Lenz PositionServo 940 User manual

S929
PositionServo with RS-232
Users Manual

Copyright ©2005 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

S94P01B2 1
Contents
1 Introduction.................................................. 5
1.1 AboutTheseInstructions............................................5
1.2 ScopeofSupply...................................................6
1.3 LegalRegulations .................................................6
2 TechnicalData............................................... 7
2.1 ElectricalCharacteristics............................................7
2.2 Environment......................................................7
2.3 OperatingModes..................................................8
2.4 ConnectionsandI/O ...............................................8
2.5 DigitalI/ORatings .................................................8
2.6 PowerRatings....................................................9
2.7 Dimensions ......................................................9
2.8 Clearance for Cooling Air Circulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3 Installation ................................................. 11
3.1 Wiring..........................................................12
3.2 ShieldingandGrounding...........................................12
3.2.1 GeneralGuidelines ........................................12
3.2.2 EMIProtection............................................13
3.2.3 Enclosure................................................13
3.3 LineFiltering ....................................................13
3.4 HeatSinking.....................................................14
3.5 Line(Mains)Fusing...............................................14
3.6 FuseRecommendations ...........................................14
4 Interface................................................... 15
4.1 ExternalConnectors ..............................................15
4.1.1 P1 & P7 - Input Power and Output Power Connections. . . . . . . . . . . . .15
4.1.2 P2 - Serial Communications Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
4.1.3 P3-ControllerInterface.....................................16
4.1.4 P4 - Motor Feedback / Second Loop Encoder Input . . . . . . . . . . . . . . .17
4.1.5 P5 - 24 VDC Back-up Power Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4.1.6 P6 - Braking Resistor and DC Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4.1.7 ConnectorandWiringNotes.................................19
4.1.8 P11 - Resolver Interface Module (option) . . . . . . . . . . . . . . . . . . . . . . .20
4.1.9 P12 - Second Encoder Interface Module (option) . . . . . . . . . . . . . . . . .21
4.2 DigitalI/ODetails.................................................22
4.2.1 Step & Direction / Master Encoder Inputs (P3, pins 1-4). . . . . . . . . . . .22
4.2.2 DigitalOutputs............................................23
4.2.3 DigitalInputs .............................................24
4.3 AnalogI/ODetails ................................................25
4.3.1 AnalogReferenceInput.....................................25
4.3.2 AnalogOutput............................................25
4.4 CommunicationInterfaces..........................................26
4.4.1 RS232Interface(standard)..................................26
4.4.2 RS485Interface(option) ....................................26
4.4.3 Using RS232 and RS485 Interfaces Simultaneously . . . . . . . . . . . . . . .26
4.4.4 MODBUSRTUSupport.....................................27
4.5 MotorSelection ..................................................27
4.5.1 MotorConnection..........................................27
4.5.2 Motor Over-Temperature Protection . . . . . . . . . . . . . . . . . . . . . . . . . . .27
4.5.3 MotorSet-up .............................................28
4.6 UsingaCustomMotor.............................................29
4.6.1 Creating Custom Motor Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4.6.2 Autophasing..............................................30
4.6.3 CustomMotorDataEntry....................................30

S94P01B2
2
Contents
5 Parameters................................................. 35
5.1 Parameter Storage and EPM Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
5.1.1 ParameterStorage.........................................35
5.1.2 EPMOperation............................................35
5.1.3 EPMFault................................................36
5.2 MotorGroup.....................................................36
5.3 Parameters .....................................................36
5.3.1 DriveOperatingModes.....................................36
5.3.2 DrivePWMFrequency......................................37
5.3.3 CurrentLimit..............................................37
5.3.4 Peak Current Limit (8kHz and 16 kHz). . . . . . . . . . . . . . . . . . . . . . . . . .37
5.3.5 AnalogInputScale(Current).................................37
5.3.6 Analog Input Scale (Velocity). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
5.3.7 ACCEL/DECEL Limits (Velocity Mode Only) . . . . . . . . . . . . . . . . . . . . .38
5.3.8 Reference................................................38
5.3.9 Step Input Type (Position Mode Only) . . . . . . . . . . . . . . . . . . . . . . . . . .38
5.3.10 FaultResetOption.........................................38
5.3.11 MotorTemperatureSensor ..................................38
5.3.12 Motor PTC Cut-off Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
5.3.13 SecondEncoder ..........................................38
5.3.14 RegenDutyCycle .........................................39
5.3.15 EncoderRepeatSource.....................................39
5.3.16 SystemtoMasterRatio .....................................39
5.3.17 Second to Prime Encoder Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
5.3.18 Autoboot.................................................39
5.3.19 GroupID ................................................40
5.3.20 EnableSwitchFunction.....................................40
5.3.21 UserUnits ...............................................40
5.4 Communication ..................................................40
5.4.1 IPSetup.................................................40
5.4.2 RS-485Configuration.......................................40
5.4.3 ModbusBaudRate ........................................40
5.4.4 ModbusReplyDelay.......................................40
5.5 AnalogI/O ......................................................40
5.5.1 AnalogOutput............................................40
5.5.2 Analog Output Current Scale (Volt /amps) . . . . . . . . . . . . . . . . . . . . . .41
5.5.3 Analog Output Velocity Scale (mV/RPM) . . . . . . . . . . . . . . . . . . . . . . . .41
5.5.4 AnalogInputDeadBand....................................41
5.5.5 Analog Input Offset Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
5.5.6 AdjustAnalogVoltageOffset.................................41
5.6 DigitalI/O.......................................................41
5.6.1 Digital Input De-bounce Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
5.6.2 HardLimitSwitchAction....................................42
5.7 VelocityLimits ...................................................42
5.7.1 ZeroSpeed ..............................................42
5.7.2 SpeedWindow............................................42
5.7.3 AtSpeed ................................................42
5.8 PositionLimits...................................................42
5.8.1 PositionError.............................................42
5.8.2 MaxErrorTime............................................42
5.8.3 Second Encoder Position Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
5.8.4 Second Encoder Max Error Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

