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Model 940 USERS MANUAL

1. 5937 Lenze S94P01A 57 9 1 2 l gain P gain 218000 l gainz 2396 Velocity window 1 I gain is increased to allow small velocity overshoot 10 as a step response This setting is very application dependent If in your application a high and more flat response is expected then leave this value so that the overshoot is no more then 10 If your application requires stiffness at zero or near zero velocity and long term stability is desired you can increase l Gain so that the overshoot reaches 30 see next section ES940 240V 10A 192 168 124 124 Channel 1 Signal Motor velocity sl choo Scale 100 00 RPM div Offset 0 00 RPM Channel 2 Signal Phase current RMS X Scale 300 Amps div Offset 0 00 Amps Time base 10 ms div y Trigger Chi rising edge e Opti ptions 100 00 A Iv Always on top Single Do Wi Close Large I Gain I Gain 7935 Overshoot 20 The l gain setting is very application dependent If in your application requires a high and flat response then the I gain should be set to give an overshoot of no more than 10 If your application requires stiffness at zero or near zero velocity and have long term stability you can increase the I Gain so that the overshoot reaches 30 see below S938 ES940 240V 10A 192 168 Max 3 43 Avg 0 40 Signal Motor velocity E Scale 100 00 RPM div Offset 0 00 ES RPM li Chann
2. Connect mains power to terminal P1 Mains power must be as defined on the drive s data label see section 2 1 If the motor is equipped with an encoder connect the encoder cable to the PositionServo feedback connector P4 If the motor is equipped with a resolver install the Resolver option module E94ZARSV1 in the lower option bay and connect the resolver cable to P11 Connect motor windings U V W sometimes called R S T to terminal P7 according to Section 5 1 1 Make sure that motor cable shield is connected as described in section 4 2 Provide an Enable switch according to Section 8 5 Perform drive configuration as described in the next section Note d You must configure the drive before it can be operated Proceed to Section 8 2 8 2 Configuration of the PositionServo Regardless of the mode in which you wish to operate you must first configure the PositionServo 940 for your particular motor mode of operation and additional features if used Drive configuration consists of following steps Motor Selection Mode of operation selection Reference source selection Very Important Drive parameters i e current limit acceleration deceleration setup Operational limits velocity or position limits setup Input Output I O setup Velocity position compensator gains setup Optionally store drive settings in a PC file and exit the MotionView program 48 S94P01A Lenze To configure drive
3. Trigger Channel 2 Rising Trigger level 0 Select Compensation from node tree Set Position P gain to 100 and Position D gain to 0 Set Position I gain to 0 and Position I limit to 0 Activate IN A3 and run the TuneP txt program Slowly increase the P gain while watching the Position Error waveform channel 1 While increasing P gain you should observe the position error decrease At some point you should start to experience high frequency oscillation noticeable on the Position Error waveform see picture below Increase D gain to suppress the oscillations Lenze S94PO1A 53 54 9 10 11 12 13 14 15 16 I Always on top Single Love om SES Dose ES940 240V 10A 192 168 124 124 Channel 1 Signat Position Error e Scale 10 00 f Pulses div Diseb ooo gt Pulses Channel 2 Signak Target position X Scale 010 Userunte div Offset ooo f Userunits Time base 150 ms div gt Trigger CH rising edge Cass S933 Continue to increase the P gain until the position error stop decreasing You will need to increase the D gain again while increasing the P gain to suppress the oscillations Stop the program The above method is suggested as a general guideline for position tuning You will have to experiment with the gains to achieve the performance and stability needed for your individual application The general goal of tuning is
4. 1 Bo 11 12 13 14 Ensure that the control is properly installed and mounted Refer to Section 4 for installation instructions Perform wiring to the motor and external equipment suitable for desired operating mode and your system requirements Connect the drive to the serial port P2 to your PC serial port Make sure that the drive is disabled Apply power to the drive and wait until d 5 shows on the display For anything other then this refer to the chart below before proceeding Drive display Meaning EP EPM missing Refer to 6 1 2 EPP EPM data Refer to 6 1 2 ws No valid firmware Monitor mode Using the drive s keypad and display check that the baud rate is set to 38 4 Kbps Using the drive s keypad and display check that the address is set to 1 Set if necessary Launch MotionView software on your computer From the MotionView menu select Project Connection setup Select UPPP over RS 485 RS 232 then select Properties and select the computer s serial port that the drive is connected to Select the Comm port that matches the serial port of the computer used for this connection Set baud rate at 38400 and rest of the parameters at default Click OK twice to dismiss both dialog boxes From Node menu choose Connect Drive Click Connect one button type 1 in the address box and press OK to dismiss dialog Drive connects and its icon appea
5. Check that no foreign material has become lodged on or fallen into the PositionServo Verify that every connection is correct and in good condition Verify that there are no short circuits or grounded connections Check that the drive s rated phase current and RMS voltage are consistent with the motor ratings For additional assistance contact your local PositionServo authorized distributor Problem External line fuse blows Possible Cause Suggested Solution Line fuses are the wrong size Motor leads or incoming power leads are shorted to ground Nuisance tripping caused by EMI noise spikes caused by poor grounding and or shielding Check that line fuses are properly sized for the motor being used Check motor cable and incoming power for shorts Check that you follow recommendation for shielding and grounding listed in section shielding and grounding early in this manual Problem Ready LED is on but motor does not run Suggested Solution If in torque or velocity mode Reference voltage input signal is not applied Reference signal is not connected to the PositionServo input properly connections are open n MotionView program check lt Parameters gt lt Reference gt set o lt External gt For Velocity mode only n MotionView check lt Parameters gt lt Compensation gt lt Velocity oop filter P gain must be set to value more then 0 in order to run Without load motor will r
6. Digital inputs circuit 24 S94P01A Lenze 5 3 Analog I O details 5 3 1 Analog reference input AIN AIN1 P3 24 and P3 25 The analog reference input can accept up to a 10V analog signal across AIN1 and AIN2 The maximum limit with respect to analog common ACOM on each input is 18VDC The analog signal will be converted to a digital value with 16 bit resolution 15 bit plus sign This input is used to control speed or torque of the motor in velocity or torque mode The total reference voltage as seen by the drive is the voltage difference between AIN1 and AIN1 If used in single ended mode one of the inputs must be connected to a voltage source while the other one must be connected to Analog Common ACOM If used in differential mode the voltage source is connected across AIN and AIN and the driving circuit common if any needs to be connected to the drive Analog Common ACOM terminal Reference as seen by drive Vref AIN1 AIN1 and 10V lt Vref lt 10V P3 23 AIN O P3 24 O Reference Source Reference Source S909 Single ended Differential AIN2 AIN2 P3 20 and P3 21 The analog reference input can accept up to a 10V analog signal across AIN2 and AIN2 The maximum limit with respect to analog common ACOM on each input is 18VDC The analog signal will be converted to a digital value with 10 bit resolution 9 bit plus sign This input is available to the User s pr
7. 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 S2P 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 inclu
8. Name Function 1 Ref Resolver reference connection 2 Ref 3 NC No Connection 4 Cos Resolver Cosine connections 5 Cos 6 Sins Resolver Sine connections 7 Sin 8 PTC Thermal sensor 9 PTC 20 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 S94P01A Lenze 5 1 9 P12 Second encoder interface module Option Bay 2 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 Se
9. waveform Increasing the P gain should increase the angle of the acceleration edge of the wave form Continue increasing the P gain to get the leading edge of the wave form as vertical as possible and stop once you start to get a slight over shoot The current wave form should be spiking during the acceleration segment of the move Continue to increase the P gain until instability starts to appear in wave form Channel 1 Signal Motor velocity El Seale 100 00 RPM div Offset 00 RPM Channel Signal Phase current RMS zl Scale 5 EX dr Offset 0 00 Amps Time base 50 ms div Y Trigger Chi rising edge y Level 100 00 RPM Close J Sxxx15 Options Always on top Single Stop Stop increasing the gain once you see oscillation appearing on either the current waveform or velocity waveform flat portion Then lower the P gain until the oscillation disappears S94P01A Lenze 14 15 16 17 ES940 240V 8A 1 1 Channel Signal Motor velocity Scale 100 00 RPM div Offset 0 00 RPM Channel2 nn Signal Phase current RMS El Scale ban Amps div Offset 0 00 Amps Time base 150 ms div Le Trigger Chi rising edge y Level 100 00 RPM Options Close T Always on top Single Stop Sxxx16 Slowly increase the Velocity
10. 10 9 10 0 30 E94P020T4N 2 7 2 0 6 400 480V E94P040T4N 3 5 5 4 0 12 320 V 0 528 V 0 E94P050T4N 6 9 5 0 15 UI 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 II 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 II prive rated at 8kHz Carrier Frequency Derate Continuous current by 1796 at 16kHz 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 5x10 RPM sec Deceleration Time Range Max Speed to Zero 0 1 5x10 RPM sec Speed Regulation typical 1 RPM Input Impedance AIN to COM and AIN to AIN 47k ohmQ 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 2 2 Environment Vibration 2 g 10 2000 Hz Ambient Operating Temperature Range 0 to 40 C Ambient Storage Temperature Range 10 to 70 C Temperature Drift 0 1 per C rise Humidity 5 90 non condensing Altitude 1500 m 5000 ft derate by 1 per 300m 1000
11. 18 Autoboot When set to Enabled the drive will start to execute the user s program immediately after cold boot reset Otherwise the user program has to be started from MotionView or from the Host interface 6 3 19 Group ID See Programmer s manual for details This parameter is only needed for operations over Ethernet network Lenze S94P01A 39 6 3 20 Enable switch function If set to Run input IN_A3 P3 29 acts as an Enable input when the user program is not executing If the user program is executing the function will always be Inhibit regardless of the setting This parameter is needed so the drive can be Enabled Disabled without running user s a program 6 3 21 User Units This parameter sets up the relationship between User Units and motor revolutions From here you can determine how many User Units there is in one motor revolution This parameter allows the user to scale motion moves to represent a desired unit of measure inches meters in sec meters sec etc For example A linear actuator allows a displacement of 2 5 with every revolution of the motor s shaft User Units Revolutions Unit User Units 1 Revolutions 2 5 Inches User Units 1 2 5 Revolutions inch User Units 0 4 Revolutions inch 6 4 Communication 6 4 1 IP Setup This action button opens dialog for TCP IP related parameters setup 6 4 2 RS 485 configuration This parameter sets how the optional RS485
12. 2500 Disable 10 Drive encoder 1 7 5 6 Disabled 12 Inhibit RPM Sec RPM Sec 1 0000 Revolutions unit 0 0000 0 0000 0 0000 3 0000 2000 0000 0 1000 0 1000 32767 1 32767 1 o SP Drive ES940 240V 10A untitled successfully connected For Help press F1 Lenze in 11 Col 8 S94P01A EthernetUDP__ Ready S934 55 9 1 1 P gain P gain 5000 l gain 20 Current didn t reach maximum possible value 10A ES940 240V 10A 192 168 124 124 Signal Motor velocity Ei Scale 100 00 RPM div Offset 0 00 ani RPM Channel 2 Signal Phase current RMS Scale h00 Amps div Offset 0 00 j Amps Time base 50 ms div y Trigger Chi rising edge v 1 fw Always on top Single Stop oe 00 00 HA S935 P gain 32767 max value I gain 20 Velocity window 2 The P gain is set to its maximum value per the 2 in the Velocity window The current value is very close to the maximum but since the P gain is maxed out we can t determine if we have achieved optimum settings Also notice that the oscilloscope Time Base is set to 10ms This will allow us to view leading edge and current impulse response better A real time oscilloscope is essential when analyzing waveforms in depth and is a distinctive feature of the PositionServo drives ES940 240V 10A 192 168 124 124 Channel 1 Signal Motor velocity y Scale 100 00 RPM div Offset 0 0
