motor PTC Cut-off Resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

5.3.13 Second Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

5.3.14 Regeneration Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

5.3.15 Encoder Repeat Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

5.3.16 System to Master Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

5.3.17 Second to Prime Encoder Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

5.3.18 Autoboot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

5.3.19 Group ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

5.3.20 Enable Switch Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

5.3.21 User Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

5.3.22 Resolver Track. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

5.3.23 Current Limit Max Overwrite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

5.4 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

5.4.1 Ethernet Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

5.4.2 RS-485 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

5.4.3 Modbus Baud Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

5.4.4 Modbus Reply Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

5.5 Analog I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

5.5.1 Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

5.5.2 Analog Output Current Scale (Volt / amps). . . . . . . . . . . . . . . . . . . .49

5.5.3 Analog Output Current Scale (mV/RPM) . . . . . . . . . . . . . . . . . . . . . .49

5.5.4 Analog Input Dead Band. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

5.5.5 Analog Input Offset Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

5.5.6 Adjust Analog Input Zero Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

5.6 Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

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

5.6.2 Hard Limit Switch Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

5.7 Velocity Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

5.7.1 Zero Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

5.7.2 Speed Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

5.7.3 At Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

5.8 Position Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

5.8.1 Position Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

5.8.2 Max Error Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

5.8.3 Second Encoder Position Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

5.8.4 Second Encoder Max Error Time . . . . . . . . . . . . . . . . . . . . . . . . . . .50

2

S94P01G

Contents

5.9 Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

5.9.1 Velocity P-gain (proportional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

5.9.2 Velocity I-gain (integral) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

5.9.3 Position P-gain (proportional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

5.9.4 Position I-gain (integral) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

5.9.5 Position D-gain (differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

5.9.6 Position I-limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

5.9.7 Gain Scaling Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

5.10 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

5.10.1 Oscilloscope Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

5.10.2 Run Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

5.11 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

6.1 Minimum Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

6.2 Configuration of the PositionServo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

6.3 Position Mode Operation (gearing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

6.4 Dual-loop Feedback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

6.5 Enabling the PositionServo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

6.6 Drive Tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

6.6.1 Tuning the Drive in Velocity Mode. . . . . . . . . . . . . . . . . . . . . . . . . . .57

6.6.2 Tuning the Drive in Position Mode. . . . . . . . . . . . . . . . . . . . . . . . . . .62

7 Quick Start Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

7.1 Quick Start - External Torque Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

7.2 Quick Start - External Velocity Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

7.3 Quick Start - External Positioning Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

8 Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

8.1 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

8.2 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

8.3 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

8.3.1 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

8.3.2 Fault Event. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

8.3.3 Fault Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

8.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

S94P01G

3

Safety Information

All safety information given in these Operating Instructions 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.

4

S94P01G

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 is available in four mains (input power) configurations:

1. 400/480V (nominal) three phase input. An external input mains (line) filter is
available. Actual voltage can range from 320 - 528 VAC.

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

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

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.

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

Depending on the primary feedback, there are two types of drives: the Model 940
PositionServo encoder-based drive which accepts an incremental encoder with Hall
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. A second encoder can be used in position and velocity modes.

The MotionView software is the setup and management tool for PositionServo drives.
All parameters can be set and monitored via this user-friendly tool. It has a real-time
oscilloscope tool for analysis and optimum tuning. The users program written with
SimpleMotion Programming Language (SML) can be utilized to command motion and
handle the drive’s inputs/outputs (I/O). The programming language is designed to be
very intuitive and easy to implement. For programming details, refer to the PositionServo
Programming Manual. All PositionServo related manuals can be downloaded from the
Technical Library on the AC Tech website (http://www.lenze-actech.com).

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

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

S94P01G

5

Introduction

C A B D E F

1.1 About These Instructions

These Operating Instructions are provided to assist the user in connecting and
commissioning the PositionServo drive with model number ending in “EX” or “RX”. Read
this manual in its entirety and observe all safety instructions contained in this document.

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

For detailed information

SN 13014745012345678

E94P120Y2NEX0XX## ##

Made in USA

Model 940

Type:
E94P120Y2NEX

ID-No: 13014745

INPUT:

1(3)/PE
120/240 V

24.0 (13.9) A
50-60 HZ

13014745012345678

OUTPUT:

3/PE
0 - 230 V

12.0 A

A B C D E F

Certifications Type Input Ratings Output

Ratings

Hardware

Version

1.2 Scope of Supply

Scope of Supply Important

• 1 Model PositionServo type E94P
or E94R.

