Lenze 9200 Series User manual

RGB ELEKTRONIKA AGACIAK CIACIEK
SPÓŁKA JAWNA
Jana Dlugosza 2-6 Street
51-162 Wrocław
Poland
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[phone]
www.rgbautomatyka.pl
www.rgbelektronika.pl
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www.rgbautomatyka.pl
www.rgbelektronika.pl
OTHER SYMBOLS:
33.9224 E.
339224E, 339224E., 339224 E, 339224 E., 33 9224E, 33 9224E., 33 9224 E, 33 9224 E., 33.9224E, 33.9224E.,
33.9224 E, 33.9224 E.
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EDB9200_E/GB
00375316 
Antriebstechnik
Operating Instructions
S
ervo controller
9
200 series

These Operating Instructions are valid for the controllers with the nameplate data:
9212 E.5x
9215 E.5x
9217 E.5x
9222 E.5x.5x
9223 E.5x.5x
9224 E.5x.5x
9225 E.5x.5x
9226 E.5x.5x
9227 E.5x.5x
9228 E.5x.5x
Controller type
Enclosure IP20
Hardware version + index
Software version + index
Corresponds to the German edition of 05/18/1995
Edition of: 05/18/1995
Date of print: 05/29/1995

1

How to use these Operating
Instructions...
These Operating Instructions are divided into three parts:
•Planning and installation
This part comprises the technical data of the supply modules,
the axis modules and of accessories available for the 9200
series (e. g. motors), instructions for installation and wiring and
descriptions of the drive connections.
•Parameter setting
Describes the basics of parameter setting and informs about
commissioning, important functions and the operation via serial
interface. At the end of this part you will find a comprehensive
code table and a signal flow chart.
•Service
Explains error messages and gives hints for trouble-shooting.
To locate information on specific topics, simply refer to the table of
contents at the beginning and to the index at the end of the
operating instructions.
A series of different symbols provide quick reference and highlight
important items.
Note
This symbol refers to items of information intended to facilitate
operation.
Caution
Notes which should be observed to avoid possible damage to or
destruction of equipment.
Warning
Notes which should be observed to avoid health risks to the
operating personnel.
Fehler! Es
ist nicht
möglich,
durch die
Bbit

2
Safety information
for electrical equipment used in industrial power installations.
The electrical devices and machines described are equipment to be
used in industrial power installations. This equipment incorporates
hazardous parts that are live, moving or rotating during operation.
Severe personal injury or damage to equipment may occur if e. g.
any required enclosures or covers are inappropriately removed or
the equipment is insufficiently serviced.
The personnel responsible for the safety of the equipment must
therefore ensure that:
•only qualified personnel are permitted to install, operate and
maintain the devices
•these Operating Instructions and any other documentation
about the equipment are consequently observed and always
available to the personnel working with the equipment.
•non-qualified personnel is prohibited from working with the
equipment or in its vicinity.
•the system is installed in accordance with local regulations.
A qualified person must by training be familiar with all relevant
standards and safety regulations and therefore be authorized to
perform the required work (For further details cf. IEC 364).
These safety instructions do not claim to be exhaustive. Should any
questions or problems occur, please contact your nearest Lenze
representative.
The information given in these Operating Instructions refer to the
specified hardware and software versions of the equipment.
The specifications, processes and ciruitry described in these
Operating Instructions are for guidance only and must be adapted
to your specific application.
Lenze cannot be held responsible for the applicability of the
processes and circuitry indicated.
The specifications in these Operating Instructions describe, not
guarantee the features of the equipment.
Hardware, software and documentation of the equipment have
been carefully checked by Lenze. Faultlessness cannot be
guaranteed.
Subject to technical alterations.