13. Lenze S94P01A 3 Dimensions 3 1 Model 940 Dimensions 38 124 p amp O l D O e 127 15 A S923 Type A mm B mm C mm Weight kg E94P020S1N 67 190 235 1 5 E94P040S1N 69 190 235 1 6 E94P020S2F 67 190 235 1 3 E94P040S2F 69 190 235 1 5 E94P080S2F 88 190 235 1 9 E94P100S2F 103 190 235 2 2 E94P020Y2N 67 190 190 1 3 E94P040Y2N 69 190 190 1 5 E94P080Y2N 95 190 190 1 9 E94P100Y2N 115 190 190 2 2 E94P020T4N 69 190 190 1 5 E94P040T4N 95 190 190 1 9 E94PO50T4N 115 190 190 2 2 Lenze S94P01A 9 3 2 Clearance for Cooling Air Circulation gt 25mm gt 3mm QU qh A amp P6 Iz bi E da VIe m Se ED E po E e amp Ji 25mm 924 Lenze S94P01A 10 4 Installation Perform the minimum system connection Please refer to section 8 1 for minimum connection requirements Observe the rules and warnings below carefully A 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
14. OR DR RC 53 9 Sample Motor Responses to Gain SettingS 55 9 1 Motor response to gain settings Velocity mode 55 Cu EE OLD PERCENT EE EE 56 9512 galli zz oett onu Fart he d In pre Rut dae VAS als o niei UE 58 9 1 3 Abnormal gains Velocity mode e ren 59 9 2 Motor response to gain settings Position Mode 60 9 21 P ga selecione ue epe aem ta 60 9 2 2 Optimal P gain D gain settings 61 10 Troubleshooting c so ai nere ere RR E Rene 63 Lenze S94P01A Safety Information All safety information given in these Operating Instruction have the same layout Signal Word Characteristics the severity of the danger Note describes the danger and informs on how to proceed Icon Signal Words Warning of DANGER Warns of impending danger hazardous electrical voltage Consequences if disregarded Death or severe injuries a general situations danger Consequences if disregarded Death or severe injuries damage to and equipment equipment Warning of WARNING Warns of potential very hazardous n Warning of STOP Warns of potential damage to material Consequences if disregarded Damage to the controller drive or its environment Information Note Designates a general useful note d If you observe it handling the controller drive system is made easier 4 S94P01A Lenze 1 General Information
15. Umax V bus voltage at regen conditions Umax 390V for 230VAC drives and 770V for 400 480VAC drives R ohm regen resistor value P W regen resistor rated power Note il If calculation of D is greater than 100 set it to 100 value If calculation of D is less than 10 then resistor power rating is too low Refer to section 5 1 6 for details on braking resistor selection 6 3 15 Encoder repeat source This parameter sets the feedback source signal for the buffered encoder repeat outputs P3 1 6 The source can be the drive s encoder input P4 or an optional feedback module resolver second encoder etc 6 3 16 Master to system ratio This parameter is used to the set scale between the reference pulse train when operating in position mode and the system feedback device In a single loop configuration the system feedback device is the motor encoder or resolver In a dual loop system the system encoder is the second encoder See sections 8 3 and 8 4 for details 6 3 17 Second to prime encoder ratio This parameter sets the ratio between the secondary encoder and the primary feedback device when the drive is configured to operate in dual loop mode When the primary feedback device is a resolver the pulse count is fixed at 65 536 The resolutions of encoders are post quadrature PPR x 4 See section 8 4 Note il Post quadrature pulse count is four times the pulses per revolution PPR of the encoder 6 3
16. and 25 such that any voltage within that window will be treated as zero volts This is useful if the analog input voltage drifts resulting in motor rotation when commanded to zero 6 5 5 Analog input offset parameter Allows you to adjust the offset voltage at AIN1 and AIN1 P3 24 and P3 25 This functions has the equivalent to the balance trim potentiometer found in analog drives Lenze recommends that this adjustment be made automatically using the Adjust analog voltage offset button while the external analog reference signal commands zero speed 6 5 6 Adjust analog voltage offset This control button is useful to allow the drive to automatically adjust the analog input voltage offset To use it command the external reference source input at AIN1 and AIN1 P3 24 and 25 to zero volts and then click this button Any offset voltage at the analog input will be adjusted out and the adjustment value will be stored in the Analog input offset parameter 6 6 Digital I O The 940 has four digital outputs These outputs can be either assigned to one of the following functions or be used by the drives internal User Program Not Assigned No special function assigned Output can be used by the User Program Zero Speed Output activated when drive is at zero speed ref Velocity Limits for settings e In Speed Window Output activated when drive is in set speed window ref Velocity Limits for settings Current Limit Output ac
17. caution when entering custom parameters Incorrect settings may cause damage to the drive or motor If you are unsure of the settings refer to the materials that were distributed with your motor or contact the motor manufacturer for assistance 1 Enter custom motor data in the Motor Parameters dialog fields Complete all sections of dialog Electrical Mechanical Feedback See Section 6 8 3 for explanation of motor parameters and how to enter them Note If unsure of the motor halls order and encoder channels A and B relationship leave B leads A for CW Halls order and inverted fields as they are You can execute autophasing see section 5 6 2 to set them correctly 2 Enter motor model and vendor in the top edit boxes Motor ID cannot be entered this is set to O for custom motors 3 Click Save File button and enter filename without extension Default extension cmt will be given when you click OK on file dialog box Note Saving the file is necessary even if the autophasing feature will be used and some of the final parameters are not known After autophasing is completed the corrected motor file can be updated before loading it to memory Click OK to exit from the Motor Parameters dialog MotionView will ask if you want to autophase your custom motor If you answer No the motor data will be loaded immediately to the drive s memory If you answer Yes the motor dialog will be
18. dismissed and the drive will start the autophasing sequence Refer to section 5 6 2 for autophasing information 6 If you answered Yes for autophasing you will be returned to the same motor selection dialog box after autophasing is complete For motors with incremental encoders the fields B leads A for CW Halls order and inverted will be assigned correct values For motors with resolvers the fields Offset in degree and CW for positive will be assigned correct values 7 Click Save File to save the custom motor file and then click OK to exit the dialog box and load the data to the drive OUR Lenze S94P01A 29 5 6 2 Autophasing The Autophasing feature determines important motor parameters when using a motor that is not in MotionView s database For motors equipped with incremental encoders Autophasing will determine the Hall order sequence Hall sensor polarity and encoder channel relationship B leads A or A leads B for CW rotation For motors equipped with resolvers Autophasing will determine resolver angle offset and angle increment direction CW for positive To perform autophasing 1 Complete the steps in the previous section Setting custom motor parameters If the motor file you are trying to autophase already exists simply load it as described under Using a custom motor at the beginning of this section 2 Make sure that the motor s shaft is not connected to any
19. parameter value can be changed Use UP and DOWN buttons to change the value Press Enter to store new setting and return back to scroll mode Display Description SERE current drive status to view rin drive running i5 drive disabled F_XX drive fault Where XX is the fault code section 7 3 2 Hx xx Hardware revision ex H2 00 Fx xx Firmware revision ex F2 06 bAUd RS232 RS485 normal mode baud rate to set QO selects 38 4 19 2 9 6 kbps baudrate Rdr Drive s address to set QO sets 0 31 drive s address FLES Stored fault s history to view QU scroll through stored faults FOXX to F7XX where XX is the fault code section 7 3 2 HE Heatsink temperature to view Shows heatsink temperature in C if greater than 40 C Otherwise shows LO low EnC Encoder activity to view Shows primary encoder counts for encoder diagnostics activity HALL Displays motor s hall sensor states to view Shows motor hall states in form XXX where X is 1 or 0 sensor logic states bUS Displays drive DC bus voltage to view Shows DC bus voltage value Curr Displays motor s phase current RMS Shows current value if drive is enabled otherwise shows d 15 Lenze S94P01A 45 7 2 Diagnostic LED s The PositionServo 940 has five diagnostic LEDs mounted on the periphery of the front panel display as shown in the drawing below These LEDs are designed
20. pins gt Note 1 If you purchase serial cables from a third party you must use a pass through cable not Null Modem not crossover Lenze S94P01A 15 5 1 3 P3 Controller Interface P3 is a 50 pin SCSI connector for interfacing to the front end of the controllers It is strongly recommended that you use OEM cables to aid in satisfying CE requirements Contact your Lenze representative for assistance P3 PIN ASSIGNMENTS CONTROLLER INTERFACE Pin Name Function 1 MA Master Encoder A Step input 2 MA Master Encoder A Step input 3 MB Master Encoder B Direction input 2 4 MB Master Encoder B Direction input 9 5 GND Drive Logic Common 6 5 5V output 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 AO1 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 9 27 IN_A1 Digital input A1 28 IN_A2 Digital input A2 29 IN_A3 Digi
21. 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 at the maximum current rating 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 4 1 Wiring A 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 C
22. the drive will automatically re enable the peak current level This technique allows for high peak torque on demanding fast moves and fast start stop operations with high regulation bandwidth The control will use only the Peak current limit parameter for the carrier frequency selected 6 3 5 Analog input scale Current scale This parameter sets the analog input sensitivity for current reference used when the drive operates in Torque mode Units for this parameter are A Volt To calculate this value use the following formula Iscale Imax Vin max Imax maximum desired output current motor phase current RMS Vin max max voltage fed to analog input at Imax Example Imax 5A phase RMS Vin max 10V Iscale Imax Vin max 5A 10V 0 5 A Volt gt value to enter 6 3 6 Analog input scale Velocity scale This parameter sets the analog input sensitivity for the velocity reference used when the drive operates in Velocity mode Units for this parameter are RPM Volt To calculate this value use the following formula Vscale VELOCITYmax Vin max VELOCITYmax maximum desired velocity in RPM Vin max max voltage fed to analog input at Velocitymax Example VELOCITYmax 2000 RPM Vin max 10V Vscale VELOCITYmax Vin max 2000 10V 200 RPM Volt value to enter Lenze S94P01A 37 6 3 7 ACCEL DECEL Limits Velocity mode only The ACCEL setting determines the time the motor takes to ramp to a higher speed The DECEL sett
23. to achieve the minimum acceptable position error while still maintaining stability By increasing the P gain you increase the response to position change and reduce the position error At the same time a large P gain can lead to instability oscillation By increasing the D gain you improve the stability of the system Generally both P gain and D gain should be increased together While the program is stopped edit the TuneP User Program and set the Accel and Decel variables to the maximum values your system can accept Compile and load the program to the drive Set oscilloscope channel 1 to Iq current Set the scale to the appropriate value to see a full current pulse Observe that current Iq waveform Check to make sure that there isn t any significant oscillation at the flat portion of the waveform If so then decrease the P gain to a level where the oscillation either disappears or is very small See pictures in section 9 2 Trying to minimize the position error during the steady state of the move is where the I gain comes into play The same is true for holding the position accuracy Increasing the I gain will increase the drive s reaction time while the I Limit will set the maximum influence that the I Gain will have on to the loop When adjusting the I gain start with a very small value for both the I gain and the I Limit then increase the I gain until stand still reaction is compensated Remember that large values of Positio
