Lenze L-force 9400 Series User manual
Contents i
3
EDS94SPP101 EN 7.1
1Preface 9..................................................................
1.1 The 9400 Servo Drives product range 10....................................
1.1.1 The system 10..................................................
1.1.2 Features 10.....................................................
1.1.3 System overview 10..............................................
1.2 About this Hardware Manual 12...........................................
1.2.1 Information provided by the Hardware Manual 12....................
1.2.2 Products to which the Hardware Manual applies 13...................
1.3 Legal regulations 17.....................................................
2Guide 19....................................................................
2.1 Terms and abbreviations used 20..........................................
2.2 Total index 22..........................................................
3 Safety instructions 27.........................................................
3.1 General safety and application notes for Lenze controllers 28..................
3.2 General safety and application instructions for Lenze motors 32................
3.3 Residual hazards 35.....................................................
3.4 Notes used 36..........................................................
4 Single-axis controllers 37......................................................
4.1 Device features 38......................................................
4.2 General data and operating conditions 39.................................
4.3 Rated data (devices for 400/500V mains) 47.................................
4.3.1 Overview 47....................................................
4.3.2 Operation at rated mains voltage 230 V 50..........................
4.3.3 Operation at rated mains voltage 400 V 53..........................
4.3.4 Operation at rated mains voltage 500 V 60..........................
4.3.5 Fuses and cable cross-sections 66..................................
4.3.6 Overcurrent operation 68.........................................
4.3.7 Current-time diagrams 75........................................
4.4 Device description 85....................................................
4.4.1 Devices in the range 2 ... 24 A (0.37 ... 11 kW) 86......................
4.4.2 Devices in the range 32 ... 104 A (15 ... 55 kW) 88.....................
4.4.3 Devices in the range 145 ... 695 A (75 ... 370 kW) 90...................
4.5 Mechanical installation 92................................................
4.5.1 Important notes 92..............................................
4.5.2 Devices in the range 2 ... 24 A (0.37 ... 11 kW) 92......................
4.5.3 Devices in the range 32 ... 104 A (15 ... 55 kW) 95.....................
4.5.4 Devices in the range 145 ... 366 A (75 ... 200 kW) 96...................
4.5.5 Devices in the range 460 ... 695 A (250 ... 400 kW) 97..................
Contentsi
4EDS94SPP101 EN 7.1
4.6 Wiring 98..............................................................
4.6.1 Important notes 98..............................................
4.6.2 Safety notes for the installation according to UL or UR 100.............
4.6.3 Earthing of internal EMC filters 103.................................
4.6.4 Devices in the range 2 ... 24 A (0.37 ... 11 kW) 107......................
4.6.5 Devices in the range 32 ... 104 A (15 ... 55 kW) 116.....................
4.6.6 Devices in the range 145 ... 695 A (75 ... 370 kW) 121...................
4.7 Control terminals 138.....................................................
5 Multi-axis controllers 155......................................................
5.1 Device features 156......................................................
5.2 General data and operating conditions 157.................................
5.3 Rated data 163..........................................................
5.3.1 Overview 163....................................................
5.3.2 Devices for 400/500V-mains 165....................................
5.3.3 Overcurrent operation 169.........................................
5.3.4 Current-time diagrams 173........................................
5.4 Mechanical installation 178................................................
5.4.1 Important notes 178..............................................
5.4.2 Devices in the range 2 ... 32 A (0.37 ... 15 kW) 182......................
5.5 Wiring 183..............................................................
5.5.1 Important notes 183..............................................
5.5.2 Safety notes for the installation according to UL or UR 185.............
5.5.3 Earthing of internal EMC filters 186.................................
5.5.4 Devices in the range 2 ... 32 A (0.37 ... 15 kW) 188......................
5.6 Installation of the standard device 196......................................
5.7 Control terminals 197.....................................................
6 Power supply module 213......................................................
6.1 Device features 214......................................................
6.2 General data and operating conditions 215.................................
6.3 Rated data (devices for 400/500V mains) 218.................................
6.3.1 Operation at rated mains voltage 230 V 219..........................
6.3.2 Operation at rated mains voltage 400 V 221..........................
6.3.3 Operation at a rated mains voltage of 500 V 223......................
6.3.4 Fuses and cable cross-sections 225..................................
6.3.5 Mains filters for power supply modules 227..........................
6.4 Device description 229....................................................
6.4.1 Devices in the range 10 ... 36 A (4 ... 18 kW) 230........................
6.4.2 Devices in the range 100 ... 245 A (48 ... 119 kW) 232...................
Contents i
5