S94P01B2 3
Contents
5.9 Compensation...................................................43
5.9.1 Velocity P-gain (Proportional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
5.9.2 VelocityI-gain(Integral).....................................43
5.9.3 Position P-gain (Proportional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
5.9.4 PositionI-gain(Integral).....................................43
5.9.5 Position D-gain (Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
5.9.6 PositionI-limit.............................................43
5.9.7 GainScalingWindow.......................................44
5.10 Tools ..........................................................44
5.10.1 OscilloscopeTool .........................................44
5.10.2 RunPanels...............................................44
5.11 FaultsGroup ....................................................44
6 Operation.................................................. 45
6.1 MinimumConnections.............................................45
6.2 Configuration of the PositionServo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
6.3 Position Mode Operation (gearing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
6.4 Dual-loopFeedback...............................................47
6.5 EnablingthePositionServo.........................................48
6.6 DriveTuning.....................................................48
6.6.1 Tuning the Drive in Velocity Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
6.6.2 Tuning the Drive in Position Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
7 QuickStartReference ........................................ 60
7.1 QuickStart-ExternalTorqueMode ..................................60
7.2 Quick Start - External Velocity Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
7.3 Quick Start - External Positioning Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
8 Diagnostics................................................. 65
8.1 Display.........................................................65
8.2 LEDs ..........................................................66
8.3 Faults..........................................................66
8.3.1 FaultCodes..............................................66
8.3.2 FaultEvent...............................................68
8.3.3 FaultReset...............................................68
8.4 Troubleshooting..................................................68

S94P01B2
4
Safety Information
All safety information given in these Operating Instruction has a similar layout:
Signal Word! (Characteristics the severity of the danger)
Note (describes the danger and informs on how to proceed)
Pictographs used in these instructions:
Icon Signal Words
Warning of
hazardous
electrical
voltage
DANGER! Warns of impending danger.
Consequences if disregarded:
Death or severe injuries.
Warning of
a general
danger
WARNING! Warns of potential, very hazardous
situations.
Consequences if disregarded:
Death or severe injuries.
Warning of
damage to
equipment
STOP! Warns of potential damage to material
and equipment.
Consequences if disregarded:
Damage to the controller/drive or its
environment.
Information NOTE Designates a general, useful note.
If you observe it, handling the controller/
drive system is made easier.