24. waveform edge aligns with the phase phase voltage waveform but the positive hall sensor cycle matches the negative phase phase waveform or visa versa you must check the Inverted check box Lenze S94P01A 33 4 The phases that correspond to the Vrs Vst Vtr voltages are Hall B then Hall C then Hall A or Halls number 2 then 3 then 1 Referring to the following table we find that 2 3 1 sequence is Halls Order number 3 We would enter 3 for the Halls Order field in motor dialog HALL ORDER NUMBERS FOR DIFFERENT HALL SEQUENCES Halls Order Hall Sequence 0 1 2 3 1 1 3 2 2 2 1 3 3 2 3 1 4 3 1 2 5 3 2 1 Note D Each Hall Voltage will be in phase with one and only one Output Voltage B leads A for CW This is the encoder phase relationship for CW CCW shaft rotation When you obtain the diagram for your motor phasing similar to shown above it s assumed by the software that the motor shaft rotates CW when looking at the mounting face of the motor For that rotation Encoder phase A must lead phase B If it does leave check box unchecked Otherwise if B leads A check B leads A for CW box Note d Lenze convention references the shaft direction of rotation from the front shaft end of the motor Some manufacturers timing diagrams are CW when viewed from the rear of the motor 5 6 3 3 For resolver equipped motors only If parameter Resolver is checked following paramet
25. 0 GH RPM Channel 2 Signal Phase current RMS si Scale 300 Amps div Offset 10 00 34 Amps Time base IDE Trigger Chi rising edge v Options v Always on top Single Stop Lever 100 00 Rpm Close S936 56 S94P01A Lenze To increase the P gain setting we need to set the Velocity window one notch higher This is done by changing the Velocity window setting from 2 to 1 After changing the Velocity window setting set the P gain to 16000 approximately the middle of the scale and restart the drive Then slowly increase the P gain again Reference the next section P gain 20322 I gain 20 Velocity window 1 We start to see a small overshoot at the leading edge of the Motor Velocity wave but the current doesn t increase anymore This is how fast the motor can reach the set velocity with current limit selected Any further increase in gain will only increase the overshoot and will not improve the response P gain should be decreased slightly approximately 10 to remove the overshoot The Final value for the P gain should be 18000 ES940 240V 10A 192 168 124 124 Channel 1 Signal Motor velocity X Scale 100 00 RPM div Offset fo 00 RPM Channel 2 Signal Phase current RMS y Scale 3 00 Amps div Offset 0 00 Amps Time base 10 ms div Trigger Chi rising edge ptions 2 EUN m o t
26. 6 9 3 Position P gain Proportional Position P gain adjusts the system s overall response to position error Position error is the difference between the commanded position of the motor shaft and the actual shaft position By adjusting the proportional gain the bandwidth of the drive is more closely matched to the bandwidth of the control signal ensuring more precise response of the servo loop to the input signal 6 9 4 Position I gain Integral The output of the Position I gain compensator is proportional to accumulative error over cycle time with I gain controlling how fast the error accumulates Integral gain also increases overall loop gain at the lower frequencies minimizing total error Thus its greatest effect is on a system running at low speed or in a steady state without rapid or frequent changes in position 6 9 5 Position D gain Differential The output of the Position D gain compensator is proportional to the difference between the current position error and the position error measured in the previous servo cycle D gain decreases the bandwidth and increases the overall system stability It is responsible for removing oscillations caused by load inertia and acts similar to a shock absorber in a car 6 9 6 Position I limit The Position I limit will clamp the Position Loan compensator to prevent excessive torque overshooting caused by an over accumulation of the I gain It is defined in terms of percent of maximum drive v
27. A 192 168 124 124 Position Error X log Pulses div 000 Pubes Channel 2 Signal T arget position X Scale 010 User units div Offset 10 00 User units Time base 50 ms div Trigger alika for fiant Ch2 rising edge e 3 aiting for tigge l Options Level 10 00 IV Always on top Single Stop Stun Close S943 9 2 2 Optimal P gain D gain settings P gain 8700 D gain 16000 Loan 0 limit 0 Positive effect Position error decreased Oscillation eliminated by D gain Side effects Possible high noise produced by high P and D gains at 0 velocity This problem arises since encoder has finite resolution A compromise might have to be made by setting the P gain and the D gain lower to smooth out the operation at 0 velocity ES940 240V 10A 192 168 124 124 Signal Position Error E Scale 20 00 Pulses div Offset 0 00 Pulses Signal Target position Scale 010 Userunits div Offset 0 00 Ex User units Time base 50 ms div y Trigger Ch2 rising edge v 0 ptions Level 10 00 u v Always on top Single Stop gi SCH Close P and D gains setting check problem P gain 12673 D gain 16000 l gain 0 I limit 0 Lenze S94P01A 61 Problem Noticeable oscillation Channel 1 on Iq current waveform Treatment Decrease the P gain setting until oscillation disappears ES940 240V 10A 192 168 124 124 C
28. Dimensions 9 3 2 Clearance for Cooling Air Circulation LL 10 4 Installation rm eR bed aU RR ed Re ees PUER RUE ES pex rd 11 ZI O 11 4 2 Shielding and grounding 12 4 2 1 General guidelines kee cee teens 12 oo IMITACI N cas als eset rot hr DES EAS T DR RE Nar 13 423 EnclosulG e iuesenekceRrd ENEE ERE Ea 13 A exe ER RR are ere qa RR Ge ped we RR RR EE WE 13 aL PP 13 45 IAS Mains USO 13 5 PositionServo 940 Connections lees 14 SCH External Connectors 97 rs a br RR RS A Oen ede 14 5 1 1 P1 amp P7 Input Power and Output Power Connections 14 5 1 2 P2 Serial Communications Port 15 5 1 3 P3 Controller Interface 16 5 1 4 P4 Motor Feedback second loop encoder input aM 5 1 5 P5 24 VDC Back up Power Input 18 5 1 6 P6 Braking Resistor and DC Bus 19 5 1 7 Connectors and Wiring Notes 19 5 1 8 P11 Resolver interface module Option Module 20 5 1 9 P12 Second encoder interface module Option Bay 2 21 5 2 Digital WOetallS iid rosse ev etr da 22 5 2 1 Step amp Direction Master Encoder Inputs P3 pins 1 4 22 5 2 2 Digital eut isst a RS a aaa Aa 23 5 2 3 Te ENT EEN 24 5 9 Analog l O details 22 ii nd bes 25 5 3 1 Analog reference Input 25 5 3 2 Analog GUIDUL iai edu sr d eara ERROR TR 25 5 4 Communication interfaces llis ee 26 5 4 1 RS232 interface standard LL 26 5 4 2 RS485
29. I gain and watch for an overshoot on the motor velocity waveform Stop increasing the setting when overshoot just starts to occur or is very narrow The setting should be less then 5mS or less then 3 596 if a steep acceleration deceleration is desired in your servo system If stiffness at low velocity or stall torque is desired then the Velocity Loan can be increased allowing step overshoot up to approximately 15 30 Finally check the motor Iq current Set the oscilloscope Channel 1 source to Iq current Observe the current waveform to insure that there is no significant oscillation Click Indexer gt Stop or alternatively Alt F5 on the keyboard to stop the program Remove voltage from IN A3 input Depending on the application you may want to set parameters Reference and Enable switch function to appropriate values Refer to section 6 for details 8 7 Tuning in position mode In this mode the Velocity gains should be set first 1 2 3 Perform velocity loop tuning as per section 8 6 Select I Gain value for minimum overshoot Make sure that the drive is disabled Load program TuneP txt found in User Data directory in current Motion View installation compile and load it to the drive but don t run it yet Select Tools then Oscilloscope tool from node tree On the Scope tool select Channel 1 Position Error Scale 100 pulses div Channel 2 Target Position Scale 0 1 Unit div Timebase 50mS
30. Instructions describe the product features without guaranteeing them e Lenze does not accept any liability for damage and operating interference caused by Disregarding the operating instructions Unauthorized modifications to the controller Operating errors Improper working on and with the controller Warranty Warranty conditions 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 6 S94P01A Lenze 2 Specifications 2 1 Electrical Characteristics Single Phase Models 1 Mains 1 Mains Current Current Rated Output Peak Output Type Mains Voltage doubler Std Current 4 Current E94P020S1N 9 7 5 0 2 0 6 120V or 240V E94P040S1N 16 8 8 6 4 0 12 E94P020S2F 5 0 2 0 6 E94P040S2F 120 240v 9 8 6 4 0 12 E94P080S2F 80 V 0 264 V 0 15 0 8 0 24 E94P100S2F 18 8 10 0 30 Single Three Phase Models 1 Mains 3 Mains Rated Output Peak Output Type Mains Voltage Current Current Current Current E94P020Y2N 5 0 3 0 2 0 6 E94P040Y2N 120 240V 8 6 5 0 4 0 12 1 or 3 E94P080Y2N 80 V 0 264 V 0 15 0 8 7 8 0 24 E94P100Y2N 18 8
31. Pin Name Function 1 24 VDC Positive 24 VDC Input 4 Return 24V power supply return WARNING N 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 18 S94PO1A Lenze 5 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 Positive DC Bus Brake Resistor 2 B 3 BR Brake Resistor 4 B Negative DC Bus 5 B 5 1 7 Connectors 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 E94ZAENCH1 or an encoder emulation of the resolver connected to the resolver option mod
32. PosiTIONServo Model 940 USERS MANUAL Copyright 02005 by AC Technology Corporation All rights reserved No part of this manual may be reproduced or transmitted in any form without written permission from AC Technology Corporation The information and technical data in this manual are subject to change without notice AC Tech makes no warranty of any kind with respect to this material including but not limited to the implied warranties of its merchantability and fitness for a given purpose AC Tech assumes no responsibility for any errors that may appear in this manual and makes no commitment to update or to keep current the information in this manual MotionView Positionservo and all related indicia are either registered trademarks or trademarks of Lenze AG in the United States and other countries This document printed in the United States of America Table of Contents 1 General Information iilis 5 1 1 About these Operating Instructions 0 eene 5 T 2 Scope of SUPPLY sired ns a wh ere a ope e 6 1 8 Legal regulati ne ies meten Rd NOE RICE QUK OL RR dd e ORO RO UR AR 6 2 Specifications iss i ss ERE er x Pd uve dore 7 ST Electrical Characteristics ic ici rt bh e REES A Ran 7 2 01 EDVIFOFTROU eg Si Na ck Ol ee eu eee eae ERE tees eda d Rad ER P 7 2 3 Operatirig Modes cies ele ee e NEES ERE 8 2 4 Gonnections and VO siii ri ke Cha pi REG id ORE 8 3 Dimensions ios abr id iP or ara 9 3 4 Model940
33. ach master pulse is established by the ratio of the master signal pulses to motor encoder pulses in single loop configuration The ratio is set by Master to System ratio parameter see section 6 3 16 Example 1 Problem Setup the drive to follow a master encoder output where 1 revolution of the master encoder results in 1 revolutions of the motor Given Master encoder 4000 pulses revolution post quadrature Motor encoder 8000 pulses revolution post quadrature Solution Ratio of Master Encoder to System motor encoder is 4000 8000 1 2 Set parameter Master to system ratio to 1 2 Example 2 Problem Setup drive so motor can follow a master encoder wheel where 1 revolution of the master encoder results in 3 revolutions of the motor Given Master encoder wheel is 1000 pulses revolution post quadrature Motor encoder 4000 pulses revolution post quadrature Desired gear ratio is 1 3 Solution Ratio is master encoder PPR divided by motor encoder PPR times the gear ratio Master PPR Motor PPR 1 3 gt 1000 4000 1 3 gt 1 12 Set parameter Mater to system ratio to 1 12 8 4 Dual loop feedback In dual loop operation position mode only the relationship between the Master input and mechanical system movement requires that two parameters be set 1 Master to system ratio sets the ratio between master input pulses and the second encoder pulses system encoder 2 Second to prime encod
34. and direction logic signals or a quadrature pulse train on pins P3 11 14 6 3 1 1 Velocity mode In velocity mode the servo controller regulates motor shaft speed velocity proportional to the analog input voltage at input AIN1 if parameter Reference is set to External Otherwise the reference is taken from the drive s internal variable See Programmer s manual for details For analog reference Target speed set speed is calculated using the following formula Set Velocity RPM Vinput Volt x Vscale RPM Volt where Vinput is the voltage at analog input AIN and AIN Vscale is the velocity scale factor input sensitivity set by the Analog input Velocity scale parameter section 6 3 6 Set Velocity RPM Vinput Volt x Vscale RPM Volt 6 3 1 2 Torque mode In torque mode the servo control provides a current output proportional to the analog input signal at input AIN1 if parameter Reference is set to External Otherwise the reference is taken from the drive s internal variable See Programmer s manual for details For analog reference Set Current current the drive will try to provide is calculated using the following formula Set Current A Vinput Volt X Iscale A Volt where Vinput is the voltage at analog input Vscale is the current scale factor input sensitivity set by the Analog input Current Scale parameter section 6 5 2 36 S94P01A Lenze 6 3 1 3 Posi