3

Content
Planning and Installation
1. Features 5
2. Technical data 6
2.1. General data 6
2.2. Unit-specific data 6
2.2.1. Rated data of supply modules 6
2.2.2. Rated data of axis modules 7
2.3. Dimensions 8
2.4. Extension of delivery 8
2.5. Application as directed 8
2.6. Manufacturer's certification 9
3. Installation 10
3.1. Mechanical installation 10
3.2. Electrical installation 11
3.2.1. Combination of several axis modules with one supply module 12
3.2.2. Screening and earthing 14
3.2.3. Radio interference suppression 16
4. Drive connections 17
4.1. Power connections 17
4.1.1. Mains and motor connection 17
4.1.2. External brake resistor 18
4.2. Control connections of supply module 20
4.2.1. Overheat of internal brake resistor (9210 X1) 20
4.2.2. Mains and DC-bus monitoring (9210 X3) 20
4.2.3. State bus 21
4.3. Control connections axis module 22
4.3.1. Control terminals 22
4.3.2. Analog input and outputs 22
4.3.3. Digital inputs and outputs 23
5. Application examples 26
5.1. Variant with integrated positioning module 2211PP 26
5.2. Wiring with positioning control SX-1 28
5.2.1. Diagram 1: Mains supply 28
5.2.2. Diagram 2: Control circuit 230V 29
5.2.3. Diagram 3: Control circuit 24V 30
5.2.4. Diagram 4: Control connections 9200 - SX1 31
5.2.5. Diagram 5: Control connections SX1 32
6. Accessories 33
6.1. External brake resistors 33
6.2. Mains chokes 33
6.3. RFI filter 34
6.4. External fuses 34
6.5. System cables 34
6.5.1. System cables for control terminal block X5 34
6.5.2. System cables for master frequency selection X2 and incremental encoder output
X4 35
6.5.3. System cables for resolver X3 36
6.5.4. System cables for power supply of servo motors 37
6.5.5. System calbes for supply fo fan and brake 38
6.6. Motors 39

4
1. LCD display 40
1.1. Key functions 40
1.2. Plain-text display 40
2. Basics of parameter setting 41
2.1. Change parameters 41
2.2. Save parameters 42
2.3. Load parameter 42
2.4. Examples 43
3. Commissioning 45
3.1. Basic parameter setting 45
3.2. Input of motor nameplate data 47
3.3. Setting of operating parameters 48
4. Additional functions 50
4.1. Mains failure detection with DC-bus control 50
4.1.1. Requirements 50
4.1.1. Wiring 52
4.1.2. Setting 53
4.2. Homing mode 56
4.3. Further additional functions 57
5. Serial interfaces 58
5.1. LECOM1 interface X1 58
5.2. LECOM status messages 59
5.3. Table of attributes 60
6. Code table 63
7. Signal flow chart axis modules 72
1. Monitoring messages 74
1.1. Monitoring without activating pulse inhibit 74
1.2. Monitoring with activating pulse inhibit 74
1.3. Monitoring with TRIP setting 74
2. LED displays 78
2.1. LED supply module 78
2.2. LED axis module 78
3. Checking the power stage 79
3.1. Checking the mains rectifier 79
3.2. Checking the output stage 79
Index 83

5

Planning and installation
1. Features
The 9200 controller series comprises 3 supply modules (types
9212, 9215 and 9217) and 7 servo modules (types 9222-9228 with
motor peak currents ranging from 8 to 82 A) for asynchronous
servo motors.
•Digital control by 16-bit microcontroller and 3 ASICs
•Field-orientated vector controlled current
•Four-quadrant operation, any speed and torque direction
•Inverter with IGBTs
•Selectable chopper frequency either low noise 8kHz or silent
16kHz
•Supply and axis modules can be combined for single or multi-
axis operation
•Efficient energy exchange by means of DC-bus for multi-axis
operation
•Controlled operation even during mains interruption.
•Supply modules with integrated brake chopper and brake
resistors
•Short-circuit protected inverter outputs
•When using the specified mains chokes, the units comply with
the overvoltage class 2 according to VDE 0160
•I x t monitoring as overload protection for the inverter
•Parameter setting and diagnosis via keypad and 2-line LCD
display in plain text German, English, and French language
•Control parameters can be modified ON-LINE
•Isolated digital inputs and outputs for 24V-PLC level
•Electronic incremental encoder simulation for use by other
drives
•Master frequency input for positioning, master/slave operation
or angular synchronization
•Drift free standstill in the case of master frequency input or
quick stop QSP
•Serial interface LECOM A/B (RS232 and RS 485) for
parameter setting, control and diagnosis
•Enclosure IP20
•Variants with additional modules are available
•Approvals: UL 508, File no. 132659
VDE 0160, VDE reg. no. 1799