S94P01B2 5
Introduction
1 Introduction
The PositionServo line of advanced general purpose servo drives utilizes the latest
technology in power semiconductors and packaging. The PositionServo uses Field
Oriented control to enable high quality motion.
The PositionServo Model 940 is available in four mains (input power) configurations:
1. 400/480V (nominal) three phase input. An external input mains (line) filter is
available. These drives have the suffix “T4N”. Actual voltage can range from
320 - 528 VAC.
2. 120/240V (nominal) Single Phase input with integrated input mains (line)
filter, Actual input voltage can range from 80VAC to 264VAC. The maximum
output voltage is approximately equal to the input voltage. These drives have
the suffix “S2F”.
3. 120V or 240V (nominal) Single or Three Phase input. Actual input voltage
can range from 80VAC to 264VAC. The maximum output voltage is
approximately equal to the input voltage. An external input mains (line) filter
is available. These drives have the suffix “Y2N”.
4. 120V or 240V (nominal) single phase input. When wired for Doubler mode
(L1-N), the input is for 120V nominal only and can range from 45VAC to 132
VAC and the maximum output voltage is double the input voltage. When
wired to terminals L1-L2/N, the input can range from 80 VAC to 264 VAC and
the maximum output voltage is equal to the input voltage. These drives have
the suffix “S1N”.
The PositionServo 940 will accept feedback from an incremental encoder (that includes
Hall channel information) or from a resolver. It accepts commands from a variety of
sources, including analog voltage, RS485 interface (PPP and Modbus RTU), Ethernet
interface, CANopen interface, digital pulse train, and master encoder reference. The
control will operate in current (torque), velocity, or position (step and direction / master
encoder) modes.
The 940 utilizes a software package called MotionView. MotionView provides a
window into the drive allowing the user to check and set parameter. It has a real-time
oscilloscope tool, for analyses and optimum tuning, as well as a User Program. This
User Program can be utilized to command motion and handle the drives I/O. The
MotionView programming language is designed to be very user friendly and easy to
implement.
The EPM (Electronic Programming Module) stores all drive setup and tuning information.
This module can be removed from the drive and reinstalled into another PositionServo
940, making field replacement of the PositionServo 940 extremely easy.
The PositionServo 940 controls supports Point-to-Point (PPP) and Modbus RTU over
RS485, Ethernet TCPIP and CANopen (DS301, DS402) communication protocols.
The PositionServo 940 supports incremental quadrature encoder or resolver feedback
devices. A second encoder can also be supported during position and velocity modes.
1.1 About These Instructions
• These Operating Instructions are provided to assist the user in connecting and
commissioning the PositionServo drive equipped with an RS232 interface in P2.
Observe all safety instructions contained in this document.
• All persons working on and with the controller must have the Operating Instructions
available and must observe the information and notes relevant for their work.
• Read these Operating Instructions in their entirety before operating the drive.

S94P01B2
6
Introduction
1.2 Scope of Supply
Scope of Supply Important
•1Model940ServotypeE94P...
•1UsersManual(English)
•1MotionViewCDROMincluding
- configuration software
- documentation (Adobe Acrobat)
After reception of the delivery, check immediately
whether the scope of supply matches the
accompanying papers. Lenze does not accept any
liability for deficiencies claimed subsequently.
Claim
•visibletransportdamageimmediatelytotheforwarder
•  visible deciencies / incompleteness immediately to
your Lenze representative.
1.3 Legal Regulations
Identification Nameplate CE Identification Manufacturer
Lenze controllers are
unambiguously designated by
the contents of the nameplate
In compliance with the EC
Low-Voltage Directive
AC Technology Corp.
member of the Lenze Group
630 Douglas Street
Uxbridge, MA 01569 USA
Application as
directed
E94P... servo controller
• must only be operated under the conditions prescribed in these Instructions.
• are components
- for closed loop control of variable speed and torque applications with PM synchronous motors
- for installation in a machine.
- for assembly with other components to form a machine.
• are electric units for the installation into control cabinets or similar enclosed operating housing.
• comply with the requirements of the Low-Voltage Directive.
• are not machines for the purpose of the Machinery Directive.
• are not to be used as domestic appliances, but only for industrial purposes.
Drive systems with E94P... servo inverters
• comply with the EMC Directive if they are installed according to the guidelines of CE-typical
drive systems.
• can be used
- for operation on public and non-public mains
- for operation in industrial premises and residential areas.
• The user is responsible for the compliance of his application with the EC directives.
Any other use shall be deemed as inappropriate!
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 specications, processes and circuitry described in these instructions are for guidance only
and must be adapted to your own specific application. Lenze does not take responsibility for the
suitability of the process and circuit proposals.
• The specications in these Instructions describe the product features without guaranteeing them.
• Lenze does not accept any liability for damage and operating interference caused by:
- Disregarding the operating instructions
- Unauthorized modifications to the controller
- Operating errors
- Improper working on and with the controller
Warranty • Warranty conditions: see Sales and Delivery Conditions of Lenze Drive Systems GmbH.
• Warranty claims must be made to Lenze immediately after detecting the deciency or fault.
• The warranty is void in all cases where liability claims cannot be made.
Disposal Material Recycle Dispose
Metal •-
Plastic •-
Assembled PCB’s -•