35. apacitors retain charge after power is removed STOP Under no circumstances should power and control wiring be bundled together Induced voltage can cause unpredictable behavior in any electronic device including motor controls Refer to section 5 1 1 for Power wiring specifications Lenze S94P01A 11 4 2 Shielding and grounding 4 2 1 General guidelines Lenze recommends the use of single point grounding SPG for panel mounted controls Serial grounding a daisy chain is not recommended The SPG for all enclosures must be tied to earth ground at the same point The system ground and equipment grounds for all panel mounted enclosures must be individually connected to the SPG for that panel using 14 AWG 2 5 mm or larger wire In order to minimize EMI the chassis must be grounded to the mounting Use 14 AWG 2 5 mm or larger wire to join the enclosure to earth ground A lock washer must be installed between the enclosure and ground terminal To ensure maximum contact between the terminal and enclosure remove paint in a minimum radius of 0 25 in 6 mm around the screw hole of the enclosure Lenze recommends the use of the special PositionServo 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
36. cal to EMI reduction 4 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 4 2 1 Proper wire routing inside the panel is critical power and logic leads must be routed in different avenues inside the panel You must ensure that the panel contains sufficient clearance around the drive Refer to Section 3 2 suggested cooling air clearance 4 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 EN50081 1 and EN50082 2 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 lf you add separate fuses add them after the AC line filter Note il 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 m
37. calculated by multiplying the Nominal AC mains voltage supplied by 1 41 When using a model with the suffix S1N where the mains are wired to the Doubler connection the Nominal Bus Voltage will be doubled Example If the mains voltage is 230VAC Vbus 230 x 1 41 325V This value is the initial voltage for the drive and the correct voltage will be calculated dynamically depending on the drive s incoming voltage value Rotor Moment of Inertia Jm From motor manufacturer or nameplate Note d Round the calculated result to 3 significant places Maximum Motor Speed in RPM This is also listed as Speed Vt motor speed at the terminal voltage rating The maximum motor speed will typically be a round even value between 1000 and 6000 RPM Number of Poles This is a positive integer number that represents the number of motor poles normally 2 4 60r 8 5 6 3 2 For motors equipped with incremental encoders only Encoder Line Count The Encoders for servomotors normally have Line Counts of 1000 1024 2000 2048 4000 or 4096 The Encoder Line Count must be a positive integer and must be pre quadrature Index pulse offset Enter 0 zero Index marker pulse position This field is reserved for backward compatibility All PositionServo drives determine actual marker pulse position automatically 32 S94P01A Lenze Halls Order Each hall signal is in phase with one of the three phase phase voltages from
38. closed in one shield and jacket around them Lenze recommends that each and every pair for example EA and EA be twisted In order to satisfy CE requirements use of an OEM cable is recommended Contact your Lenze representative for assistance The PositionServo 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 front end controller NOT be connected to the PositionServo 940 s 5 VDC supply as this will result in damage to the PositionServo 940 e Note 1 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 recommend
39. commissioning the Model 940 servo drive Important safety instructions are contained in this document which must be observed carefully All persons working on and with the controller must have the Operating Instructions available and must observe the information and notes relevant for their work e The Operating Instructions must always be in a complete and perfectly readable state Lenze S94P01A 5 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 deficiencies incompleteness immediately to your Lenze representative 1 3 Legal regulations Identification Nameplate CE Identification Manufacturer Lenze controllers are In compliance with the EC AC Technology Corp unambiguously designated by Low Voltage Directive member of the Lenze Group the contents of the nameplate 630 Douglas Street Uxbridge MA 01569 USA Application as E94P servo controller directed e must only be operated under the conditions prescribed in these Instructions are c
40. cond 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 See section Dual loop feedback Section 8 4 for details 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 Lenze S94P01A 21 5 2 Digital I O details 5 2 1 Step amp Direction Master Encoder Inputs P3 pins 1 4 You can connect a master encoder with quadrature outputs or a step and direction pair of signals to control position in step direction operating mode stepper motor emulation These inputs are optically isolated from the rest of the drive circuits and from each other Both inputs can operate from any voltage source in the range of 5 to 24 VDC and do not require additional series resistors for normal operation STEP DIRECTION CW CCW Timing characteristics for Step And Direction signals SS B lt lt CW CCW gt Timing characteristics for Master Encoder signals S905 Input type output compatibility Ins
41. des 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 Operating Instructions These Operating Instructions are provided to assist the user in connecting and
42. e 10 ms div Tri Chi rising edge v Opti ptions 1 V Always on top Single 125510000 ML Close S941 Lenze S94P01A 59 9 2 Motor response to gain settings Position Mode 9 2 1 P gain selection P gain 2500 D gain 0 Loan 0 limit 0 Problem Insufficient P gain cause large position error as motor changing position rapidly Treatment Increase P gain Side effects Increasing the P gain might cause oscillations and might require an increase of the D gain as well to overcome this problem ES940 240V 10A 192 168 124 124 Channel 1 Signal Position Error Scale 20 00 Pulses div Offset 0 00 Ex Pulses Channel 2 Signal Target position X Scale 0 10 Userunits div Offset o oo User units Time base 50 ms div v Trigger a xt biog Ch2 rising edge wv ES Iv Always on top Single Stop 0 pean Close P gain increase 942 P gain 8700 D gain 0 Loan 0 limit 0 Positive effect Position error decreased Problem Noticeable oscillation Channel 1 P gain can t be set any higher due to increasing oscillation instability Treatment Increase D gain and then P gain until position error stop decreasing Side effects Possible high noise produced by excess of D gain A compromise between the D gain setting and an acceptable position error must be reached This will be mainly controlled by value of P gain 60 S94P01A Lenze ES940 240V 10
43. e node address set in this packet doesn t match the node address of the drive the drive will resend the packet via RS485 to the next drive on the network This process will continue until the target drive is reached The following message Device with address not present in the network will appear If the target node could not be found 26 S94PO1A Lenze 5 4 4 MODBUS RTU support As a default the RS232 and RS485 interfaces are configured to support MotionView program operations In addition the RS485 interface can be configured to support the MODBUS RTU slave protocol The interface can be configured through the MotionView program When configured for MODBUS operation the baud rate for RS485 is set by the parameter Modbus baud rate in MotionView while the RS232 baud rate is set on the drive s front panel Thus RS485 and RS232 can have different speeds at the same time if RS485 is configured for MODBUS operation Please note that if RS485 is configured for MODBUS operation the command repeat function see 5 4 3 is unavailable even if baud rates are set the same for both interfaces The Modbus RTU slave interface protocol definitions can be found in the MotionView help menu under Product Manuals 5 5 Motor Selection The PostionServo 940 drive is compatible with many 3 phase AC synchronous servo motors MotionView is equipped with a motor database which contains over 600 motors for use with the 940 drive If the desired
44. ed Lenze S94P01A 17 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 E94ZARSV1 installed A second encoder can then be connected to the A and B lines of the P4 connector for dual loop operation See Dual loop feedback operation for details Section 8 4 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 15 HC Hall Sensor C Input MU See Note 1 Section 5 1 7 Connector and Wiring Notes 5 1 5 P5 24VDC Back up Power Input P5 is a 2 pin quick connect terminal block that can be used with an external 24 VDC 2 amp 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
45. ed in RPM Desired motor speed in RPM velocity mode only Difference in RPM between actual and commanded motor speed Difference between actual and commanded position Step amp Direction mode only DC bus voltage Voltage at drive s analog input Absolute position actual position Requested position This button activates the Autophasing feature as described in section 5 6 2 However in this panel only the motor phasing is checked the motor data is not modified 6 11 Faults Group Faults Group loads the fault history from the drive The 8 most recent faults are displayed with the newer faults replacing the older faults in a first in first out manner In all cases fault O is the most recent fault To clear the faults history from the drive s memory click on the Reset Fault history button Each fault has its code and explanation of the fault See section 7 3 for details on faults Lenze 44 S94P01A 7 Display and Diagnostics 7 1 Diagnostic display The PositionServo 940 drives are equipped with a diagnostic LED display and 3 push buttons to select displayed information and to edit a limited set of parameter values Parameters can be scrolled by using the UP and DOWN Q buttons To view a value press Enter 48 To return back to scroll mode press Enter again After pressing the Enter button on editable parameters the yellow LED C see figure in the next section will blink indicating that
46. eet 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 is a machinery directive 4 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 4 5 Line Mains fusing External line fuses must be installed on all PositionServo drives Connect the external line fuse in series with the AC line voltage input Use fast acting fuses rated for 250 VAC or 600 VAC depending on model and approximately 200 of the maximum RMS phase current Lenze S94P01A 13 5 PositionServo 940 Connections 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 Repre
47. el 2 Uu Signal Phase curent RMS y Scale 3 00 Amps div Offset fo 00 Amps Time base 10 ms div y Trigger Ch1 rising edge y Options V Always on top Single LI ee 939 58 S94PO1A Lenze 9 1 3 Abnormal gains Velocity mode I Gain is too high P gain 18000 I gain 12000 Velocity window 1 Notice below that there is a large overshoot and a noticeable oscillation in the flat portion of the Motor Velocity waveform The current waveform also has a small trace of instabilities at the flat portion of the waveform ES940 240V 10A 192 168 124 124 Channel 1 Signal Motor velocity E Scale 100 00 RPM div Offset 0 00 Ex RPM Channel 2 Signal Phase curent AMS y Scale 3 00 Amps div Offset 000 Amps Time base 10 ms div KA Trigger bi Chi rising edge v ptions Eege Single Levet 100 00 RPM S940 P gain is too high P gain 22720 I gain 20 Velocity window 0 Notice below that there is a large overshoot and a noticeable oscillation in flat portion of the Motor Velocity waveform The current waveform also has some instability on trailing edge of the current impulse response ES940 240V 10A 192 168 124 124 Channel 1 Signal Motor velocity Scale 100 00 4 Offset 0 00 Channel 2 Signal Phase current RMS y Scale 300 Amps div Offset 0 00 Amps Time bas