6
2. Technical data
2.1. General data
Enclosure Steel sheet housing, IP20 to DIN 40050
Noise immunity: Severity 4 to IEC 801-4
Influence of installation height on
rated current: 1000 m: 100% rated current
2000 m: 95% rated current
3000 m: 90% rated current
4000 m: 85% rated current
Ambient temperature 0 °C...+45 °C during operation
-25 °C...+55 °C during storage
-25 °C...+70 °C during transport
Permissible humidity relative humidity 80%, no condensation
Permissible pollution Pollution strength 2 to VDE 0110, part 2.
Do not expose units to corrosive or explosive gases.
2.2. Unit-specific data
2.2.1. Rated data of supply modules
Supply module type 9212_E 9215_E 9217_E
Order no. 33.9212_E 33.9215_E 33.9217_E
Mains voltage [V] 3 x 480; 50 - 60 Hz
permissible range 3 x 330...528 ±0%;
DC-bus voltage
(at rated current) [V] 1.35 x Vmains
Mains current [Aeff]62040
Permanent power1)
(at Vmains = 3 x 480 V) [kW] 4.9 16.5 33
Peak power
(t=5 s) [kW] 12 37 60
Permanent brake power (with int.
brake resistor) [W] 250
Permanent brake power (with
appropriate ext. brake resistor) [kW] 4.9 16.5 33
Peak brake power
with int. or ext. brake resistor [kW] 19.4 51.1 66.1
min. permissible resistance for int.
or ext. brake resistor [Ω] 29 11 8.5
Power loss (without brake resistor) [W] 110 110 110
Weight [kg] 9.0 10.5 11.0
1) With low mains voltages, the permissible permanent power is reduced to Pzul = Pn ⋅Vmains / 480 V

7

2.2.2. Rated data of axis modules
Axis module type 9222_E 9223_E 9224_E 9225_E
Order no. 33.9222_E 33.9223_E 33.9224_E 33.9225_E
Output current
(fch = 8 kHz) [Aeff] 4.5 5.5 13.5 18
Output current
(fch = 16 kHz) [Aeff] 2.3 2.9 6.9 9.5
Peak current
(for t = 5 s at fch = 8 kHz;
for t = 2.5 s at fch = 16 kHz)
[Aeff] 8 10 24 33
Permanent power
(VA = 3 x 480 V and fch = 8 kHz) [kVA] 3.7 4.5 11.2 14.9
Permanent power
(VA = 3 x 480 V and fch = 16 kHz) [kVA] 1.9 2.4 5.7 7.9
Peak power
(VA = 3 x 480 V) [kVA] 6.6 8.3 19.9 27.4
Output voltage VA[V] 3 x 0...Vmains
Field frequency [Hz] 0... ±300
Speed [min-1 ] 0... ±8000
Power loss at permanent power [W] 200 250 340 510
Power loss at controller inhibit [W]454545125
Weight [kg] 9.2 9.5 9.5 20.5
Type 9226_E 9227_E 9228_E
Order no. 33.9226_E 33.9227_E 33.9228_E
Output current
(fch = 8 kHz) [Aeff]25 32 46
Output current
(fch = 16 kHz) [Aeff] 13 16.5 23.5
Peak current
(for t = 5s at fch = 8kHz;
for t = 2.5 s at fch = 16kHz)
[Aeff]45 57 82
Permanent power
(VA = 3 x 480 V and fch = 8 kHz) [kVA] 20.2 26.6 38.2
Permanent power
(VA = 3 x 480 V and fch = 16 kHz) [kVA] 10.8 13.7 19.5
Peak power
(VA = 3 x 480 V) [kVA] 37.4 47.3 68.1
Output voltage VA[V] 3 x 0...Vmains
Field frequency [Hz] 0... ±300
Speed [min-1 ] 0... ±8000
Power loss at permanent power [W] 640 800 1000
Power loss at controller inhibit [W] 125 125 125
Weight [kg] 21 22 22