EDS94SPP101 EN 7.1
6.5 Mechanical installation 234................................................
6.5.1 Important notes 234..............................................
6.5.2 Devices in the range 10 ... 36 A (4 ... 18 kW) 234........................
6.5.3 Devices in the range 100 ... 245 A (48 ... 119 kW) 238...................
6.6 Wiring 242..............................................................
6.6.1 Important notes 242..............................................
6.6.2 Safety notes for the installation according to UL or UR 243.............
6.6.3 Design of the cables 244...........................................
6.6.4 Earthing of internal EMC filters 245.................................
6.6.5 Devices in the range 10 ... 36 A (4 ... 18 kW) 247........................
6.6.6 Connecting busbars 248...........................................
6.6.7 Terminal assignment 249..........................................
6.6.8 Devices in the range 100 ... 245 A (48 ... 119 kW) 251...................
6.6.9 Connecting busbars 252...........................................
6.6.10 Terminal assignment 253..........................................
6.7 Control terminals 256.....................................................
6.8 Final works 260..........................................................
7 Regenerative power supply modules 261.........................................
7.1 Device features 262......................................................
7.2 General data and operating conditions 263.................................
7.3 Rated data (devices for 400/500V mains) 265.................................
7.3.1 Operation at rated mains voltage 230 V 266..........................
7.3.2 Operation at rated mains voltage 400 V 268..........................
7.3.3 Operation at a rated mains voltage of 500 V 270......................
7.3.4 Regenerative feedback with brake chopper 272.......................
7.3.5 Fuses and cable cross-sections 274..................................
7.3.6 Current-time diagrams 275........................................
7.3.7 Mains filters for regenerative power supply modules 279...............
7.4 Device description 282....................................................
7.5 Mechanical installation 285................................................
7.5.1 Important notes 285..............................................
7.5.2 Dimensions 286..................................................
7.5.3 Arrangement of the devices 289....................................
7.5.4 Mounting steps 290..............................................
Contentsi
6EDS94SPP101 EN 7.1
7.6 Wiring 291..............................................................
7.6.1 Important notes 291..............................................
7.6.2 Connection plan 293..............................................
7.6.3 Earthing of internal EMC filters 294.................................
7.6.4 Connecting busbars 296...........................................
7.6.5 Design of the cables 297...........................................
7.6.6 How to connect the shield 297......................................
7.6.7 Terminal assignment 298..........................................
7.6.8 Wiring of control connections 300...................................
7.6.9 Communication modules 305......................................
7.6.10 Memory modules 306.............................................
7.6.11 Safety modules 307...............................................
7.7 Final works 308..........................................................
7.7.1 Initial commissioning on 400 V mains voltage 308.....................
7.7.2 Initial commissioning on 230 V or 500 V mains voltage 308.............
7.7.3 Further settings 308..............................................
8 DC-bus operation 309.........................................................
8.1 Introduction 310.........................................................
8.1.1 Terminology and abbreviations used 310.............................
8.1.2 Comparison single-axis controllers / multi-axis controllers 311..........
8.1.3 Advantages of a drive system 312...................................
8.1.4 General information on the accessories 313..........................
8.2 Conditions for trouble-free DC-bus operation 314.............................
8.2.1 Voltages 314....................................................
8.2.2 Number of feeding points 314......................................
8.2.3 Other conditions 314..............................................
8.3 DC-bus variants 315......................................................
8.3.1 Supply from a supply module 315...................................
8.3.2 Supply from controllers 316........................................
8.4 Rated data 317..........................................................
8.4.1 General data 317.................................................
8.4.2 DC-supply power 319.............................................
8.4.3 DC-power requirements 323.......................................
8.4.4 DC fuses 325.....................................................
Contents i
7
EDS94SPP101 EN 7.1
8.5 Basic dimensioning 328...................................................
8.5.1 General information 328..........................................
8.5.2 Power distribution of controllers 329................................
8.5.3 Motor efficiency 330..............................................
8.5.4 Power loss of devices 330..........................................
8.5.5 Determining the power requirements 330............................
8.5.6 Determining the regenerative power requirements 330.................
8.5.7 Cable protection 331..............................................
8.5.8 Filters 331.......................................................
8.5.9 Cables 334......................................................