48. elocity This is especially helpful when position error is integrated over a long period of time Lenze S94P01A 43 6 9 7 Second encoder I gain Integral This parameter sets second encoder position I gain when the drive is in a dual loop configuration 6 9 8 Velocity regulation window Sets the total velocity loop gain multiplier 2n where n is the velocity regulation window If during motor tuning the velocity gains become too small or too large this parameter is used to adjust loop sensitivity If the velocity gains are too small decrease the total loop gain value by deceasing this parameter If gains are at their maximum setting and you need to increase them even more use a larger value for this parameter 6 10 Tools Group 6 10 1 Oscilloscope tool The oscilloscope tool gives real time representation of different signals inside the PositionServo 940 drive and is helpful when debugging and tuning drives Operation of the oscilloscope tool is described in more detail in the MotionView Software User s Manual The following are the signals that can be observed with the oscilloscope tool Phase Current RMS Phase Current Peak Iq Current Motor Velocity Commanded Velocity Velocity Error Position Error Bus voltage Analog input Absolute position Target position 6 10 2 Run Panels Check Phasing Motor phase current Motor peak current Measures the motor Iq torque producing current Actual motor spe
49. ence could be taken from MA MB master encoder step and directions inputs available in terminal P3 or from trajectory generator Access to the trajectory generator is provided trough the User Program s motion statements MOVEx and MDV See Programmer s Manual for details on programming Whether the reference comes from an external device AIN1 or MA MB or from the drives internal variables digital reference and trajectory generator will depend on the parameter settings Reference in Parameters group in MotionView 6 1 Parameters storage and EPM operation 6 1 1 Parameter s storage All settable parameters are stored in the drive s internal non volatile memory Parameters are saved automatically when they are changed In addition parameters are copied to the EPM memory module located on the drive s front panel In the unlikely event of drive failure the EPM can be removed and inserted into the replacement drive thus making an exact copy of the drive being replaced This shortens down time by eliminating the configuration procedure The EPM can also be used for replication of the drive s settings 6 1 2 EPM operation When the drive is powered up it first checks for a white EPM in the EPM Port If the EPM Port is empty no further operation is possible until a white EPM is installed into the EPM Port The drive will display EP until an EPM is inserted If a different color EPM is inserted the drive may appear to function howe
50. 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 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 Installation according to EMC Drive Models ending in the suffix 2F are in Requirements compliance with class A limits according to EN 55011 if installed in a control cabinet and the motor cable length does not exceed 10m Models ending in N will require an appropriate line filter A Screen clamps B Control cable C Low capacitance motor cable core core 75 pF m core screen 150 pF m D Earth grounded conductive mounting plate E Encoder Feedback Cable F Footprint Filter optional 12 S94PO1A Lenze 4 2 2 EMI Protection Electromagnetic interference EMI is an important concern for users of digital servo control systems EMI will cause control systems to behave in unexpected and sometimes dangerous ways Therefore reducing EMI is of primary concern not only for servo control manufacturers such as Lenze but the user as well Proper shielding grounding and installation practices are criti
51. er counts before enabling the Second encoder max error time clock described next 6 8 4 Second Encoder Max Error Time Specifies maximum allowable time in mS during which the second encoder s position error can exceed the value set for the Second encoder position error parameter before a Position Error Excess fault is generated 42 S94P01A Lenze 6 9 Compensation group 6 9 1 Velocity P gain Proportional Proportional gain adjusts the system s overall response to a velocity error The velocity error is the difference between the commanded velocity of a motor shaft and the actual shaft velocity as measured by the primary feedback device By adjusting the proportional gain the bandwidth of the drive is more closely matched to the bandwidth of the control signal ensuring more precise response of the servo loop to the input signal 6 9 2 Velocity I gain Integral The output of the velocity integral gain compensator is proportional to the accumulative error over cycle time with I gain controlling how fast the error accumulates Integral gain also increases the overall loop gain at the lower frequencies minimizing total error Thus its greatest effect is on a system running at low speed or in a steady state without rapid or frequent changes in velocity Note d The following four position gain settings are only active if the drive is operating in Position mode They have no effect in Velocity or Torque modes
52. er ratio sets the ratio between the second and primary motor encoder If the motor is equipped with a resolver connected to the resolver option module E94ZARSV1 the primary encoder resolution of 65536 post quadrature must be used When operating in this mode the second encoder input is applied to integral portion of the position compensator Therefore it is important that the Position I gain and Position I limit parameters are set to non O values Always start from very small values of Position I limit values e Note 1 When operating with a resolver as the primary feedback a second encoder can be connected to P4 50 S94P01A Lenze 8 5 Enabling the PositionServo Regardless of the selected operating mode the PositionServo must be enabled before it can operate A voltage in the range of 5 24 VDC connected between P3 26 and 29 input IN_A3 is used to enable the drive There is a difference in the behavior of input IN_A3 depending on how the Enable switch function is set When the Enable switch function is set to RUN IN_A3 acts as positive logic ENABLE or negative logic INHIBIT input depending on If user program is not running Activating IN_A3 enables the drive User program running Activating IN_A3 acts as negative logic Inhibit and operates exactly as if parameter Enable switch function set to Inhibit see below When the Enable switch function set to Inhibit IN_A3 acts a
53. ers appear on the form Offset in degree electrical This parameter represents offset between resolver s 0 degree and motor s windings 0 degree CW for positive This parameter sets the direction for positive angle increment Offset in degree and CW for positive will be set during Auto Phasing of the motor 34 S94P01A Lenze 6 Programmable Features and Parameters All PositionServo 940 series drives are configured through one of the interfaces RS232 RS485 or Ethernet The drives have many programmable and configurable features and parameters These features and parameters are accessible via a universal software called MotionView Please refer to the MotionView Manual for details on how to make a connection to the drive and change parameter values This chapter covers programmable features and parameters specific to the PositionServo Model 940 drive in the order they appear in the Parameter Tree of MotionView Programmable parameters are divided into groups Each group holds one or more user s adjustable parameters All 940 series drives can execute a User Program in parallel with motion Motion can be specified by variety of sources and in three different modes Torque Velocity Position In Torque and Velocity mode Reference can be taken from Analog Input AIN1 or from the User Program by setting a particular variable digital reference See Programmer s Manual for details on programming In Position mode the refer
54. ft above 1500m 5000 ft Lenze S94P01A 7 2 3 Operating Modes Torque Reference Torque Range Current Loop Bandwidth Velocity Reference Regulation Velocity Loop Bandwidth Speed Range Position Reference Minimum Pulse Width Loop Bandwidth Accuracy 10 VDC 16 bit scalable 100 1 Up to 3 kHz x 10 VDC or 0 10 VDC scalable 1 RPM Up to 400 Hz 5000 1 with 5000 ppr encoder 0 2 MHz Step and Direction or 2 channels quadrature input scalable 500 nanoseconds Up to 200 Hz 1 encoder count 2 4 Connections and UO RS232 serial interface Encoder Feedback primary Standard 9 pin D shell DCE P2 Standard 15 pin D shell P4 Encoder Feedback secondary Option module with standard 9 pin D shell P12 Resolver feedback Encoder buffered repeat Mains Power Motor Power Regen and Bus Power Keep Alive 24VDC Power Digital Inputs Digital Outputs Analog Input Analog Output UO Controller Windows Software Option module with standard 9 pin D shell P11 In 25 pin D shell controller connector P3 4 pin removable terminal block P1 6 pin pin removable terminal block P7 5 pin removable terminal block P6 2 pin removable terminal block P5 1 dedicated ENABLE 1 programmable 5 24V P3 2 programmable 5 24V 100mA P3 1 differential 10 VDC 16 bit P3 1 single ended 10 VDC 10 bit P3 Standard 25 pin D shell P3 MotionView Windows 98 NT 2000 XP
55. gn an output as a Special Purpose Output then that output can not be utilized by the User Program The RDY Output has a fixed function ENABLE which will become active when the drive is enabled and the output power transistors becomes energized Digital outputs electrical characteristics Circuit type Isolated Open Collector Digital outputs load capability 100mA Digital outputs Collector Emitter max voltage 30V o OUT1 C SY L__ 165 ouri E 190 OUT2 C I mg OUT2 E Digital outputs circuit A La S907 Lenze S94P01A 23 5 2 3 Digital inputs IN_Ax IN_Bx IN_Cx P3 26 30 P3 31 35 P3 36 40 The PositionServo 940 Drive has 12 optically isolated inputs These inputs are compatible with a 5 24V voltage source No additional series resistors are needed for circuit operation The 12 inputs are segmented into three groups of 4 Inputs A1 A4 Inputs B1 B4 and Inputs C1 C4 Each group A B and C have their own corresponding shared COM terminal ACOM BCOM and CCOM All inputs have separate software adjustable de bounce time Some of the inputs can be set up as Special Purpose Inputs For example inputs A1 and A2 can be configured as limit inputs input A3 can be set up as an Enable input and input C4 can be used as a registration input Reference the 940 Programming Manual for more detail 1 6 KQ IN1 O ENABLE AY K 1 6 KQ IN2 gs PROGAMMABLE AY is E IN COM of 908
56. hannel 1 Signat lq current Scale 4 00 Amps div Offset 000 Amps Channel 2 Signat Target postion a Scale 010 Usecunits div Offset 0 00 User units Time base 20 ms div D Trigger Che ng edge ZER Options V Always on top sg Las LZ zm _ Cove 944 P and D gains setting check corrected P gain 12673 D gain 16000 l gain 0 I limit 0 Positive effect Oscillation stopped and stability is increased ES940 240V 10A 192 168 124 124 Channel 1 Signal jo current Scale lo Amps div Offset 0 00 Amps Channel 2 Signal T arget position Scale 10 10 ES User units div Offset 0 00 H User units Time base 20 ms div y Trigger Ch2 rising edge v ER v Always on top Single uj HU MERLI Close S946 62 S94P01A Lenze 10 Troubleshooting DANGER A 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 at least 60 seconds before servicing drive Capacitors retain charge after power is removed Before troubleshooting Perform the following steps before starting any procedure in this section Disconnect AC or DC voltage input from the PositionServo Wait at least 60 seconds for the power to discharge Check the PositionServo closely for damaged components
57. he drive is ENABLED a new motor cannot be set You can only set a new motor when the drive is DISABLED To View selected motor parameters or to make a new motor selection e Click Click here to change the motor from the Parameter View Window see figure above If you are just viewing motor parameters click Cancel on Motor Parameters dialog when done to dismiss the dialog box e Select motor Vendor from the right list box and desired motor from the left list box If you will be using a custom motor not listed in our motor database go to Using a custom motor topic in the next section Finally click the OK button to dismiss the dialog and return to MotionView s main program 28 S94PO1A Lenze 5 6 Using a custom motor You can load a custom motor from a file or you can create a new custom motor e To create a custom motor click CREATE CUSTOM and follow the instructions in the next section Creating custom motor parameters To load a custom motor click OPEN CUSTOM button then select the motor file and click the OPEN button to select or click the CANCEL button to return to the previous dialog box e Click OK to load the motor data and return to the main MotionView menu or Cancel to abandon changes When clicking OK for a custom motor a dialog box will appear asking if you want to execute Autophasing see section 5 6 2 5 6 1 Creating custom motor parameters STOP Use extreme