• 1 Users Manual (English)

• 1 MotionView CD ROM including:

- configuration software

- documentation (Adobe Acrobat)

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

1.3 Legal Regulations

Identification Nameplate CE Identification Manufacturer

Application
as directed

Lenze controllers are
unambiguously designated
by the contents of the
nameplate

E94P or E94R servo controller

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

• are components for:

- closed loop control of variable speed/torque applications with PM 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.

Drive systems with E94P or E94R servo inverters

• comply with the EMC Directive if they are installed according to the guidelines of CE­typical 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!

In compliance with
the EC Low-Voltage
Directive

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

refer to instruction

Manual: S94P01

Software

Version

6

S94P01G

Introduction

Liability

Warranty

• 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 that have already been
supplied cannot be derived from the information, illustrations, and descriptions.

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

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

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

- Disregarding the operating instructions

- Unauthorized modifications to the controller

- Operating errors

- Improper working on and with the controller

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

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

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

Disposal Material Recycle Dispose

Metal

Plastic

Assembled PCB’s

• -

• -

- •

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.

Electrical Products in the 94 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
050 = 5 Amps 120 = 12 Amps
060 = 6 Amps 180 = 18 Amps
080 = 8 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

E94 P 020 S 1 N E X

Secondary Feedback

E = Incremental Encoder
R = Standard Resolver

EN954-1 Safety Circuit

X = No EN954 Safety Circuit

S94P01G

7

Introduction

Filter Part Number Designation

Electrical Option in the 94 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

Servo Option Part Number Designation

E94Z F 4 T 4 A1

Electrical Option in the 94 Series

A = COMM, Feedback or Breakout Module

Module Type:

CAN = CANopen COMM Module ENC = 2nd Encoder Feedback Module
RS4 = RS485 COMM Module RSV = Resolver Feedback Module
ETH = Ethernet COMM Module HBK = Motor Brake Terminal Module

Variations

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

E94Z A CAN 1

TBO = Terminal Block I/O Module
SCA = Panel Saver I/O Module

8

S94P01G

Technical Data

2 Technical Data

2.1 Electrical Characteristics

Single-Phase Models

1~ Mains

(1)

Type

E94_020S1N_X

E94_040S1N_X 15 8.6 4.0 12

Mains Voltage

(3)

120V

or 240V

Current

(2)

(doubler)

(4)

E94_020S2F_X

E94_040S2F_X -- 8.6 4.0 12

E94_080S2F_X -- 15.0 8.0 24

120 / 240V

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

(4)

E94_100S2F_X -- 18.8 10.0 30

Single/Three-Phase Models

(1)

Type

Mains Voltage

E94_020Y2N_X

E94_040Y2N_X 8.6 5.0 4.0 12

E94_080Y2N_X 15.0 8.7 8.0 24

E94_100Y2N_X 18.8 10.9 10.0 30

120 / 240V

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

(4)

1~ or 3~

E94_120Y2~_X 24.0 13.9 12.0 36

E94_180T2~_X

240V 3~

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

E94_020T4N_X

E94_040T4N_X -- 5.5 4.0 12

E94_050T4N_X -- 6.9 5.0 15

E94_060T4~_X -- 7.9 6.0 18

400 / 480V

3~

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

E94_090T4~_X -- 12.0 9.0 27

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

When the 10th digit is marked by “~”, “N” = No line filter or “F” = Integrated line filter
The second “_” equals “E” for incremental encoder (must have E94P drive) or “R” for the standard resolver

(must have E94R drive).

(2) Mains voltage for operation on 50/60 Hz AC supplies (48 Hz -0% … 62Hz +0%).
(3) 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.

(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.

Applies to all models:

Acceleration Time Range (Zero to Max Speed) 0.1 … 5x106 RPM/sec
Deceleration Time Range (Max Speed to Zero) 0.1 … 5x106 RPM/sec
Speed Regulation (typical) ± 1 RPM
Input Impedance (AIN+ to COM and AIN+ to AIN-) 47 kΩ
Power Device Carrier Frequency (sinusoidal commutation) 8,16 kHz
Encoder Power Supply (max) +5 VDC @ 300 mA
Maximum Encoder Feedback Frequency 2.1 MHz (per channel)
Maximum Output Frequency (to motor) 400Hz
Resolver Carrier Frequency 4.5 - 5.5kHz (5kHz nominal)
Resolver Turns Ratio between Reference and SIN/COS signal 2:1

Mains

(2)

Current

1~ Mains

Current

(Std.)