8.6 Braking operation in a drive system 335.....................................
8.6.1 Basic considerations 335..........................................
8.7 Application examples 336.................................................
8.7.1 Example 1 - supply module with multi-axis controllers 336.............
8.7.2 Example 2 - single-axis controller with multi axes 337..................
9 Accessories (overview) 339.....................................................
9.1 Overview 341............................................................
9.1.1 System overview 341..............................................
9.1.2 Assignment of accessories 343.....................................
9.2 Type-specific accessories 345..............................................
9.3 Communication modules 346..............................................
9.3.1 Possible device module combinations 348............................
9.3.2 Ethernet interface 349............................................
9.3.3 DeviceNet 371...................................................
9.3.4 PROFIBUS 376....................................................
9.3.5 PROFINET 382...................................................
9.3.6 CAN port 386....................................................
9.4 Function modules 390....................................................
9.4.1 Digital frequency 392.............................................
9.5 Memory modules 396.....................................................
9.6 Safety modules 403......................................................
9.6.1 SM0 406........................................................
9.6.2 SM100 407......................................................
9.6.3 SM301 411......................................................
9.7 Motor holding brake control modules 419....................................
9.7.1 Motor holding brake control module E94AZHX0051 420................
9.7.2 Motor holding brake control module E94AZHY0101 429................
9.7.3 Motor holding brake control module E94AZHN0025 439................
9.7.4 Motor holding brake control module E94AZHY0025 446................
9.7.5 Motor holding brake control module E94AZHN0026 452................
9.7.6 Motor holding brake control module E94AZHY0026 460................
Contentsi
8EDS94SPP101 EN 7.1
9.8 Accessories for diagnostics 467.............................................
9.8.1 USB diagnostic adapter 467........................................
9.8.2 Keypad 469......................................................
9.8.3 Hand-held terminal 476...........................................
9.9 Components for operation in the DC-bus connection 481.......................
9.9.1 DC-feeding point 481.............................................
9.9.2 GG1 busbar mounting set 488......................................
9.9.3 GG2 busbar mounting set 490......................................
9.9.4 GG3 busbar mounting set 492......................................
9.10 Filters 494..............................................................
9.10.1 Mains filters for single-axis controllers 495...........................
9.10.2 Mains filters for power supply modules 501..........................
9.10.3 Mains filters for regenerative power supply modules 511...............
9.10.4 RFI filters for single-axis controllers 518..............................
9.10.5 RFI filters for power supply modules 527.............................
9.10.6 Sinusoidal filters 4 ... 16.5 A 538.....................................
9.10.7 Sinusoidal filter 23.5 ... 90 A 542....................................
9.10.8 Sinusoidal filter 115 ... 150 A 547....................................
9.10.9 Sinusoidal filter 180 ... 480 A 551....................................
9.11 General accessories 556...................................................
9.11.1 Introduction 556.................................................
9.11.2 Shield mounting 557..............................................
9.11.3 Brake resistors 560...............................................
9.11.4 Power supply unit 574............................................
Preface 1
9
EDS94SPP101 EN 7.1
1Preface
1.1 The 9400 Servo Drives product range 10....................................
1.1.1 The system 10..................................................
1.1.2 Features 10.....................................................
1.1.3 System overview 10..............................................
1.2 About this Hardware Manual 12...........................................
1.2.1 Information provided by the Hardware Manual 12....................
1.2.2 Products to which the Hardware Manual applies 13...................
1.3 Legal regulations 17.....................................................
Preface
The 9400 Servo Drives product range
The system
1
10 EDS94SPP101 EN 7.1
1.1 The 9400 Servo Drives product range
1.1.1 The system
9400 Servo Drives range is the product family with the components required for an
intelligent servo drive system in automation. The product range comprises
ƒservo drive controllers
ƒI/O components
ƒsoftware
ƒaccessories
ƒmotors
ƒgearboxes
ƒDC-supply modules
1.1.2 Features
The Servo Drives 9400 feature:
ƒcompact design
ƒwide power range
ƒinnovative installation concept
ƒintelligent technology functions
ƒhigh control precision
ƒscalable safety technology
1.1.3 System overview
The following figure shows the most important components for the implementation of a
drive system with the Servo Drives 9400 product range.
On the way from the mains connection to the motor, you can see the basic principle of a
drive system on the left path. On the right path, the basic principle of a single-axis drive is
described.
In accordance with the requirements of your drive solution, your drive system can be
equipped or extended with specially adapted components.
Preface
The 9400 Servo Drives product range
System overview
1
11
EDS94SPP101 EN 7.1
0
1
2
3
4
567
8
9
:
;
<
=
>?