58. i If the units for the phase to phase winding Inductance L are given in micro henries uH then divide by 1000 to get mH Nominal phase current RMS Amps Nominal continuous phase current rating In in Amps RMS Do not use the peak current rating Note Sometimes the phase current rating will not be given The equation below may be used to obtain the nominal continuous phase to phase winding current from other variables In Continuous Stall Torque Motor Torque Constant Kt The same force x distance units must be used in the numerator and denominator in the equation above If torque T is expressed in units of pound inches Ib in then Kt must be expressed in pound inches per Amp Ib in A Likewise if T is expressed in units of Newton meters N m then units for Kt must be expressed in Newton meters per Amp N m A Example Suppose that the nominal continuous phase to phase winding current In is not given Instead we look up and obtain the following Continuous stall torque T 3 0 Ib in Motor torque constant Kt 0 69 Ib in A Dividing we obtain In 3 0 Ib in 0 69 Ib in A 4 35 A Our entry for In would be 4 35 Note that the torque Ib in units cancelled in the equation above leaving only Amps A We would have to use another conversion factor if the numerator and denominator had different force x distance units Lenze S94P01A 31 Nominal Bus Voltage Vbus The Nominal Bus Voltage can be
59. ing determines the time the motor takes to ramp to a lower speed If the ENABLE ACCEL DECEL LIMITS is set to DISABLE the drive will automatically accelerate and decelerate at maximum acceleration limited only by the current limit established by the PEAK CURRENT LIMIT and CURRENT LIMIT settings 6 3 8 Reference The REFERENCE setting selects the reference signal being used by the drive This reference signal can be either External or Internal An External Reference can be one of three types a Analog Input signal a Step and Direction Input or a Input from a external Master Encoder The Analog Input reference is used when the drive is either in Torque or Velocity mode The Master Encoder and Step and Direction reference is used when the drive is in Position Mode An Internal Reference is when the motion being generated is derived from drive s internal variable s or User Program See programmer s manual 6 3 9 Step input type position mode only This parameter sets the type of input for position reference the drive expects to see Signal type can be step and direction S D type or quadrature pulse train Master Encoder Electronic Gearing Refer to section 5 2 1 for details on these inputs 6 3 10 Fault Reset Option The FAULT RESET OPTION selects the type of action required to reset the drive after a FAULT signal has been generated by the drive ON DISABLE clears the fault when the drive is disabled This is useful if you have a single dr
60. interface option module LL 26 5 4 8 Using RS232 and RS485 interfaces simultaneously 26 5 44 MODBUS RTU SUpport Ed ANE ENEE idas 27 5 5 Motor Selection wei alia ai 27 5 5 1 Motor COMECON v i aeg em rmt Eee RE aeg A 27 5 5 2 Motor over temperature protection 27 e EE EE 28 5 6 Using a custom moer 0 cir a Ae OG ARR NEE wl 29 5 6 1 Creating custom motor parameters lis lis esses 29 5 6 2 AUTOPMASING organica a A 30 5 6 3 Custom Motor Data Ent 30 Lenze S94P01A Programmable Features and Parameter 35 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 Parameters storage and EPM operation LL 35 6 1 1 Parameters StOrage sss ser ARA REO LARE aa 35 6 12 EPM OHSEM o us ci boe RR EXE RERERETRRASTISERQER dda es 85 6 119 BPM fault ets Seda ec a 36 Motor Groups PEE a i 36 Parameters Groban ARRE 36 6 3 1 Drive Operating MoOdES ces disc oc RE Se beg worn greens 36 6 9 2 Drive PWM fr qiency isse ee rip 37 6 33 Current Limits ccc xu arrendar E MARE RE 37 6 3 4 8 KHZ Peak current limit and 16 KHZ Peak current limit 37 6 3 5 Analog input scale Current scale n uuuuuuunau nuu 37 6 3 6 Analog input scale Velocity scale o on nauru u ane 37 6 3 7 ACCEL DECEL Limits Velocity mode oni 38 CRIS 38 6 3 9 Step input type position mode oni 38 6 3 10 Fault ReSet Opiion cirie E dE 38 6 3 11 Motor temperature sengt 38 6 3 12 Motor PTC cut off resista
61. interface will function The RS485 interface can be configured for normal operation programming and diagnostics using MotionView software or as a Modbus RTU slave See section 5 4 for details on communication interfaces 6 4 3 Modbus baud rate This parameter sets the baud rate for RS485 interface in Modbus RTU mode When the drive is operating in normal mode the baud rate is set to the same setting as the RS232 interface 6 4 4 Modbus reply delay This parameter sets the time delay between the drives reply to the Modbus RTU master This delay is needed for some types of Modbus masters to function correctly 6 5 Analog I O Group 6 5 1 Analog output The PositionServo 940 has one analog output with 10 bit resolution on P3 23 The signal is scaled to 10V The analog output can be assigned to following functions Not Assigned Phase current RMS Phase current Peak Motor Velocity Phase R current Phase S current Phase T current Iq current Torque component Id current Direct component S94P01A Lenze S o 6 5 2 Analog output current scale Volt amps Applies scaling to all functions representing CURRENT values 6 5 3 Analog output velocity scale mV RPM Applies scaling to all functions representing VELOCITY values Note that mV RPM scaling units are numerically equivalent to volts kRPM 6 5 4 Analog input dead band Allows the setting of a voltage window in mV at the reference input AIN1 and AIN1 P3 24
62. ive and motor connected in a single drive system The ON ENABLE option clears the fault when the drive is re enabled Choose ON ENABLE if you have a complex servo system with multiple drives connected to an external controller This makes troubleshooting easier since the fault will not be reset until the drive is re enabled Thus a technician can more easily determine which component of a complex servo system has caused the fault 6 3 11 Motor temperature sensor This parameter enables disables motor over temperature detection lt must be disabled if the motor PTC sensor is not wired to either P7 1 2 or to the resolver option module P11 6 3 12 Motor PTC cut off resistance This parameter sets the cut off resistance of the PTC which defines when the motor reaches the maximum allowable temperature See section 5 5 2 for details how to connect motor s PTC 6 3 13 Second encoder Disables or enables second encoder Effectively selects single loop or double loop configuration in position mode The second encoder connects to the Encoder Option Module E94ZAENC1 connector P12 Refer to section 8 4 for details on dual loop operation 38 S94P01A Lenze 6 3 14 Regen duty cycle This parameter sets the maximum duty cycle for the brake regen resistor This parameter can be used to prevent brake resistor overload Use the following formula to set the correct value for this parameter D P R Umax 100 where D regen duty cycle
63. l be correctly set 8 Click Save File to save the completed motor file you can use the same filename as you use to save initial data in step 1 and click OK to load the motor data to the drive 5 6 3 Custom Motor Data Entry A Custom Motor file is created by entering motor data into the Motor Parameters dialog box This box is divided up into the following three sections or frames Electrical constants Mechanical constants Feedback When creating a custom motor you must supply all parameters listed in these sections All entries are mandatory except the motor inertia Jm parameter A value of O may be entered for the motor inertia if the actual value is unknown 30 S94P01A Lenze 5 6 3 1 Electrical constants Motor Torque Constant Kt Enter the value and select proper units from the drop down list Note 1 Round the calculated result to 3 significant places Motor Voltage Constant Ke The program expects Ke to be entered as a phase to phase Peak voltage If you have Ke as an RMS value multiply this value by 1 414 for the correct Ke Peak value Phase to phase winding Resistance R in Ohms This is also listed as the terminal resistance Rt The phase to phase winding Resistance R will typically be between 0 05 and 200 Ohms Phase to phase winding Inductance L This must be set in millihenries mH The phase to phase winding Inductance L will typically be between 0 1 and 200 0 mH Note
64. le with appropriate connectors and in various lengths Contact your Lenze representative for assistance Wire size 1 lt 8A 16 AWG 1 5 mm or 14 AWG 2 5 mm 8A lt I lt 12A 14 AWG 2 5 mm or 12 AWG 4 0 mm 212A 12 AWG 4 0 mm 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 14 S94PO1A Lenze P7 PIN ASSIGNMENTS OUTPUT POWER Pin Terminal Function Ww Motor Power Out 1 Ti Thermistor PTC Input 2 T2 Thermistor PTC Input 3 U Motor Power Out 4 V Motor Power Out 5 6 PE Protective Earth Chassis Ground 5 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 drives All levels must be RS 232C compliant P2 PIN ASSIGNMENTS COMMUNICATIONS Pin Name Function 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 STOP Do not make any connection to Reserved
65. m from file and choose file named TuneV When program is loaded into the program pane click menu Indexer gt Compile and send to drive Alternatively you can press Shift F6 on the keyboard or use toolbar button 6 Select Oscilloscope tool from the node tree to engage the oscilloscope Check checkbox Always on top so MotionView main window doesn t cover the oscilloscope tool Lenze S94P01A 51 7 11 12 13 52 On the Scope tool select Channel 1 Motor Velocity Scale 100 Rpm Volt e Channel 2 Phase Current RMS Scale Motor peak current parameter 3 Timebase 50mS Trigger Channel 1 Rising Trigger level 100 Rpm Choose closest integer value if 10A 3 3 33 3 choose 3A Select Compensation from the Node tree Set the Velocity regulation window to 2 if the motor is equipped with an encoder and to 4 if the motor is equipped with a resolver Set P gain to 5000 and I gain to 20 Select Compensation from the node tree Set the Velocity gain window to 2 for encoder feedback motors or to 4 for resolver feedback motors Apply voltage to IN_A3 input and press F5 on the keyboard Alternatively you can use menu Indexer gt Run or use button on the toolbar If the motor vibrates uncontrollably disable the drive rest P Gain to 1000 and re enable the drive Slowly increase the Velocity P gain and observe the motor velocity
66. mechanical load and can freely rotate STOP Autophasing will energize the motor and will rotate the shaft Make sure that the motor s shaft is not connected to any mechanical load and can freely and safely rotate 3 Make sure that the drive is not enabled 4 Itis not necessary to edit the field Hall order and check boxes inverted and B leads A for CW as these values are ignored for autophasing 5 Click OK to dismiss motor selection dialog MotionView responds with the question Do you want to perform autophasing 6 Click OK A safety reminder dialog appears Verify that it is safe to run the motor then click Proceed and wait until autophasing is completed Note If there was a problem with the motor connection hall sensor connection or resolver connection MotionView will respond with an error message Common problems are with power shield and ground terminations or an improper cable is being used Correct the wiring problem s and repeat steps 1 6 If the error message repeats exchange motor phases U and V R and S and repeat If problems persist contact the factory 7 If autophasing is completed with no error then MotionView will return to the motor dialog box For motors with incremental encoders the parameter field Hall order and the check boxes inverted B leads A for CW will be filled in with correct values For resolver equipped motors fields Offset and CW for positive wil
67. motor is in the database no data to set it up is needed Just select the motor and click OK However if your motor is not in the database it can still be used but some electrical and mechanical data will need to be provided to create a custom motor profile The auto phasing feature of the 940 allows the user to correctly determine the relationship between phase voltage and hall sensor signals eliminating the need to use a multi channel oscilloscope 5 5 1 Motor connection Motor phase U V W or R S T are connected to terminal P7 Itis very important that motor cable shield is connected to Earth ground terminal PE or the drive s case The motor feedback cable must be connected to encoder terminal P4 if the motor is equipped with an incremental encoder If the motor is equipped with a resolver it needs to be connected to terminal P11 on the resolver option module E94ZARSV1 5 5 2 Motor over temperature protection If using a motor equipped with an encoder and PTC thermal sensor the encoder feedback cable will have flying leads exiting the P4 connector to be wired to the P7 1 T1 and P7 2 T2 terminals If using a motor equipped with a Resolver and a PTC sensor the connector on the Resolver Option Module P11 provides this connection Use parameter Motor PTC cut off resistance see section 6 3 12 to set the resistance which corresponds to maximum motor allowed temperature The parameter Motor temperature sensor