Rated

Output

Current

Peak

Output

(5)

Current

9.7 5.0 2.0 6

-- 5.0 2.0 6

1~

3~

Mains

Current

Rated

Output

Current

Peak

Output

(5)

Current

5.0 3.0 2.0 6

-- 19.6 18.0 54

-- 2.7 2.0 6

(6)

(6)

S94P01G

9

Technical Data

2.2 Power Ratings

Power Loss at

Rated Output

Current

(8kHz)

Type

(1)

Output kVA at

Rated Output

Current (8kHz)

(2)

Leakage Current

Units kVA mA Watts Watts
E94_020S1N_X

E94_040S1N_X

0.8

1.7

19 21

29 30

E94_020S2F_X 0.8 19 21

E94_040S2F_X 1.7 29 30

E94_080S2F_X 3.3 61 63

E94_100S2F_X 4.2 80 85

E94_020Y2N_X 0.8 19 21

E94_040Y2N_X 1.7 29 30

E94_080Y2N_X 3.3 61 63

E94_120Y2~_X 5.0 114 129

Typically >3.5 mA.

Consult factory for

applications requiring

<3.5 mA.

E94_180T2~_X 7.5 171 195

E94_020T4N_X 1.7 31 41

E94_040T4N_X 3.3 50 73

E94_050T4N_X 4.2 70 90

E94_060T4~_X 5.0 93 122

E94_090T4~_X 7.5 138 182

Power Loss at

Rated Output

Current

(16 kHz)

2.3 Fuse Recommendations

Type

(1)

AC Line

Input Fuse

(1ø/3ø)

Miniature

Circuit Breaker

(1ø/3ø)

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

E94_040S1N_X M32/M20 C32/C20 30/20 20

E94_020S2F_X M20 C20 20 15

E94_040S2F_X M20 C20 20 20

E94_080S2F_X M32 C32 32 40

E94_100S2F_X M40 C40 40 45

E94_020Y2N_X M20/M16 C20/C16 20/15 15

E94_040Y2N_X M20/M16 C20/C16 20/15 20

E94_080Y2N_X M32/M20 C32/C20 30/20 40

E94_120Y2~_X M50/M32 C50/C32 50/30 55

E94_180T2~_X M40 C40 40 80

E94_020T4N_X M10 C10 10 10

E94_040T4N_X M10 C10 10 20

E94_050T4N_X M16 C16 15 25

E94_060T4~_X M20 C20 20 30

E94_090T4~_X 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.

When the 10th digit is marked by “~”, “N” = No line filter or “F” = Integrated line filter

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

(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

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.

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

(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.

rated

] / 1000

(6)

AC Line Input

(4)

Fuse

or

(5)

Breaker

(N. America)

DC Bus Input

Fuse

(3)

(7)

10

S94P01G

Technical Data

2.4 Digital I/O Ratings

Scan

Linearity Temperature Drift Offset Current

Times

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.
De-bounce time is programmable and can be set as low as 0. Propagation delay is typical 20 us

(1)

512 Depend on load 2.2 k 5-24

Input

Impedance

Voltage

Range

2.5 Environment

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

1500m (5000 ft)]

2.6 Operating Modes

Torque

Reference ± 10 VDC 16-bit; scalable
Torque Range 100:1
Current-Loop Bandwidth Up to 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 & Direction or 2 channels quadrature input; scalable
Minimum Pulse Width 500 nanoseconds
Loop Bandwidth Up to 200 Hz*
Accuracy ±1 encoder count for encoder feedabck
±1.32 arc-minutes for resolver feedback (14-bit resolution)
* = motor and application dependent

2.7 Connections and I/O

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

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

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

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

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

- Analog Output 1 single ended; ±10 VDC (10-bit) (P3)
Encoder Feedback (E94P drive) Feedback connector, 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)
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, RS485) (P21)
Windows® Software: MotionView (Windows 98, NT, 2000, XP)

S94P01G

11

Technical Data

C

2.8 PositionServo Dimensions

38

dia = 4.57

4.57

A

D B

S923

34

12

12

15

(1)

Type

E94_020S1N_X 68 190 190 182 1.1

E94_040S1N_X 69 190 190 182 1.2

E94_020S2F_X 68 190 235 182 1.3

E94_040S2F_X 69 190 235 182 1.5

E94_080S2F_X 87 190 235 182 1.9

E94_100S2F_X 102 190 235 182 2.2

E94_020Y2N_X 68 190 190 182 1.3

E94_040Y2N_X 69 190 190 182 1.5

E94_080Y2N_X 95 190 190 182 1.9

E94_100Y2N_X 114 190 190 182 2.2

E94_120Y2~_X 68 190 235 182 1.5

E94_180T2~_X 68 242 235 233 2.0

E94_020T4N_X 68 190 190 182 1.5

E94_040T4N_X 95 190 190 182 1.9

E94_050T4N_X 114 190 190 182 2.2

E94_060T4~_X 68 190 235 182 1.4

E94_090T4~_X 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.

