PositionServo

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
 Table of Contents

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 About these Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Scope of Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Legal Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.4 Part Number Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Power Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Fuse Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 Digital I/O Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.6 Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.7 Connections and I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1 PositionServo Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Shielding and Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2.1 General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2.2 EMI Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2.3 Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3 Line Filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4 Heat Sinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.5 Line (Mains) Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5 PositionServo Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1 External Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1.1 P1 & P7 - Input Power and Output Power Connections . . . . . . . . . . . . . 18
5.1.2 P2 - Ethernet Communications Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1.3 P3 - Controller Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1.4 P4 - Motor Feedback / Second Loop Encoder Input . . . . . . . . . . . . . . . . 21
5.1.5 P5 - 24 VDC Back-up Power Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1.6 P6 - Braking Resistor and DC Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1.7 Connectors and Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1.8 P11 - Resolver Interface Module (option module) . . . . . . . . . . . . . . . . . . 23
5.1.9 P12 - Second Encoder Interface Module (option bay 2) . . . . . . . . . . . . . 25
5.2 Digital I/O Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2.1 Step & Direction / Master Encoder Inputs (P3, pins 1-4) . . . . . . . . . . . . 26
5.2.2 Buffered Encoder Output (P3, pins 7-12) . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2.3 Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2.4 Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.3 Analog I/O Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.3.1 Analog Reference Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.3.2 Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.4 Communication Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4.1 Ethernet Interface (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4.2 RS485 Interfaces (option module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4.3 RS485 Communication Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4.4 MODBUS RTU Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.5 Motor Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.5.1 Motor Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.5.2 Motor Over-temperature Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.5.3 Motor Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

S94P01D 
 5.6 Using a Custom Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.6.1 Creating Custom Motor Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.6.2 Autophasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.6.3 Custom Motor Data Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

6 Programmable Features and Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.1 Parameter Storage and EPM Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.1.1 Parameter Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.1.2 EPM Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.1.3 EPM Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.2 Motor Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.3 Parameters Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.3.1 Drive Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.3.2 Drive PWM frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3.3 Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3.4 Peak Current Limit (8 kHz and 16 kHz) . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3.5 Analog Input Scale (current scale) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3.6 Analog Input Scale (velocity scale) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.3.7 ACCEL/DECEL Limits (velocity mode only) . . . . . . . . . . . . . . . . . . . . . . . 41
6.3.8 Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.3.9 Step Input Type (position mode only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.3.10 Fault Reset Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.3.11 Motor Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.3.12 Motor PTC Cut-off Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.3.13 Second Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.3.14 Regeneration Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.3.15 Encoder Repeat Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.3.16 System to Master Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.3.17 Second to Prime Encoder Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.3.18 Autoboot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.3.19 Group ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.3.20 Enable Switch Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.3.21 User Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.3.22 Resolver Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.3.23 Current Limit Max Overwrite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.4 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.4.1 Ethernet Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.4.2 RS-485 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.4.3 Modbus Baud Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.4.4 Modbus Reply Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.5 Analog I/O Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.5.1 Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.5.2 Analog Output Current Scale (Volt / amps) . . . . . . . . . . . . . . . . . . . . . . . 48
6.5.3 Analog Output Current Scale (mV/RPM) . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.5.4 Analog Input Dead Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.5.5 Analog Input Offset Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.5.6 Adjust Analog Voltage Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.6 Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.6.1 Digital Input De-bounce Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.6.2 Hard Limit Switch Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.7 Velocity Limits Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.7.1 Zero Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.7.2 Speed Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.7.3 At Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.8 Position Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.8.1 Position Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.8.2 Max Error Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.8.3 Second Encoder Position Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.8.4 Second Encoder Max Error Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

 S94P01D
 6.9 Compensation Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.9.1 Velocity P-gain (proportional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.9.2 Velocity I-gain (integral) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.9.3 Position P-gain (proportional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.9.4 Position I-gain (integral) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.9.5 Position D-gain (differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.9.6 Position I-limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.9.7 Gain Scaling Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.10 Tools Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.10.1 Oscilloscope Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.10.2 Run Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.11 Faults Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