68. must also be set to ENABLE If the motor doesn t have a PTC sensor set this parameter to DISABLE This input will also work with N C thermal switches which have only two states Open or Closed In this case Motor PTC cut off resistance parameter can be set to the default value Lenze S94P01A 27 5 5 3 Motor set up Once you are connected to the PostionServo 940 via MotionView a Parameter Tree will appear in the Parameter Tree Window The various parameters of the drive are shown here as folders and files If the Motor folder is selected all motor parameters can be viewed in the Parameter View Window To view selected motor parameters or to select a new motor click the section marked CLICK HERE TO CHANGE L4 Untitled MotionView94 E94S040x2x 1 untitled Project Node Tools View Help gt gt n suja x le Bi E945040x2x 1 untitled Parameter name Value Motor C Parameters Motor ID 519 LJ Communication Motor model 520 10 200 10 Motor vendor AC TECH SIMPLESERVO 0 Limits Torque constant 0 15 3 a ae Voltage constant 8 80 i racks Inductance phase phase 1 81 Resistance phase phase 2 22 Max phase current 2 88 Terminal voltage max 325 Rotor moment of inertia 0 000016 Max velocity 6000 Hall code 3 Number of poles 4 Encoder For Help press F1 Ln 2000 Col 200 Off line MotionView s Motor Group folder and its contents Sio Note If t
69. n I limit can cause large instability and unsettled oscillation of the mechanism Note Remember that these are only initial settings for your system Your ap plication will likely require fine tuning To optimize settings you will need to experiment with combinations of all gains P and D and the I limit S94P01A Lenze 9 Sample Motor Responses to Gain Settings 9 1 Motor response to gain settings Velocity mode Initial settings a Untitled MotionView94 ES940 Project Node Tools View Help olsalar wl amp Sg ES940 240V 10A 192 168 124 12 Cy Motor 3 Parameters QI Communication C3 10 C3 Limits I Compensation C Indexer program I Tools BD Oscilloscope C Run panels C3 Faults I Documents Parameter 240V 10A 192 168 124 124 RUNNING lue Drive name Drive mode Drive PWM frequency Current limit 8 KHZ peak current limit 16 KHZ peak current limit Analog input current scale Analog input velocity scale Enable Accel Decel limits Accel limit Decel limit Step input type Fault reset Motor temperature sensor Motor ptc cutt off resistance Second encoder Regen duty cyde Encoder repeat source Master to system ratio Second to prime encoder ratio Autoboot Group ID Enable switch function User units Velocity 16 KHZ 6 0000 A 30 0000 A 10 0000 A 0 2000 ANolt 200 0000 RPM Volt Disable 100 0000 100 0000 Internal Master encoder on disable Disable
70. nce 00 eee 38 6 3 13 Second encoder sisi arrienda a 38 63 14 Fegerduly ES ooi saque a A aa eee eee eb 39 6 3 15 Encoder repeat SOUrCE ANEN RR Dede idad haies 39 6 3 16 Master tO system alio 1 ss eee deme hb ir eee es 39 6 3 17 Second to prime encoder ratio c sesccccaresris riaistiiiverta 39 6 318 ENEE EE 39 6 39 49 Group Device RAISAT RESET 39 6 3 20 Enable switch fUNCUON esse ABEE iI 40 63 21 User UN iii EE EE ARE AAA 40 COMMUNICAI N 3 2 acera TE Ri te ie RUE oer 40 GE WP SOUP Emm 40 6 4 2 RS 485 configUratiO mesos ricardo 40 619 Modbus baudtate oes dde ex Ed da eee 40 6 4 4 Modbus reply delay ene 40 Analog VO Eet BEE 40 6 5 1 Analog OUEDUL erica Reo rta 40 6 5 2 Analog output current scale Volt amps 0 41 6 5 3 Analog output velocity scale MV RPM sess 41 654 Analog input dead band iii AR A 41 6 5 5 Analog input offset parameter 0 41 65 6 Adjust analog voltage Offset coins aia a ba a rad 41 Digital Me EE 41 6 6 1 Digital input de bounce me 41 6 6 2 Hard limit wien SOON oues epe hone bs Rabe ce Oe em at 42 Velocity Limits GIrOUp uere ore tombent dee SEIL A SEELEN Rede 42 B M Zeno SPCC rag iin REED etse manta uiui eser m eed Sys be bietet 42 6 7 2 Speed Kine siria dace sober o 42 0 7 9 ASPE tipi RE PIC T ahaha EE 42 POSIUODJIItS ria FREE dH acd dd ARA 42 68 1 Poston BHO eue seee teer Rem bx RR RR FRE E EG Rx Rn E Sg 42 552 MENO TIE ups eraot done as carp baa aee 42 6 8 3 Seco
71. nd Encoder Position Error LL 42 6 8 4 Second Encoder Max Error Time uuauaauaunauuuan a 42 Compensation group seo REG eer ex ape n Ra ei anta E Dis 43 6 9 1 Velocity P gain Proportional 43 6 9 2 Velocity Loan Integral 43 6 9 3 Position P gain Proportional i 43 6 9 4 Position I gain Integral o coooommaor iii 43 6 9 5 Position D gain Differential liess 43 69 6 Position Him crsonorrerirrco ton 43 6 9 7 Second encoder Loan Integral lisse esses 44 6 9 8 Velocity regulation window LL 44 S94P01A Lenze ACA aaa it 44 6 103 Oscilloscope tool oan a ra a Err 44 FAMI eo a esc IR ett ta d eo enr dace E40 EN 44 BCL Faus Gong g t H ete rere eC Den RR e ion oen RUE ide 44 7 Display and Diagnostics ees 45 Tal DHAQHOSUC display usa iuris rd da c 45 qae Diagnostic LED Suri RS REX ERRARE Fa up adr bx dades dani Er A M DER 46 13 FAUNS querais eos ER DR UL Ra eR PP based RR 47 KC e FAULECODES v ppi ados 47 1 32 Ful EVenb loa sseRR x a pr Rp E rra 47 e sci a4 eee pag EEE LI ag AREA aes od 47 8 Operation a a 48 8 1 Minimum Connections 2 sse cia A a E 48 8 2 Configuration of the PositionServo 0 0 eee 48 8 3 Position mode operation gearing LL 50 BA Dual loop feedback eh A o edam RR RACE RO eee eee ORO RR E 50 8 5 Enabling the PositionServo 0 eee eh 51 8 6 Tuning in velocity mode Liri 51 8 7 Tuning in positiorumode xico rios vd ad EORR
72. ogram This input does not have a predefined function Scaling of this input is identical to AIN1 5 3 2 Analog output AO P3 23 The analog output is a single ended signal with reference to Analog Common ACOM which can represent the following Motor data e Not Assigned Phase U Current Iq current RMS Phase Current Phase V Current e Id current Peak Phase Current Phase W Current Motor Velocity MotionView Setup program can be used to select the signal source for the analog output as well as its scaling If the output function is set to Not Assigned then the output can be controlled directly from user s program See the 940 Programming Manual for details on programming Lenze S94P01A 25 5 4 Communication interfaces 5 4 1 RS232 interface standard Programming and diagnostics of the 940 drive is done over the standard RS232 communication port The baud rate for this port can be configured to one of 10 different setting ranging from 2400 to 921600 Drives are addressable with up to 32 addresses from 0 31 Communication speed and address are set from the drive s front panel display 5 4 2 RS485 interface option module PositionServo 940 drives can be equipped with an RS485 communication interface option module E94ZARS41 which is optically isolated from the rest of the drive s circuitry This option module can be used for two functions drive programming and diagnostics using MotionView from a PC with RS485 p
73. omponents 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 e 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 Liability The information data and notes in these instructions met the state of the art at the time of publication Claims on modifications referring to controllers which have already been supplied cannot be derived from the information illustrations and descriptions The specifications processes and circuitry described in these instructions are for guidance only and must be adapted to your own specific application Lenze does not take responsibility for the suitability of the process and circuit proposals The specifications in these
74. on is set to true in the internal controller logic The zero speed condition can also trigger a programmable digital output if selected 6 7 2 Speed Window Specifies the speed window width used with the In speed window output 6 7 3 At Speed Specifies the speed window center used with the In speed window output These last two parameters specify speed limits If motor shaft speed is within these limits then the condition AT SPEED is set to TRUE in the internal controller logic The AT SPEED condition can also trigger a programmable digital output if selected For example if AT SPEED is set for 1000 RPM and the SPEED WINDOW is set for 100 then AT SPEED will be true when the motor velocity is between 950 1050 RPM 6 8 Position limits 6 8 1 Position Error Specifies the maximum allowable position error in the primary motor mounted feedback device before enabling the Max error time clock described next When using an encoder the position error is in post quadrature encoder counts When using a resolver position error is measured at a fixed resolution of 65 536 counts per motor revolution 6 8 2 Max Error Time Specifies maximum allowable time in mS during which a position error can exceed the value set for the Position error parameter before a Position Error Excess fault is generated 6 8 3 Second Encoder Position Error Specifies the maximum allowable error of the second encoder in post quadrature encod
75. ort or as a Modbus RTU slave The 940 family of drives support 10 different baud rates ranging from 240 to 921600 Drives are addressable with up to 32 addresses from 0 31 The factory setting for the baud rate is 38 400 with a node address of 1 The drives address must be set from the front panel display of the drive When used with MotionView software the communication speed is also set from the front panel display Please note that baud rate and address are applied to both RS232 and RS485 interfaces in this case If used for Modbus RTU communications the Modbus baud rate is set as a parameter within MotionView PIN ASSIGNMENTS RS485 interface Pin Name Function 1 ICOM Isolated Common 2 TXB Transmit A 3 TXA Transmit B 5 4 3 Using RS232 and RS485 interfaces simultaneously When establishing communication between MotionView and a 940 drive a communication method must be selected The connection choice can be either UPP over RS485 RS232 or Ethernet The UPP over RS485 RS232 selection establishes a RS232 connection between MotionView and the first drive on the network Multiple drives can then be added to the networked via RS485 Each drive on the network will have a different Node Address When setting up communications the node address of the target drive must be set MotionView will then send out a communications packet to the first drive on the network via the RS232 connection If th
76. ror exceeded maximum value F bd Bad motor data Motor profile data invalid or no motor is selected F 09 Motor over Optional motor temperature sensor PTC indicates that the H temperature motor windings have reached maximum temperature Error in data exchange between processors Usually E 10 a happens when EMI level is high resulting from poor shielding and grounding Happens bus voltage level drops below 50 of nominal bus E 4 Undervoltage voltage while drive is operating Attempt to enable drive with low bus voltage also result in this fault F_ 15 Hardware overload Happens if phase current at any time becomes higher then protection 400 of total drive s current capability for more then 5uS F_33 Negative Limit Switch Negative limit switch is activated E 20 Positive Limit Switch Positive limit switch is activated i Drive disabled while operating or attempt to enable drive Drive Disabled by aba u eg Sar cU F_J6 User at Enable Input si deactivating Inhibit input Inhibit input has reverse There are additional error codes related to the programming of the 940 Please reference the programmer s manual for more information 7 3 2 Fault Event When drive encounters any fault the following events occur Drive is disabled nternal status is set to Fault Fault number is logged in the drive s internal memory for later interrogation Digital output s if configured for Run Time Fault are asserted Digi
77. rs in the left node tree of the MotionView s Screen Note D MotionView s Connection setup properties need only be configured 15 16 17 18 19 20 21 the first time MotionView is operated or if the port connection is changed Refer to MotionView User s Manual for details on how to make a connection to the drive Double click on the drive s icon to expand parameter group s folders Select the motor to be used according to the Section 5 5 Expand the folder Parameters and choose the operating mode for the drive Refer for details to Section 6 3 1 for details on operating modes Click on the Current limit parameter 6 3 3 and enter current limit in Amp RMS per phase appropriate for the motor Click on the appropriate Peak current limit parameter 6 3 4 based on the Drive PWM frequency parameter 6 3 2 used and enter the peak current limit in Amp RMS per phase appropriate for your motor Set up additional parameters suitable for the operating mode selected in step 17 After you configure the drive proceed to the tuning procedure if operating in Velocity or Position mode Torque mode doesn t require additional tuning or calibration Refer to Section 8 6 for details on tuning Lenze S94P01A 49 8 3 Position mode operation gearing In position mode the drive will follow the master reference signals at the P3 1 4 inputs The distance the motor shaft rotates per e