When the 10th digit is marked by “~”, “N” = No line filter, “F” = Integrated line filter or “C” = Cold plate drive.
The second “_” equals “E” for incremental encoder (must have E94P drive) or “R” for the standard resolver

(must have E94R drive).

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

12

S94P01G

Technical Data

2.9 Clearance for Cooling Air Circulation

>25mm

>25mm

>3mm

S94P01G

S924

13

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

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

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

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

• Avoid excessive vibration to prevent intermittent connections

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

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

• Control Terminals provide basic isolation (insulation per EN
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.

14

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.

S94P01G

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.

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 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).

2

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

S94P01G

15

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.

Screen clamps

A

Control cable

B

Low-capacitance motor cable

C

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

Earth grounded conductive mounting plate

D

Encoder Feedback Cable

E

Footprint or Sidemount Filter (optional)

F

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

F

A

EDB C

S930

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 for the recommended cooling air clearance.

16

S94P01G

Installation

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 IEC61800-3:2004, an appropriate
filter must be installed within 20cm of the drive power inputs.

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

NOTE

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

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

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.

S94P01G

17

Interface

4 Interface

The standard PositionServo drive contains seven connectors: four quick-connect
terminal blocks, one SCSI connector and one subminiature type “D” 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, 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 in this section
identify the connector pin assignments.

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.

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)

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

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

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

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

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

Terminal

Torque (lb-in)

Wire Size

18

S94P01G

Interface

4

P1 Pin Assignments (Input Power)

Standard Models Doubler Models

Pin Name Function Name Function

1 PE

2 L1 AC Power in N

3 L2 AC Power in L1 AC Power in

4 L3

Protective Earth
(Ground)

AC Power in
(3~ models only)

PE Protective Earth (Ground)

AC Power Neutral
(120V Doubler only)

AC Power in

L2/N

(non-doubler operation)

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)

6

5

W

V

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)

3

L3

U

2

L2

4

3

T2

1

L1

2

1

T1

Pin Name Function

1 + TX Transmit Port (+) Data Terminal

2 - TX Transmit Port (-) Data Terminal

3 + RX Receive Port (+) Data Terminal

4 N.C.

5 N.C.

6 - RX Receive Port (-) Data Terminal

7 N.C.

8 N.C.

P2

ETHERNET

1

8

NOTE

To communicate from the PC directly to the drive a crossover cable is
required. If using a hub or switch, use a regular patch cable.

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Interface

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 Connector

1 MA+ Master Encoder A+ / Step+ input

2 MA- Master Encoder A- / Step- input

3 MB+ Master Encoder B+ / Direction+ input

4 MB- Master Encoder B- / Direction- input

5 GND Drive Logic Common

6 5+ +5V output (max 100mA)

7 BA+ Buffered Encoder Output: Channel A+

8 BA- Buffered Encoder Output: Channel A-

9 BB+ Buffered Encoder Output: Channel B+

10 BB- Buffered Encoder Output: Channel 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 (max 10 mA)

24 AIN1+ Positive (+) of Analog signal input

25 AIN1 - Negative (-) of Analog signal input

26 IN_A_COM Digital input group ACOM terminal

27 IN_A1 Digital input A1

28 IN_A2 Digital input A2

29 IN_A3 Digital input A3

30 IN_A4 Digital input A4

31 IN_B_COM Digital input group BCOM terminal

32 IN_B1 Digital input B1

33 IN_B2 Digital input B2

34 IN_B3 Digital input B3

35 IN_B4 Digital input B4

36 IN_C_COM Digital input group CCOM terminal

37 IN_C1 Digital input C1

38 IN_C2 Digital input C2

39 IN_C3 Digital input C3

40 IN_C4 Digital input C4

41 RDY+ Ready output Collector

42 RDY- Ready output Emitter

43 OUT1-C Programmable output #1 Collector

44 OUT1-E Programmable output #1 Emitter

45 OUT2-C Programmable output #2 Collector

46 OUT2-E Programmable output #2 Emitter

47 OUT3-C Programmable output #3 Collector

48 OUT3-E Programmable output #3 Emitter

49 OUT4-C Programmable output #4 Collector

50 OUT4-E Programmable output #4 Emitter

(1)

See Note 1, Section 4.1.7 - Connector and Wiring Notes

(2)

See Note 2, Section 4.1.7 - Connector and Wiring Notes

(3)

See Note 3, Section 4.1.7 - Connector and Wiring Notes

(3)

20

S94P01G

(2)

(2)

(2)

(2)

(1)

(1)

(1)

P3

(1)

(1)

(1)

1

(3)

26

CONTROLLER I/O

25

50

Interface

4.1.4 P4 - Motor Feedback / Second Loop Encoder Input

For encoder-based 940 drives, P4 is a 15-pin DB connector that contains connections
for an incremental encoder with Hall emulation tracks or Hall sensors. For synchronous
servo motors, Hall sensors or Hall emulation tracks are necessary for commutation. If
an asynchronous servo motor is used, it is not necessary to connect Hall sensor inputs.
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.