7 Display and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

7.1 Diagnostic Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.2 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.3 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.3.1 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.3.2 Fault Event . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.3.3 Fault Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.1 Minimum Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.2 Configuration of the PositionServo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.3 Position Mode Operation (gearing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.4 Dual-loop Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.5 Enabling the PositionServo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.6 Tuning in Velocity Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.7 Tuning in Position Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

9 Sample Motor Responses to Gain Settings . . . . . . . . . . . . . . . . . . . . . . . . 62

9.1 Motor Response to Gain Settings (velocity mode) . . . . . . . . . . . . . . . . . . . . . . . 62
9.1.1 P-gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.1.2 I-gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9.1.3 Abnormal Gains (velocity mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.2 Motor Response to Gain Settings (position mode) . . . . . . . . . . . . . . . . . . . . . . . 66
9.2.1 P-gain selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.2.2 Optimal P-gain / D-gain Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

S94P01D 
 Safety Information
All safety information given in these Operating Instructions have the same layout:

Signal Word! (Characteristics the severity of the danger)

Note (describes the danger and informs on how to proceed)

Icon Signal Words

Warning of DANGER! Warns of impending danger.
hazardous Consequences if disregarded:
electrical Death or severe injuries.
voltage
Warning of WARNING! Warns of potential, very hazardous situations.
a general Consequences if disregarded:
danger Death or severe injuries.
Warning of STOP! Warns of potential damage to material and
damage to equipment.
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.

 S94P01D
1 General Information
The PositionServo line of advanced general purpose servo drives utilizes the latest
technology in power semiconductors and packaging. The PositionServo uses Field
Oriented control to enable high quality motion.
The PositionServo is available in four mains (input power) configurations:
1. 400/480V (nominal) three phase input. An external input mains (line) filter is
available. Actual voltage can range from 320 - 528 VAC.
2. 120/240V (nominal) Single Phase input with integrated input mains (line)
filter, Actual input voltage can range from 80VAC to 264VAC. The maximum
output voltage is approximately equal to the input voltage.
3. 120V or 240V (nominal) Single or Three Phase input. Actual input voltage
can range from 80VAC to 264VAC. The maximum output voltage is
approximately equal to the input voltage. An external input mains (line) filter
is available.
4. 120V or 240V (nominal) single phase input. When wired for Doubler mode
(L1-N), the input is for 120V nominal only and can range from 45VAC to 132
VAC and the maximum output voltage is double the input voltage. When
wired to terminals L1-L2/N, the input can range from 80 VAC to 264 VAC and
the maximum output voltage is equal to the input voltage.
The PositionServo drive can operate in one of three mode settings, torque (current),
velocity, or position (step & direction or master encoder). The drive’s command or
reference signal can come from one of three sources. The first is an external reference.
An external reference can be an analog input signal, a step and direction input or an
input from a master encoder. The second reference is an internal reference. An internal
reference is when the commanded move is derived from the drive’s user program.
The third reference is when the commanded move is done via a host device over a
communications network. This Host device can be an external motion controller, PLC,
HMI or PC. The communication network can be over, RS485 (Point-to-Point or Modbus
RTU), Ethernet (using MotionView DLL’s), Modbus over TCP/IP, or CANopen (DS301
and DS402).
Depending on the primary feedback, there are two types of drives: the Model 940
PositionServo encoder-based drive which accepts an incremental encoder with Hall
channel inputs and the Model 941 PositionServo resolver-based drive which accepts
resolver inputs. The feedback signal is brought back to the P4 connector on the drive.
This connector will be a 15 pin D-sub for the encoder version and a 9 pin D-sub for the
resolver version. A second encoder can be used in position and velocity modes.
The MotionView software is the setup and management tool for PositionServo drives.
All parameters can be set and monitored via this user-friendly tool. It has a real-time
oscilloscope tool for analysis and optimum tuning. The users program written with
SimpleMotion Programming Language (SML) can be utilized to command motion and
handle the drive’s inputs/outputs (I/O). The programming language is designed to be
very intuitive and easy to implement. For programming details, refer to the PositionServo
Programming Manual. All PositionServo related manuals can be downloaded from the
Technical Library on the AC Tech website (http://www.lenze-actech.com).
On each PositionServo drive, there is an Electronic Programming Module (EPM), which
stores all drive setup and tuning information. This module can be removed from the drive
and reinstalled into another drive, making the field replacement of the drive extremely
easy. This also makes it easy to duplicate the settings for several drives.
The PositionServo drive supports a variety of communication protocols, including Point-
to-Point (PPP), Modbus RTU over RS485, Ethernet TCP/IP, Modbus over TCP/IP and
CANopen (DS301 and DS402).