S94P01B2 7
Technical Data
2 Technical Data
2.1 Electrical Characteristics
Single-Phase Models
Type Mains Voltage (1)
1~ Mains
Current
(doubler)
1~ Mains
Current
(Std.)
Rated Output
Current (4) Peak Output Current (5)
E94P020S1N 120V(2) or 240V(3) 9.7 5.0 2.0 6
E94P040S1N 15 8.6 4.0 12
E94P020S2F
120 / 240V(3)
(80 V -0%...264 V +0%)
-- 5.0 2.0 6
E94P040S2F -- 8.6 4.0 12
E94P080S2F -- 15.0 8.0 24
E94P100S2F -- 18.8 10.0 30
Single/Three-Phase Models
Type Mains Voltage (1) 1~ Mains Current
3~ Mains
Current
Rated Output
Current (4) Peak Output Current (5)
E94P020Y2N
120 / 240V(3)
1~ or 3~
(80 V -0%...264 V +0%)
5.0 3.0 2.0 6
E94P040Y2N 8.6 5.0 4.0 12
E94P080Y2N 15.0 8.7 8.0 24
E94P100Y2N 18.8 10.9 10.0 30
E94P120Y2N 24.0 13.9 12.0 36
E94P020T4N
400 / 480V
3~
(320 V -0%...528 V +0%)
-- 2.7 2.0 6
E94P040T4N -- 5.5 4.0 12
E94P050T4N -- 6.9 5.0 15
E94P060T4N -- 7.9 6.0 18
(1) Mains voltage for operation on 50/60 Hz AC supplies (48 Hz -0% … 62Hz +0%).
(2) Connection of 120VAC (45 V … 132 V) to input power terminals L1 and N on these models doubles the voltage
on motor output terminals U-V-W for use with 230VAC motors.
(3) Connection of 240VAC or 120VAC to input power terminals L1 and L2 on these models delivers an equal voltage
as maximum to motor output terminals U-V-W allowing operation with either 120VAC or 230VAC motors.
(4) Drive rated at 8kHz Carrier Frequency. Derate Continuous current by 17% at 16kHz.
(5) Peak RMS current allowed for up to 2 seconds. Peak current rated at 8kHz. Derate by 17% at 16kHz.
Applies to all models:
Acceleration Time Range (Zero to Max Speed) 0.1 … 5x106RPM/sec
Deceleration Time Range (Max Speed to Zero) 0.1 … 5x106RPM/sec
Speed Regulation (typical) ± 1 RPM
Input Impedance (AIN+ to COM and AIN+ to AIN-) 47k Ω
Power Device Carrier Frequency (sinusoidal commutation) 8,16 kHz
Encoder power supply (max) +5 VDC @ 300 mA
Maximum encoder feedback frequency 2.1 MHz (per channel)
2.2 Environment
Vibration 2 g (10 - 2000 Hz)
Ambient Operating Temperature Range 0 to 40ºC
Ambient Storage Temperature Range -10 to 70ºC
Temperature Drift 0.1% per ºC rise
Humidity 5 - 90% non-condensing
Altitude 1500 m/5000 ft [derate by 1% per 300m
(1000 ft) above 1500m (5000 ft)]

S94P01B2
8
Technical Data
2.3 Operating Modes
Torque Reference ± 10 VDC 16-bit; scalable
Torque Range 100:1
Current-Loop Bandwidth Up to 1.5 kHz*
Velocity Reference ± 10 VDC or 0…10 VDC; scalable
Regulation ± 1 RPM
Velocity-Loop Bandwidth Up to 200 Hz*
Speed Range 5000:1 with 5000 ppr encoder
Position Reference 0…2 MHz Step and Direction or
2 channels quadrature input; scalable
Minimum Pulse Width 500 nanoseconds
Loop Bandwidth Up to 200 Hz*
Accuracy ±1 encoder count
* = motor and application dependent
2.4 Connections and I/O
Mains Power 4-pin removable terminal block (P1)
RS232 Port Standard 9-pin D-shell (DCE) Connector (P2)
I/O Connector Standard 50-pin SCSI. (P3)
- Buffered Encoder Output A, B & Z channels with compliments (5V @ 20mA) (P3)
- Digital Inputs 12 programmable, 1 dedicated (5-24V) (P3)
- Digital Outputs 4 programmable, 1 dedicated(5-24V @ 15mA) (P3)
- Analog Input 1 differential; ±10 VDC (16 bit) (P3)
- Analog Output 1 single ended; ±10 VDC (10-bit) (P3)
Encoder Feedback (primary) Standard 15-pin D-shell (P4)
24VDC Power “Keep Alive” 2-pin removable terminal block (P5)
Regen and Bus Power 5-pin removable terminal block (P6)
Motor Power 6-pin pin removable terminal block (P7)
Resolver feedback (option bay) Option module with standard 9-pin D-shell (P11)
Encoder Feedback (option bay) Option module with standard 9-pin D-shell (P12)
Comm Option Bay Optional Comm Modules (CAN, Ethernet, RS485) (P21)
Windows® Software: MotionView (Windows 98, NT, 2000, XP)
2.5 Digital I/O Ratings
Scan
Times Linearity Temperature Drift Offset Current Input Impedance
Voltage
Range
Units ms % % % mA Ohm VDC
Digital Inputs(1) 512 Depend on load 2.2 k 5-24
Digital Outputs 512 15 max N/A 30 max
Analog Inputs 512 ± 0.013 0.1% per °C rise ± 0 adjustable Depend on load 47 k ± 18
Analog Outputs 512 0.1% per °C rise ± 0 adjustable 10 max N/A ± 10
(1) Inputs do not have scan time. Their values are read directly by indexer program statement.
Notes for Power Ratings Table in section 2.6:
(1) At 240 VAC line input for drives with suffixes “S1N”, “S2F”, “Y2N”. At 480 VAC line input for drives with suffixes “T4N”.
a. The output power is calculated from the formula: output kVA = [( 3) x ULL x I rated] /1000
b. The actual output power (kW) depends on the motor in use due to variations in motor rated voltage, rated speed and
power factor, as well as actual max operating speed and desired overload capacity.
c. Typical max continuous power (kW) for PM servo motors runs 50-70% of the kVA ratings listed.
(2) At 16 kHz, de-rate continuous current by 17%
(3) Leakage Current is typically >3.5mA. Contact factory for applications requiring <3.5mA