8
2.3. Dimensions
Type a
[mm] b [mm] c [mm] d [mm] e [mm] g [mm]
9212 - 9217
9222 - 9224 125 440 95 425 300 5
9225 - 9228 290 440 250 425 300 5
2.4. Extension of delivery
•Axis module or supply module
•Accessory kit (busbars, State-bus line, control terminals)
•Operating Instructions
2.5. Application as directed
The units of the 9200 series are electrical units which are designed
for the application in control cabinets in industrial power
installations. They are designed for variable speed operations with
three-phase AC motors.

9

2.6. Manufacturer's certification
We hereby certify that the below listed electronic controllers are
control components for variable speed motors intended for the
assembly into machines or together with other components to form
a machine. According to the "Council directive ... relating to
machinery" 89/392/EWG, our controllers are no machines.
The Operating Instructions supplied together with the controllers
give advice and recommendations for the installation and use of the
electronic equipment.
As long as the conformity with the protection and safety
requirements of the "Council directive ... relating to machinery"
89/392/EWG and its amendment 91/368/EWG is not proved,
operation of the machine is prohibited.
The measures required for typically configurated controllers to
comply with the EMC limit values are indicated in the Operating
Instructions. The electromagnetic compatibility of the machine
depends on the method and accuracy of the installation. The user
is responsible for the compliance of the machine with the "Council
directive ... relating to electromagnetic compatibility" 89/336/EWG
and its amendment 92/31/EWG.
Considered standards and regulations:
•Electronic equipment for use in electrical power installations and
their assembly into electrical power installations: DIN VDE 0160,
5.88 (pr EN 50178)
•Standards for the erection of power installations:
DIN VDE 0100
•IP - enclosures: EN 60529, 10.91
•Base material for printed circuits:
DIN IEC 249 part 1, 10.90; DIN IEC 249 part 2-15, 12.89
•Printed circuits, printed boards:
DIN IEC 326 part 1, 10.90; EN 60097, 9.93
•Creepage distances and clearances:
DIN VDE 0110 part 1-2, 1.89; DIN VDE 0110 part 20, 8.90
•Electrostatic discharge (ESD):
prEN 50082-2, 8.92, IEC 801-2, 9.87 (VDE 0843, part 2)
•Electrical fast transient interference (Burst):
prEN 50082-2, 8.92, IEC 801-4, 9.87 (VDE 0843, part 4)
•Surge immunity requirements: IEC 801-5,10.93
•Radio interference suppression of electrical equipment and
plants:
EN 50081-2, 3.94; EN 55011 (VDE 0875, part 11,7.92)
•Radio interference suppression of radio frequency equipment
for industrial purposes: VDE 0871, 6.78

10 
3. Installation
3.1. Mechanical installation
•The units are designed as housing units with enclosure IP20.
•Install the units vertically with the power terminals at the top.
•Ensure a free space of 100 mm at both the bottom and the top.
Caution!
When working with the maximum brake power, the temperature of the output air of
the supply modules can reach up to 120°C.
•The axis modules should be installed at the same height at the righthand side of
the supply module:
−If the axis modules have different power outputs, the more
powerful axis module must be placed directly next to the
supply module.
•The interface connectors X1 to X4 and other terminals must be
covered with the supplied dust protectors or unused connectors
when not used.