78. s negative logic INHIBIT input regardless of mode or program status Activating input IN_A3 doesn t enables the drive The drive can be enabled from the user s program or interface only when IN_A3 is active Attempt to enable drive by executing the program statement ENABLE or from interface will cause the drive to generate a fault 36 Regardless of the mode of operation if the input is deactivated while the drive is enabled the drive will be disabled and will generate a fault 36 WARNING N Enabling the servo drive allows the motor to operate depending on the reference command The operator must ensure that the motor and machine are safe to operate prior to enabling the drive and that moving elements are appropriately guarded Failure to comply could result in damage to equipment and or injury to personnel 8 6 Tuning in velocity mode In this mode the settings for Position compensation will have no effect 1 Make sure that power is applied to the drive and that the drive is connected to a PC running MotionView software 2 Make sure that the drive is disabled 3 Select the Parameters folder from the node tree Click on Reference parameter and change it to Internal This will tell drive to use the internally generated reference 4 Make sure that Enable Accel Decel limits is set to Disable 5 Select Indexer program click anywhere in programs pane then select menu Indexer gt Import progra
79. sentative for assistance As this manual makes reference to specific pins on specific connectors we will use the convention PX Y where X is the connector number and Y is the pin number 5 1 External Connectors 5 1 1 P1 amp P7 Input Power and Output Power Connections P1 is a 3 or 4 pin quick connect terminal block used for input mains power P7 isa 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 A 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 All conductors must be enclosed in one shield and jacket around them The shield on the drive end of the motor power cable should be terminated to the conductive machine panel using screen clamps as shown in section 4 2 The other end should be properly terminated at the motor shield Feedback cable shields should be terminated in a like manner Lenze recommends Lenze cables for both the motor power and feedback These are availab
80. tal 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 5 1 7 Connector and Wiring Notes 2 See Note 2 Section 5 1 7 Connector and Wiring Notes 3 See Note 3 Section 5 1 7 Connector and Wiring Notes 16 Lenze S94P01A 5 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 en
81. tal output s if configured for READY are de asserted e If the display is in the default status mode the LED s display F XX where XX is current fault code Enable LED turns OFF 7 3 3 Fault Reset Fault reset is accomplished by disabling or re enabling the drive depending on the setting of the Reset option parameter section 6 3 10 S94P01A 47 Lenze 8 Operation This section offers guidance on configuring the PositionServo drive for operations in torque velocity or position modes without requiring a user program To use advanced programming features of PositionServo please perform all steps below and then refer to the Programmer s Manual on details on how to write motion programs 8 1 Minimum Connections For the most basic operation connect the PositionServo 94 to mains line power at terminal P1 the servomotor power at P7 and the motor feedback as appropriate DANGER A 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 at least 60 seconds before servicing drive Capacitors retain charge after power is removed Below is a list of the minimum necessary connections Connect serial cable between PositionServo s P2 and your PC serial port using a straight through 9 pin RS232 cable available as EWLCOO3BA1NA
82. the motor windings Hall order number defines which hall sensor matches which phase phase voltage Motor phases are usually called R S T or U V W or A B C Phase Phase voltages are called Vrs Vst Vtr Halls are usually called HALL A HALL B HALL C or just Halls 1 2 3 A motor s phase diagram is supplied by motor vendor and usually can be found in the motor data sheet or by making a request to the motor manufacturer A sample phase diagram is shown below Vis 2 Vat aA Vir AN 1 HALL A b f o Hara L 3 HALL C 912 The Halls Order is obtained as follows 1 By looking at the Vrs Output Voltage determine which Hall Voltage is lined up with or in phase with this voltage We can determine which Hall Voltage is in phase with the Vrs Output Voltage by drawing vertical lines at those points where it crosses the horizontal line zero The dashed lines at the zero crossings above indicate that Hall B output is lined up with and in phase with the Vrs Output Voltage Look at the Vst Output Voltage Determine which Hall Voltage is in phase with this Voltage As can be seen Hall C output is in phase with the Vst Output Voltage Look at the Vtr Output Voltage Determine which Hall Voltage is in phase with this Voltage As can be seen Hall A output is in phase with the Vtr Output Voltage Note il If hall sensors are in phase with the corresponding phase voltage but are inverted 180 degrees hall sensor
83. tion mode In this mode the drive reference is a pulse train applied to P3 1 4 terminals if the parameter Reference is set to External Otherwise the reference is taken from the drive s internal variable See Programmer s manual for details P3 1 4 inputs can be configured for two types of signals step and direction and Master encoder quadrature signal Refer to section 5 2 1 for details on these inputs connections Refer to section 8 3 for details about positioning and gearing When the Reference is set to Internal the drives reference position theoretical or Target position is generated by trajectory generator Access to the trajectory generator is provided by motion statements MOVEx and MDV from the User Program See Programmer s manual for details 6 3 2 Drive PWM frequency This Parameter sets the PWM carrier frequency Frequency can be changed only when the drive is disabled Maximum overload current is 300 of the drive rated current when the carrier is set to 8KHZ it is limited to 250 at 16KHZ 6 3 3 Current Limit The CURRENT LIMIT setting determines the nominal current in amps RMS per phase 6 3 4 8 KHZ Peak current limit and 16 KHZ Peak current limit Peak current sets the motor RMS phase current that is allowed for up to 2 Seconds After this two second limit the current limit will be reduced to the value set in the Current Limit parameter When the motor current drops below nominal current for two seconds
84. tivated when drive detects current limit Run Time Fault A fault has occurred Refer to Section 7 3 for details on faults Ready Drive is enabled Brake Command for the holding brake option E94ZAFFD1 for control of a motor mounted brake This output is active 10ms after the drive is enabled and deactivates 10ms before the drive is disabled In position Position mode only See 940 Programming Manual for details 6 6 1 Digital input de bounce time Sets de bounce time for the digital inputs to compensate for bouncing of the switch or relay contacts This is the time during an input transition that the signal must be stable before it is recognized by the drive Lenze S94P01A 41 6 6 2 Hard limit switch action Digital inputs IN_A1 IN_A2 can be used as limit switches if their function is set to Fault or Stop and Fault Activation of this input while the drive is enabled will cause the drive to Disable and go to a Fault state The Stop and Fault action is available only in Position mode when the Reference parameter is set to Internal i e when the source for the motion is the Trajectory generator See Programmer s Manual for details on Stop and Fault behavior 6 7 Velocity Limits Group These parameters are active in Velocity Mode Only 6 7 1 Zero Speed Specifies the upper threshold for motor zero speed in RPM When the motor shaft speed is at or below the specified value the zero speed conditi
85. to help monitor system status and activity as well as troubleshoot any faults C A x W D B W WE S913 LED Function Description A Enable Orange LED indicates that the drive is ENABLED running B Regen Yellow LED indicates the drive is in regeneration mode C Data Entry Yellow LED will flash when changing Red LED illuminates upon a communication fault D Comm Fault available in CANbus only E Comm Activity Green LED flashes to indicate communication activity 46 S94PO1A Lenze 7 3 Faults 7 3 1 FAULT CODES Below are fault codes mostly caused by hardware operations Additional fault codes are listed in Programmer s manual Fault Code Fault Description Drive bus voltage reached the maximum level typically due n Ez Over voltage to motor regeneration F_Fb Feedback error Resolver signal lost or at least one motor hall sensor is inoperable or not connected Drive exceeded peak current limit Software un capable to F UL Over current regulate current within 1596 for more then 20mS Usually results in wrong motor data or poor tuning E Dt Over temperature Go heatsink temperature has been reached maximum E ER External fault input Digital input was programmed as external fault input and has si activated been activated E UG Over speed Motor reached velocity above its specified limit F PE Excess position error Position er
86. ulated compatible with Single ended or differential outputs 5 24 VDC Max frequency per input 2 MHz Min pulse width negative or positive 500nS Min pulse width negative or positive 250nS Input impedance 700 Q approx 6000 1000 MA STEP O MB DIR Z vw A 5 6V MA STEP MB DIR 9 S906 Master encoder step and direction input circuit Differential signal inputs are preferred when using Step and Direction Single ended inputs can be used but are not recommended Sinking or sourcing outputs may also be connected to these inputs The function of these inputs Master Encoder or Step and Direction is software selectable Use MotionView set up program to choose desirable function 22 S94PO1A Lenze 5 2 2 Digital outputs There are a total of five digital outputs OUT1 OUT4 and RDY available on the PositionServo 940 drive These outputs are accessible from the P3 connector Outputs are open collector type that are fully isolated from the rest of the drive circuits See the following figure for the electrical diagram These outputs can be either used via the drives internal User Program or they can be configured as Special Purpose outputs When used as Special Purpose each output OUT1 OUT4 can be assigned to one of the following functions Not assigned Zero speed e In speed window Current limit Run time fault Ready Brake motor brake release Please note that if you assi
87. ule E94ZARSV1 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 Note 3 Digital Input 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 Lenze S94P01A 19 5 1 8 P11 Resolver interface module Option Module 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 E94ZARSV1 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 P11 PIN ASSIGNMENTS Resolver Feedback Pin
88. un with P gain set as low as 20 but under load might not If P gain is set to O motor will not run at all In position mode with master encoder motion source no program Reference voltage input signal source is not properly selected n MotionView program check lt Parameters gt lt Reference gt set to lt External gt In position mode using indexing program Variables ACCEL DECEL MAXV UNITS are not set or set to 0 Before attempting the move set values of motion parameters ACCEL DECEL MAXV UNITS Problem In velocity mode the motor runs away Possible Cause Suggested Solution Hall sensors or encoder miswired PositionServo not programmed for motor connected e Check Hall sensor and encoder connections Check that the proper motor is selected Lenze S94P01A 63 AC Technology Corporation member of the Lenze Group 630 Douglas Street Uxbridge MA 01569 Telephone 508 278 9100 Facsimile 508 278 7873
89. ver some operations will not be correct and the drive may hang The White EPM is the only acceptable EPM for the PositionServo 940 drive If a white EPM is detected the drive compares data in the EPM to that in its internal memory In order for the drive to operate the contents of the drive s memory and EPM must be the same Press the enter button to load the EPM this will take a moment STOP If the EPM contains any data from an inverter drive that data will be overwritten during this procedure Lenze S94P01A 35 6 1 3 EPM fault If the EPM fails during operation or the EPM is removed from the EPM Port the drive will generate a fault and will be disabled if enabled The fault is logged to the drives memory Further operation is not possible until the EPM is replaced inserted and the drive s power is cycled The fault log on the display shows F_ EP fault 6 2 Motor Group The motor group shows the data for the currently selected motor Refer to Section 5 5 for details on how to select another motor from the motor database or to configure a custom motor 6 3 Parameters Group 6 3 1 Drive operating modes The PositionServo has 3 operating mode selections Torque Velocity and Position For Torque and Velocity modes the drive will accept an analog input voltage on the AIN and AIN pins of P3 see section 5 3 1 This voltage is used to provide a torque or speed reference For Position mode the drive will accept step

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