S94P01B2 9
Technical Data
2.6 Power Ratings
Type(1) Output kVA at Rated
Output Current (8kHz)(1)
Leakage
Current (3)
Power Loss at Rated
Output Current (8kHz)
Power Loss at Rated
Output Current (16 kHz)(2)
Units kVA Typical:
>3.5mA*
Watts Watts
E94P020S1N 0.8 19 21
E94P040S1N 1.7 29 30
E94P020S2F 0.8
Typical:
>3.5mA*
19 21
E94P040S2F 1.7 29 30
E94P080S2F 3.3 61 63
E94P100S2F 4.2 80 85
E94P020Y2N 0.8
Typical:
>3.5mA*
19 21
E94P040Y2N 1.7 29 30
E94P080Y2N 3.3 61 63
E94P100Y2N 4.2 80 85
E94P120Y2N 5.0 114 129
E94P020T4N 1.7
Typical:
>3.5mA*
31 41
E94P040T4N 3.3 50 73
E94P050T4N 4.2 70 90
E94P060T4N 5.0 93 122
Refer to Notes that precede this table.
2.7 Dimensions
C
15
12
12
A
38
182 B
34
S923
Type A (mm) B (mm) C (mm) Weight (kg)
E94P020S1N 68 190 190 1.1
E94P040S1N 69 190 190 1.2
E94P020S2F 68 190 235 1.3
E94P040S2F 69 190 235 1.5
E94P080S2F 87 190 235 1.9
E94P100S2F 102 190 235 2.2
E94P020Y2N 68 190 190 1.3
E94P040Y2N 69 190 190 1.5
E94P080Y2N 95 190 190 1.9
E94P100Y2N 114 190 190 2.2
E94P120Y2N 68 190 235 1.5
E94P020T4N 68 190 190 1.5
E94P040T4N 95 190 190 1.9
E94P050T4N 114 190 190 2.2
E94P060T4N 68 190 235 1.4

S94P01B2
10
Technical Data
2.8 Clearance for Cooling Air Circulation
>25mm
>3mm
>25mm

S94P01B2 11
Installation
3 Installation
Perform the minimum system connection. Please refer to section 6.1 for minimum
connection requirements. Observe the rules and warnings below carefully:
DANGER!
Hazard of electrical shock! Circuit potentials are up to 480 VAC
above earth ground. Avoid direct contact with the printed circuit board
or with circuit elements to prevent the risk of serious injury or fatality.
Disconnect incoming power and wait 60 seconds before servicing drive.
Capacitors retain charge after power is removed.
STOP!
• The PositionServo 940 must be mounted vertically for safe
operation and enough cooling air circulation.
• Printed circuit board components are sensitive to electrostatic
fields. Avoid contact with the printed circuit board directly. Hold the
PositionServo 940 by it’s case only.
• Protect the drive from dirt, filings, airborne particles, moisture,
and accidental contact. Provide sufficient room for access to the
terminal block.
• Mount the drive away from any and all heat sources. Operate
within the specified ambient operating temperature range.
Additional cooling with an external fan may be recommended in
certain applications.
• Avoid excessive vibration to prevent intermittent connections
• DO NOT connect incoming (mains) power to the output motor
terminals (U, V, W)! Severe damage to the drive will result.
• Do not disconnect any of the motor leads from the PositionServo
940 drive unless (mains) power is removed. Opening any one
motor lead may cause failure.
• Control Terminals provide basic isolation (insulation per EN61800-
5-1). Protection against contact can only be ensured by additional
measures, e.g., supplemental insulation.
WARNING!
For compliance with EN61800-5-1, the following warning applies.
This product can cause a d.c. current in the protective earthing
conductor. Where a residual current-operated protective (RCD) or
monitoring (RCM) device is used for protection in case of direct or
indirect contact, only an RCD or RCM of Type B is allowed on the
supply side of this product.