S94P01D 
1.1 About these Instructions
These Operating Instructions are provided to assist the user in connecting and
commissioning the PositionServo drive. Important safety instructions are contained in
this document and must be observed carefully.
All persons working on or with the controller must have the Operating Instructions
available and must observe the information and notes relevant for their work.
A B C D E F

Type: INPUT: 1(3)/PE OUTPUT: 3/PE For detailed information

E94P120Y2N 120/240 V 0 - 230 V refer to instruction
12.0 A Manual: S94P01
ID-No: 13014745 24.0 (13.9) A
50-60 HZ SN 13014745012345678
Made in USA
E94P120Y2N000XX## ##

Model 940

A B C D E F
Certifications Type Input Ratings Output Hardware Software
Ratings Version Version

1.2 Scope of Supply

Scope of Supply Important
• 1 Model PositionServo type E94P After reception of the delivery, check immediately
or E94R. whether the scope of supply matches the accompanying
• 1 Users Manual (English) papers. Lenze- AC Tech does not accept any liability for
• 1 MotionView CD ROM including: deficiencies claimed subsequently.
- configuration software Claim
- documentation (Adobe Acrobat) • visible transport damage immediately to the
forwarder
• visible deficiencies / incompleteness immediately to
your Lenze representative.

1.3 Legal Regulations

Identification Nameplate CE Identification Manufacturer
Lenze controllers are In compliance with AC Technology Corp.
unambiguously designated the EC Low-Voltage member of the Lenze Group
by the contents of the Directive 630 Douglas Street
nameplate Uxbridge, MA 01569 USA
Application E94P or E94R servo controller
as directed • must only be operated under the conditions prescribed in these Instructions.
• are components for:
- closed loop control of variable speed/torque applications with PM synchronous motors.
- installation in a machine.
- assembly with other components to form a machine.
• are electric units for installation in control cabinets or similarly enclosed housing.
• comply with the requirements of the Low-Voltage Directive.
• are not machines for the purpose of the Machinery Directive.
• are not to be used as domestic appliances, but only for industrial purposes.
Drive systems with E94P or E94R servo inverters
• comply with the EMC Directive if they are installed according to the guidelines of CE-
typical drive systems.
• can be used for:
- for operation on public and non-public mains
- for operation in industrial premises and residential areas.
• The user is responsible for the compliance of his application with the EC directives.
Any other use shall be deemed as inappropriate!

 S94P01D
 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 that have already been
supplied cannot be derived from the information, illustrations, and descriptions.
• The specifications, processes and circuitry described in these instructions are for guidance
only and must be adapted to your own specific application. Lenze does not take
responsibility for the suitability of the process and circuit proposals.
• The specifications in these Instructions describe the product features without guaranteeing
them.
• Lenze does not accept any liability for damage and operating interference caused by:
- Disregarding the operating instructions
- Unauthorized modifications to the controller
- Operating errors
- Improper working on and with the controller

Warranty • Warranty conditions: see Sales and Delivery Conditions of Lenze Drive Systems GmbH.
• Warranty claims must be made to Lenze immediately after detecting the deficiency or fault.
• The warranty is void in all cases where liability claims cannot be made.