@./
=
SSP94SYS01
Mains voltage 3/PE AC 180 ... 550 V ±0 % or 3/PE AC 380 ... 550 V ±0 %
(depending on the device size/device power)
Mains fusing (not contained in the delivery programme)
Single Drives 9400 37
and corresponding installation backplanes
Mains filter for Single Drives 9400 495
RFI filter for Single Drives 9400 518
Multi Drives 9400 155
and corresponding installation backplanes
Power supply modules 9400
213, 261
(for DC bus installations with Multi Drives 9400)
Mains filter for power supply modules 9400 227
RFI filter for power supply modules 9400 527
Equipment for all axis modules (device-dependent options):
Communication modules and extension modules 346
Memory modules 396
Safety modules 403
Motor holding brake control modules 419
Brake resistors 560
Diagnostic adapters 467
L-force Engineer (software)
Servo motors (motor catalogue)
Geared servo motors (”)
Standard geared motors (”)
Motor cables/system cables
(manual ”System cables”)
Preface
About this Hardware Manual
Information provided by the Hardware Manual
1
12 EDS94SPP101 EN 7.1
1.2 About this Hardware Manual
1.2.1 Information provided by the Hardware Manual
Target group
ThisHardwareManualisintended forall personswhoinstall,commission,andadjust9400
servo controllers.
Together with the catalog it forms the basis of project planning for the manufacturers of
machines and plants.
Contents
This Hardware Manual is meant as an addition to the Mounting Instructions included in
the scope of supply:
ƒThe features and functions are described in detail.
ƒIt provides detailed information on additional ranges of application.
How to find information
Each chapter forms a complete unit and informs you about an individual subject:
ƒYou therefore only have to read the chapter containing the information you need.
ƒThe Table of Contents and Index help you to find all information about a certain
topic.
ƒDescriptions and data of other Lenze products (drive PLC, Lenze geared motors,
Lenze motors, ...) can be found in the corresponding catalogs, Operating Instructions
and Manuals. The required documentation can be ordered at your Lenze sales
partner or downloaded as PDF file from the Internet.
Availability
This Hardware Manual is designed as a loose-leaf collection and available as a PDF file on
the Internet. At the bottom of each page you can see the version and publication date.
Documentation and software updates for further Lenze products can be found
on the Internet in the ”Services & Downloads” area under Lenze website.
Preface
About this Hardware Manual
Products to which the Hardware Manual applies
1
13
EDS94SPP101 EN 7.1
1.2.2 Products to which the Hardware Manual applies
Power modules
c
E94 x x x E xxx x x xx xx xx
Type / product range
9400 Servo Drives
Version
A=1.
N = not relevant
Design
S = single-axis controller (Single Drive)
M = multi-axis controller (Multi Drive)
P = power supply module
R = regenerative power supply module
Variant
H=HighLine
N = not relevant
P=PLC
Mechanical version
E = installation
Rated current (rounded)
e.g.
007=7A
024 = 23.5 A
...
Voltage class
2 = 230 V ~ / 300 V =
4 = 400 V ~ / 540 V =
Safety module
A ... D
Memory module
11 ... 44
Extension module 1
xx
Extension module 2
xx
Preface
About this Hardware Manual
Products to which the Hardware Manual applies
1
14 EDS94SPP101 EN 7.1
Extension modules
c
E94 x Y x xx
Type / product range
9400 Servo Drives
Generation
A=1.
N = not relevant
Identification
Y=module
Module group
C = communication
I = I/O
F = feedback
M = memory
A=safety
Module identification
CA = CANopen
DN = DeviceNet
EN = Ethernet
EP = Ethernet Powerlink
ET = EtherCAT
PM = PROFIBUS MC
LF = digital frequency
1x = MM1x0memory module
2x = MM2x0memory module
3x = MM3x0memory module
4x = MM4x0memory module
x1 = MMx10 memory module with MC StateLevellicence
x2 = MMx20 memory module with MC HighLevellicence
x3 = MMx30 memory module with MC TopLevellicence
x4 = MMx40 memory module with PLClicence
A=SM0safetymodule
B = SM100 safety module
E = SM301safety module
Preface
About this Hardware Manual
Products to which the Hardware Manual applies
1
15
EDS94SPP101 EN 7.1
Power-related accessories
c
E94 A Z x x xxx x
Type / product range
9400 Servo Drives
Generation
Identification
Z = accessories
Component class 1
H = brake control
P = mounting backplane
M = mains filter
R = RFI filter
Component class 2
M = multiple axes
P = power supply module
R = regenerative module
S = single axis
X,Y = type
N=notspecified
Rated current (rounded)
e.g.