S94P01B2
12
Installation
UL INSTALLATION INFORMATION
• Suitable for use on a circuit capable of delivering not more than
200,000 rms symmetrical amperes, at the maximum voltage rating
marked on the drive.
• Use Class 1 wiring with minimum of 75ºC copper wire only.
• Shall be installed in a pollution degree 2 macro-environment.
3.1 Wiring
DANGER!
Hazard of electrical shock! Circuit potentials are up to 480 VAC above
earth ground. Avoid direct contact with the printed circuit board or
with circuit elements to prevent the risk of serious injury or fatality.
Disconnect incoming power and wait 60 seconds before servicing the
drive. Capacitors retain charge after power is removed.
WARNING!
Leakage current may exceed 3.5mA AC. Minimum size of the protective
earth conductor shall comply with local safety regulations for high
leakage current equipment.
STOP!
Under no circumstances should power and control wiring be bundled
together. Induced voltage can cause unpredictable behavior in any
electronic device, including motor controls.
Refer to section 4.1.1 for power wiring specifications.
3.2 Shielding and Grounding
3.2.1 General Guidelines
Lenze recommends the use of single-point grounding (SPG) for panel-mounted controls.
Serial grounding (a “daisy chain”) is not recommended. The SPG for all enclosures
must be tied to earth ground at the same point. The system ground and equipment
grounds for all panel-mounted enclosures must be individually connected to the SPG
for that panel using 14 AWG (2.5 mm2) or larger wire.
In order to minimize EMI, the chassis must be grounded to the mounting. Use 14 AWG
(2.5 mm2) 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 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).

S94P01B2 13
Installation
EMC
Compliance with EN 61800-3/A11
This is a product of the restricted sales distribution class according to IEC 61800-3.
In a domestic environment this product may cause radio interference in which the
user may be required to take adequate measures
Noise emission
Drive Models ending in the suffix “2F” are in
compliance with class A limits according to
EN 55011 if installed in a control cabinet and
the motor cable length does not exceed 10m.
Models ending in “N” will require an appropriate
line filter.
Installation according to EMC
Requirements
E
D
B C
A
F
S930
AScreen clamps
BControl cable
CLow-capacitance motor cable
(core/core < 75 pF/m, core/screen < 150 pF/m)
DEarth grounded conductive mounting plate
EEncoder Feedback Cable
FFootprint or Sidemount Filter (optional)
3.2.2 EMI Protection
Electromagnetic interference (EMI) is an important concern for users of digital
servo control systems. EMI will cause control systems to behave in unexpected and
sometimes dangerous ways. Therefore, reducing EMI is of primary concern not only
for servo control manufacturers such as Lenze, but the user as well. Proper shielding,
grounding and installation practices are critical to EMI reduction.
3.2.3 Enclosure
The panel in which the PositionServo 940 is mounted must be made of metal, and must
be grounded using the SPG method outlined in section 3.2.1.
Proper wire routing inside the panel is critical; power and logic leads must be routed in
different avenues inside the panel.
You must ensure that the panel contains sufficient clearance around the drive. Refer to
Section 2.6 suggested cooling air clearance.
3.3 Line Filtering
In addition to EMI/RFI safeguards inherent in the PositionServo 940 design, external
filtering may be required. High frequency energy can be coupled between the circuits via
radiation or conduction. The AC power wiring is one of the most important paths for both
types of coupling mechanisms. In order to comply with IEC61800-3, an appropriate filter
must be installed within 20cm of the drive power inputs.
Line filters should be placed inside the shielded panel. Connect the filter to the
incoming power lines immediately after the safety mains and before any critical control
components. Wire the AC line filter as close as possible to the PositionServo 940 drive.