11

3.2. Electrical installation
•The breakaway torque for the power terminals is 2.3 Nm
(20 lb in). Marking of terminals:
at 921X: +UG, -UG, RBr, L1, L2, L3
at 922X: +UG, -UG, U, V, W
Supply modules
•Without additional protective measures (e.g. zeroing) the units
may not be connected to a mains with e.l.c.b. (VDE
0160/05.88). In the event of an earth fault, a DC component in
the fault current can prevent the release of the e.l.c.b.
•Operate the supply module with assigned mains choke.
•Power input
Recommended cable diameter and number of cores
Supply module 9212 9215 9217
Number of cores 4
(L1,L2,L3,PE) 4 (L1,L2,L3,PE) 4 (L1,L2,L3,PE)
Cable diameter [mm²]
or 1,5 4 10
AWG 14/15 10/11 6/7
Protect input cables according to their diameter with adapted
cable protection fuses.
•Protection of the input rectifier:
−Total protection with external very quick acting fuses in the
mains input (see chapter "Accessories")
−If total protection is not required:
The normal cable protection fuses or miniature circuit
breakers which are adapted to the cable diameter offer
sufficient protection.
•The peak power of the supply module must be equal to or
higher than the total peak power of the connected axis modules
and the rated power of the suply module must also be equal to
or higher than the total permanent power of the axis module
(see chap. 3.2.1).
Note
The supply modules 921x hardware version E.4x onwards described in these
Operating Instructions may only be used in combination with the axis modules of
the hardware version E.4x and higher.
Axis modules
•Connect only one motor to each axis module.
•The cable diameter of the motor cables must correspond to the
rated current of the motor.
Protection by means of:
−cable protection fuses or
−adapted motor protection relay
•Ensure motor protection:
−use motor protection relay and monitor the thermostat of the
motor.
•The connected motor may not be operated when the controller
is enabled, except for safety shutdown.

12 
3.2.1. Combination of several axis modules with one supply module
Please note the following conditions when combining several axis
modules with one supply module:
•The State-bus (X6) can supply max. 10 axis modules.
•The sum of the total capacity of the DC-bus may not exceed a
certain value (see chart):
The permissible total capacity depends on the interval between
two closing operations and the mains voltage. The total capacity
is the sum of the capicities of the supply module and the axis
modules.
−For intervals between two closing operations longer than
15 min, the max. permissible capacities are applied.
DC-bus capacities of the 9200 series
Type 9212 9215 9217 9222
9223 9224 9225 9226 9227 9228
CZK [
µ
F] 235 705 1175 235 340 1100 2200
Permissible total capacity depending on the interval between two closing
operations and the mains voltage
9215; 9217
V mains=400V-480V
9212
V mains=400V
9212
V mains=480V
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
0 1 2 3 4 5 6 7 8 9101112131415
Switch-on distance / min
C (total) / µF

13

•When selecting the power of the supply module, proceed as
follows to find out about the required input power.
1. Determine the power profile of all axis modules connected to
the DC-bus by means of the process profile and the load
torques during a system cycle.
2. The power losses are stated in the technical data, for units
the losses are stated during rated power and for motors the
power loss during rated operation. These losses are
assumed to be constant during the whole cycle.
3. Find out the resultant powr by adding the power losses and
the power profiles:
calculate a positive motor power
and a negative generator power.
4. Determine the effective power during the system cycle:
Do not calculate a negative resultant power (generator
power). These ranges can taken into consideration when
calculating the effective brake power.
5. Select the supply module according to the effective power
during a system cycle:
Please note that the supply module must have enough
capacity to supply the effective peak power and that, in the
event of mains voltage reductions, the permissible power of
the supply module will be reduced according to the reduction
of the mains voltage.
6. If the calculated effective permanent power exceeds the
permissible value of the supply module 9217:
Subdivide the DC-bus sets and install further supply
modules.