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 pull-up 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.

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
section 6.4 (“Dual-loop Feedback Operation”) for details.

P4A Pin Assignments (Encoder Feedback - E94P Drives)

Pin Name Function 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 GND 15 HC- Hall Sensor C- Input

8 SHLD Shield

(1) See 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.

(1)

(1)

(1)

(1)

(1)

(1)

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

(2)

(2)

(2)

P4

1

ENCODER

8

9

15

(2)

(2)

(2)

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Interface

RESOLVER

P4

P4B Pin Assignments (Resolver Feedback - E94R Drives)

Pin Name Function

1 Ref +

2 Ref -

3 N/C No Connection

4 Cos+

5 Cos-

6 Sin+

7 Sin-

8 PTC+

9 PTC-

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.

Resolver reference connection

Resolver Cosine connections

Resolver Sine connections

Motor PTC Temperature Sensor

P5 Pin Assignments (Back-up Power)

1

5

6

9

Pin Name Function

1 +24 VDC Positive 24 VDC Input

2 Return 24V power supply return

+

-

24

+

-

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 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

DANGER!

Hazard of electrical shock! Circuit potentials are up to 680 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.

B+
B+

BR

B­B-

22

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Interface

4.1.7 Connector and Wiring Notes

Note 1 - Buffered Encoder Inputs

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/resolver, (primary feedback), or from an auxiliary
encoder/resolver when an optional feedback module is used.

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 (E94ZARSV2 or E94ZARSV3).

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 Input:

P3

P3

Power Supply

+

1

CONTROLLER /O

25

26

50

Pin 26 IN A COM

Pn 5 GND

Pin 29 N A3

Pin 6 +5V

1

CONTROLLER /O

25

Pin 26 IN A COM

26

50

Pin 29 IN A3

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Interface

4.1.8 P11 - Resolver Interface Module (option)

PositionServo drives can operate motors equipped with resolvers from either the (P4)
connection, for a resolver-based (E94R) drive, or from the Resolver option module for
an encoder-based (E94P) drive. The option module 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.

The E94ZARSV3 has a fixed resolution of 1024 PPR prequadrature or 4096
postquadrature. The E94ZARSV2 has a selectable set of 15 resolutions. The resolution
refers to the pulses per revolution (PPR) of the Buffered Encoder Outputs (P3-7 to P3-

12) if the Encoder Repeat Source is set as “Optional Feedback Input” in MotionView.

When using the E94ZARSV2, the default resolution is 1024 PPR prequadrature.
Depending on the hardware/software revision of the E94ZARSV2 module, the available
PPRs are different. Refer to the table below for the Dip Switch settings for SW1 and the
different resolutions.

SW1 DIP Switch Settings

Dip Switch SW1 PPR prequadrature

Position 1 Position 2 Position 3 Position 4 Hardware/Software

OFF OFF OFF OFF 250 1024 (default)

OFF OFF OFF ON 256 256

OFF OFF ON OFF 360 360

OFF OFF ON ON 400 400

OFF ON OFF OFF 500 500

OFF ON OFF ON 512 512

OFF ON ON OFF 720 720

OFF ON ON ON 800 800

ON OFF OFF OFF 1000 1000

ON OFF OFF ON 1024 (default) 1024 (default)

ON OFF ON OFF 2000 2000

ON OFF ON ON 2048 2048

ON ON OFF OFF 2500 2500

ON ON OFF ON 2880 2880

ON ON ON OFF 4096 250

ON ON ON ON 4096 4096

(1) For PPR postquadrature, multiply by 4.
(2) Hardware/Software Revision can be found on the dataplate label attached to the plastic cover of the module.
For example, the revision in the example below is 1B11.

(2)

Revision

1A10,

1A11, 1B11, 1C11

(1)

Hardware/Software

Revision

(2)

1C12

and higher

24

Made in USA

94/940

P11

Scalable Resolver

Feedback Option

TYPE: E94ZARSV2
ID NO: 13127865

S94P01G

SN 13127865012345678

E94ZARSV2000XX1B11