S94P01B2
14
Installation
NOTE
The ground connection from the filter must be wired to solid earth
ground, not machine ground.
If the end-user is using a CE-approved motor, the AC filter combined with the
recommended motor and encoder cables, is all that is necessary to meet the EMC
directives listed herein. The end user must use the compatible filter to comply with CE
specifications. The OEM may choose to provide alternative filtering that encompasses
the PositionServo 940 drive and other electronics within the same panel. The OEM has
this liberty because CE requirements are for the total system.
3.4 Heat Sinking
The PositionServo 940 drive contains sufficient heat sinking within the specified ambient
operating temperature in their basic configuration. There is no need for additional heat
sinking. However, you must ensure that there is sufficient clearance for proper air
circulation. As a minimum, you must allow an air gap of 25 mm above and below the
drive.
3.5 Line (Mains) Fusing
External line fuses must be installed on all PositionServo drives. Connect the external
line fuse in series with the AC line voltage input. Use fast-acting fuses rated for 250
VAC or 600 VAC (depending on model), and approximately 200% of the maximum
RMS phase current.
3.6 Fuse Recommendations
Type(1)
AC Line
Input Fuse
(1ø/3ø)
Miniature
Circuit Breaker (1)
(1ø/3ø)
AC Line
Input Fuse or
Breaker (2) (3)
(N. America)
DC Bus Input
Fuse(4)
Amp Ratings
E94P020S1N M20/M10 C20/C10 20/10 10
E94P040S1N M32/M20 C32/C20 30/20 20
E94P020S2F M20 C20 20 15
E94P040S2F M20 C20 20 20
E94P080S2F M32 C32 32 40
E94P100S2F M40 C40 40 45
E94P020Y2N M20/M16 C20/C16 20/15 15
E94P040Y2N M20/M16 C20/C16 20/15 20
E94P080Y2N M32/M20 C32/C20 30/20 40
E94P100Y2N M40/M25 C40/C25 40/25 45
E94P120Y2N M50/M32 C50/C32 50/30 55
E94P020T4N M10 C10 10 10
E94P040T4N M10 C10 10 20
E94P050T4N M16 C16 15 25
E94P060T4N M20 C20 20 30
(1) Installations with high fault current due to large supply mains may require a type D circuit breaker.
(2) UL Class CC or T fast-acting current-limiting type fuses, 200,000 AIC, preferred. Bussman KTK-R, JJN, JJS or equivalent.
(3) Thermal-magnetic type breakers preferred.
(4) DC-rated fuses, rated for the applied voltage. Examples Bussman KTM or JJN as appropriate.

S94P01B2 15
Interface
4 Interface
The standard PositionServo 940 drive contains seven connectors: four quick-connect
terminal blocks, one SCSI connector and two subminiature type “D” connectors. These
connectors provide communications from a PLC or host controller, power to the drive,
and feedback from the motor. Prefabricated cable assemblies may be purchased from
Lenze to facilitate wiring the drive, motor and host computer. Contact your Lenze Sales
Representative for assistance.
As this manual makes reference to specific pins on specific connectors, we will use the
convention PX.Y where X is the connector number and Y is the pin number.
4.1 External Connectors
4.1.1 P1 & P7 - Input Power and Output Power Connections
P1 is a 3 or 4-pin quick-connect terminal block used for input (mains) power. P7 is a
6-pin quick-connect terminal block used for output power to the motor. P7 also has a
thermistor (PTC) input for motor over-temperature protection. The tables below identify
connector pin assignments.
DANGER!
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 3.2. The other end should be properly
terminated at the motor shield. Feedback cable shields should be terminated in a like
manner. Lenze recommends Lenze cables for both the motor power and feedback.
These are available with appropriate connectors and in various lengths. Contact your
Lenze representative for assistance.
Wire Size
Current (Arms) Terminal Torque (lb-in) Wire Size
I<8 4.5 16 AWG (1.5mm2) or 14 AWG (2.5mm2)
8<I<12 4.5 14 AWG (2.5mm2) or 12 AWG (4.0mm2)
12<I<15 4.5 12 AWG (4.0mm2)
15<I<20 5.0 - 7.0 10 AWG (6.0mm2)
20<I<24 11.0 - 15.0 10 AWG (6.0mm2)
P1 PIN ASSIGNMENTS (INPUT POWER)
Standard Models Doubler Models
Pin Name Function Name Function
1 PE Protective Earth (Ground) PE Protective Earth (Ground)
2 L1 AC Power in N AC Power Neutral (120V Doubler only)
3 L2 AC Power in L1 AC Power in
4 L3 AC Power in (3~ models only) L2/N AC Power in (non-doubler operation)

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Interface
P7 PIN ASSIGNMENTS (OUTPUT POWER)
Pin Terminal Function
1 T1 Thermistor (PTC) Input
2 T2 Thermistor (PTC) Input
3 U Motor Power Out
4 V Motor Power Out
5 W Motor Power Out
6 PE Protective Earth (Chassis Ground)
4.1.2 P2 - Serial Communications Port
P2 is a 9-pin D-sub connector that is used to communicate with a host computer via
standard RS-232 interface using a proprietary Point-to-Point Protocol (PPP). This port
is present on all Model 94 and 940 RS-232-based drives. All levels must be RS-232C
compliant.
P2 PIN ASSIGNMENTS (COMMUNICATIONS)
Pin Name Function RS-232 Connector
1 Reserved P2
RS-232
1
59
6
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 pins!
NOTE
If you purchase serial cables from a third party, you must use a pass-
through cable, not Null-Modem (not crossover)
4.1.3 P3 - Controller Interface
P3 is a 50-pin SCSI connector for interfacing to the front-end of the controllers. It is
strongly recommended that you use OEM cables to aid in satisfying CE requirements.
Contact your Lenze representative for assistance.
P3 PIN ASSIGNMENTS (CONTROLLER INTERFACE)
Pin Name Function
1 MA+ Master Encoder A+ / Step+ input (2)
2 MA- Master Encoder A- / Step- input (2)
3 MB+ Master Encoder B+ / Direction+ input (2)
4 MB- Master Encoder B- / Direction- input (2)
5 GND Drive Logic Common
6 5+ +5V output (max 100mA)
7 BA+ Buffered Encoder Output: Channel A+ (1)
8 BA- Buffered Encoder Output: Channel A- (1)
9 BB+ Buffered Encoder Output: Channel B+ (1)