14 
3.2.2. Screening and earthing
In order to avoid radio interference, care must be taken with the design and
connection of digital drives to avoid EMC disturbances during operation.
Digital drives are not more vulnerable to interference than analog drives, but the
effect is generally different. Interference of analog devices becomes obvious as
irregularities in speed. Interference of digital drives may cause
program errors; therefore it is important that the drives are inhibited
immediately when interference occurs. This is done by setting the
TRIP function (CCr).
In order to avoid these problems, care must be taken with ground
(GND), protective earth (PE) connections as well as screening.
•Screen control cables and motor cables.
•Ensure effective screening:
−a non-earthed conductior should be used to maintain screen
integrity where cahbles are interrupted (terminal strips,
relays, fuses).
Caution!
To increase the EMC (electromagnetic compatibility), the reference GND is
connected to the protective earth (PE) inside the drive.
To ensure an optimum interference suppression, the screening and the GND-PE-
connection is made differently for single drive and multi drive
networks.
Single drive
•Connect the screen of the control cables to PE of the drive at
one end to avoid earth loops.
•GND and PE are connected by a jumper inside the drive.
•In case of firmly installed computer connections, a mains
isolation (e.g. Lenze Converter 2101) is mandantory between
computer and axis module.
•The screens of the motor cables
−should be as large as possible.
−connected to the two sides.
Fehler! Es
ist nicht
möglich,
durch die
Bbit

15

Multi drive networking
•When laying the ground cables, care must be taken that there
are no ground loops. To ensure this, the GND-PE connection
must be removed in every drive. For the 9200 drives, turn the
four screws on the cover one haft turn CCW and pull out the
control board. Remove the jumper PE-BR on the board 9220
MP. CAUTION: Ensure that the mains has been disconnected
and the drive has been switched off at least 5 minutes before
removing any parts.
BR-PE
PE cable Control board 9220MP
SubD-plugs
X1 X2 X3 X4 X5 X6
Control terminals
•All ground cables must then be lead to external, insulated
central points, centralized again from there and connected to
PE in the central supply. The PE-GND reference is necessary
as the electronics insulation (SubD plug) does not allow
voltages >50V~ AC at PE.
•In case of firmly installed computer connections, a mains
isolation (e.g. Lenze Converter 2101) is mandatory between
computer and axis module.
•The individual cable screens must be connected to external
insulated centreal points, which are then connected to the PE
potential at one point.
•The screens of the motor cables
−should be as large as possible.
−should be connected to the two sides.

16 
3.2.3. Radio interference suppression
According to §13 and §14 of the legislation of the European
Community relating to the electromagnetic compatibility of devices
(EMVG v. 09.11.92) the national standards and regulations are only
interim standards vilid until December 31, 1995. In addition, the
harmonized European standards can be fulfilled following the
recommendations below. Measures against radio interference
suppression depend on the site of the device to be installed:
Previous national standards
The application without radio interference suppression in electrical
systems within connected working areas or industrial premises can
only be allowed if, outside the industrial premises, the limit values
according to VDE 0871/6.78, class B are not exceeded (General
allowance according to the standard on the operation of high-
frequency devices of December 14, 1984, official no. 1045/1046).
For operation within residential areas or when exceeding the limit
value class B outside of industrial premises, radio interference
suppression according to VDE 0871, limit value class B is required.
Future hormonized standards
The standard prEN 50081-2 is valid for the radio interference
suppression.
It refers to standard EN 55011 (VDE 0875, part 11, limit value class
A and B).
•Within industrial premises, which are not connected to the public
low-voltage supply, the limit values to EN 55011, limit value
class A apply.
•Within residential areas or industrial premises, which are
connected to the plublic low-voltage supply, the limit values to
EN 55011, limit value class B apply.
Radio interference suppression to EN 55011, limit value class
A or B, can be achieved by:
•Using a suitable mains filter and screening of motor cables,
brake resistor cables and the power cable between mains filter
and inverter (for recommended mains filters see "Accessories").