008=8A
024 = 23.5 A
...
Voltage class
1=24V=
2 = 230 V ~ / 300 V =
4 = 400 V ~ / 540 V =
Preface
About this Hardware Manual
Products to which the Hardware Manual applies
1
16 EDS94SPP101 EN 7.1
Power-independent accessories
c
E94 A Z x xxx
Type / product range
9400 Servo Drives
Generation
Identification
Z = accessories
Accessory group
J = mechanical components, other
S=software
K=keypad
N=notspecified
Module identification
Preface
Legal regulations
1
17
EDS94SPP101 EN 7.1
1.3 Legal regulations
Labelling
Lenze drive controllers are clearly labelled and defined by the contents of the nameplate.
Manufacturer
Lenze Automation GmbH, Hans-Lenze-Str. 1, D-31855 Aerzen
CE conformity
Complies with the ”Low voltage” EC Directive
Application as directed
The following applies to 9400 servo controllers and the accessories:
ƒThey must only be operated under the operating conditions described in this
Hardware Manual.
ƒThey are components for open and closed loop control of control variable speed
drives with asynchronous standard motors, asynchronous servo motors, PM
synchronous servo motors.
ƒThey are components for installation into a machine.
ƒThey are components used for assembly together with other components to form a
machine.
ƒThey comply with the protection requirements of the ”Low Voltage” EC Directive.
ƒThey are not machines for the purposes of the ”EC ”Machinery” Directive.
ƒThey are not to be used as household appliances but for industrial purposes only.
The following applies to drives with 9400 servo controllers:
ƒThey comply with the EC ”Electromagnetic Compatibility” Directive if they are
installed according to the guidelines of CE-typical drive systems.
ƒThey can be used for operation at public and non-public mains.
ƒThey can be used in industrial premises as well as residential and commercial
premises.
ƒThe user is responsible for the compliance of his application with the EC Directives.
Any other use shall be deemed inappropriate!
Preface
Legal regulations
1
18 EDS94SPP101 EN 7.1
Liability
The information, data, and notes in this Hardware Manual met the state of the art at the
time of printing. Claims referring to drive systems which have already been supplied
cannot be derived from the information, illustrations, and descriptions given in this
Manual.
The specifications, processes, and circuitry described in this Hardware Manual are for
guidance only and must be adapted to your own application. Lenze does not take any
responsibility for the suitability of the process and circuit proposals.
The specifications in this Hardware Manual describe the product features without
guaranteeing them.
Lenze does not accept any liability for damage and failures caused by:
ƒDisregarding the Hardware Manual
ƒUnauthorised modifications to the controller
ƒOperating errors
ƒImproper working on and with the controller
Warranty
See Terms of sale and delivery.
Warranty claims must be made to your Lenze representative immediately after detecting
the deficiency or fault.
The warranty is void in all cases where liability claims cannot be made.
Guide 2
19
EDS94SPP101 EN 7.1
2Guide
2.1 Terms and abbreviations used 20..........................................
2.2 Total index 22..........................................................
Guide
Terms and abbreviations used
2
20 EDS94SPP101 EN 7.1
2.1 Terms and abbreviations used
Cross-reference to a chapter with the corresponding page number
AC AC current or AC voltage
Axis, drive Lenze controller combined with a motor or geared motor and other
Lenze drive components
Basic insulation Insulation for the basic protection against dangerous shock currents
CE Communauté Européene
Controller Any frequency inverter, servo inverter, or DC speed controller
Cxxxxx/y Subcode y of code Cxxxx
(e.g. C0410/3 = subcode 3 of code C0410)
DC DC current or DC voltage
DIN Deutsches Institut für Normung
Double insulation Basic insulation and additional insulation
EMC Electromagnetic compatibility
EN European standard
fmax [Hz] Maximum frequency
Functional insulation Insulation for perfect operation
ILN [A] Rated mains current
IaN [A] Rated output current
IaM [A] Maximum output current
IEC International Electrotechnical Commission
IP International Protection Code
IPE [mA] Discharge current
L[mH] Inductance
MN[Nm] Rated torque
NEMA National Electrical Manufacturers Association
PN[kW] Rated motor power
PV[W] Inverter power loss
PDC [kW] Power on the DC voltage side
R[Ω]Resistance
Reinforced insulation Standardised insulating system, equivalent protection to double
insulation
SN[kVA] Apparent output power of controller
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