S94P01B2 17
Interface
Pin Name Function
10 BB- Buffered Encoder Output: Channel B- (1)
11 BZ+ Buffered Encoder Output: Channel Z+ (1)
12 BZ- Buffered Encoder Output: Channel Z- (1)
13-19 Empty
20 AIN2+ Positive (+) of Analog signal input
21 AIN2- Negative (-) of Analog signal input
22 ACOM Analog common
23 AO Analog output
24 AIN1+ Positive (+) of Analog signal input
25 AIN1 - Negative (-) of Analog signal input
26 IN_A_COM Digital input group ACOM terminal (3)
27 IN_A1 Digital input A1
28 IN_A2 Digital input A2
29 IN_A3 Digital input A3 (3)
30 IN_A4 Digital input A4
31 IN_B_COM Digital input group BCOM terminal
32 IN_B1 Digital input B1
33 IN_B2 Digital input B2
34 IN_B3 Digital input B3
35 IN_B4 Digital input B4
36 IN_C_COM Digital input group CCOM terminal
37 IN_C1 Digital input C1
38 IN_C2 Digital input C2
39 IN_C3 Digital input C3
40 IN_C4 Digital input C4
41 RDY+ Ready output Collector
42 RDY- Ready output Emitter
43 OUT1-C Programmable output #1 Collector
44 OUT1-E Programmable output #1 Emitter
45 OUT2-C Programmable output #2 Collector
46 OUT2-E Programmable output #2 Emitter
47 OUT3-C Programmable output #3 Collector
48 OUT3-E Programmable output #3 Emitter
49 OUT4-C Programmable output #4 Collector
50 OUT4-E Programmable output #4 Emitter
(1) See Note 1, Section 4.1.7 - Connector and Wiring Notes
(2) See Note 2, Section 4.1.7 - Connector and Wiring Notes
3) See Note 3, Section 4.1.7 - Connector and Wiring Notes
4.1.4 P4 - Motor Feedback / Second Loop Encoder Input
P4 is a 15-pin DB connector that contains connections for Hall Effect sensors and
incremental encoder feedback. Refer to the P4 pin assignments table for the connector
pin assignments. Encoder inputs on P4 have 26LS32 or compatible differential receivers
for increased noise immunity. Inputs have all necessary filtering and line balancing
components so no external noise suppression networks are needed.
All conductors must be enclosed in one shield and jacket around them. Lenze
recommends that each and every pair (for example, EA+ and EA-) be twisted. In order
to satisfy CE requirements, use of an OEM cable is recommended. Contact your Lenze
representative for assistance.

S94P01B2
18
Interface
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.
NOTE
• The PositionServo 940 encoder inputs are designed to accept
differentially driven hall signals. Single-ended or open-collector
type hall signals are also acceptable by connecting “HA+”, “HB+”,
“HC+” and leaving “HA-,HB-,HC-” inputs unconnected. You do not
need to supply pull-up resistors for open-collector hall sensors.
The necessary pull-up circuits are already provided.
• Encoder connections (A, B, and Z) must be full differential.
PositionServo doesn’t support single-ended or open-collector type
outputs from the encoder.
• An encoder resolution of 2000 PPR (pre-quadrature) or higher is
recommended.
Using P4 as second encoder input for dual-loop operation.
P4 can be used as a second loop encoder input in situations where the motor is
equipped with a resolver as the primary feedback. If such a motor is used, the drive
must have a resolver feedback option module installed. A second encoder can then be
connected to the A and B lines of the P4 connector for dual loop operation. Refer to
“Dual-loop Feedback Operation” for details (Section 6.4).
P4 PIN ASSIGNMENTS (ENCODER)
Pin Name Function
1 EA+ Encoder Channel A+ Input (1)
2 EA- Encoder Channel A- Input (1)
3 EB+ Encoder Channel B+ Input (1)
4 EB- Encoder Channel B- Input (1)
5 EZ+ Encoder Channel Z+ Input (1)
6 EZ- Encoder Channel Z- Input (1)
7 GND Drive Logic Common/Encoder Ground
8 SHLD Shield
9 PWR Encoder supply (+5VDC)
10 HA- Hall Sensor A- Input
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
(1) See Note 1, Section 4.1.7 - Connector and Wiring Notes