Disposal Material Recycle Dispose

Metal • -
Plastic • -
Assembled PCB’s - •

1.4 Part Number Designation

The table herein describes the part number designation for the PositionServo drive. The
available filter and communication options are detailed in separate tables.

E94 P 020 S 1 N E X
Electrical Products in the 94 Series
P = PositionServo Model 940 with Encoder Feedback
R = PositionServo Model 941 with Resolver Feedback
Drive Rating in Amps:
020 = 2 Amps 090 = 9 Amps
040 = 4 Amps 100 = 10 Amps
050 = 5 Amps 120 = 12 Amps
060 = 6 Amps 180 = 18 Amps
080 = 8 Amps
Input Phase:
S = Single Phase Input only
Y = Single or Three Phase Input
T = Three Phase Input only
Input Voltage:
1 = 120 VAC Doubler (120V, 1~ in/ 240V, 3~ out)
2 = 200/240 VAC
4 = 400/480 VAC
Line Filter
N = No Line Filter
F = Integrated Line Filter

Secondary Feedback
E = Incremental Encoder
R = Standard Resolver
EN954-1 Safety Circuit
X = No EN954 Safety Circuit

S94P01D 
Filter Part Number Designation

E94Z F 4 T 4 A1
Electrical Option in the 94 Series
F = EMC Filter
Filter Current Rating in Amps:
04 = 4.4 Amps 12 = 12 Amps
07 = 6.9 Amps 15 = 15 Amps
10 = 10 Amps 24 = 24 Amps
Input Phase:
S = Single Phase
T = Three Phase
Max Voltage:
2 = 240 VAC
4 = 400/480 VAC
Degree of Filtering/Variation
A1 = Industrial/1st Variation
A2 = Industrial/2nd Variation

Servo Option Part Number Designation

E94Z A CAN 1
Electrical Option in the 94 Series
A = COMM, Feedback or Breakout Module
Module Type:
CAN = CANopen COMM Module ENC = 2nd Encoder Feedback Module
RS4 = RS485 COMM Module RSV = Resolver Feedback Module
ETH = Ethernet COMM Module HBK = Motor Brake Terminal Module
TBO = Terminal Block I/O Module
SCA = Panel Saver I/O Module
Variations
1 = 1st Variation
2 = 2nd Variation
3 = 3rd Variation

 S94P01D
2 Specifications
2.1 Electrical Characteristics
Single-Phase Models
1~ Mains 1~ Mains Rated Peak
Current Current Output Output
Type (1) Mains Voltage (2) (doubler) (Std.) Current (5) Current (6)
E94_020S1N_X 9.7 5.0 2.0 6
120V(3) or 240V(4)
E94_040S1N_X 16.8 8.6 4.0 12
E94_020S2F_X -- 5.0 2.0 6
E94_040S2F_X 120 / 240V (4) -- 8.6 4.0 12
(80 V -0%...264 V +0%)
E94_080S2F_X -- 15.0 8.0 24
E94_100S2F_X -- 18.8 10.0 30

Single/Three-Phase Models
1~ 3~ Rated Peak
Mains Mains Output Output
Type (1) Mains Voltage (2) Current Current Current (5) Current (6)
E94_020Y2N_X 5.0 3.0 2.0 6
E94_040Y2N_X 8.6 5.0 4.0 12
120 / 240V(4)
E94_080Y2N_X 1~ or 3~ 15.0 8.7 8.0 24
(80 V -0%...264 V +0%)
E94_100Y2N_X 18.8 10.0 30
E94_120Y2~_X 24.0 13.9 12.0 36

240V 3~
E94_180T2~_X -- 19.6 18.0 54
(180 V -0%...264 V +0%)

E94_020T4N_X -- 2.7 2.0 6

E94_040T4N_X -- 5.5 4.0 12
400 / 480V
E94_050T4N_X 3~ -- 6.9 5.0 15
(320 V -0%...528 V +0%)
E94_060T4~_X -- 7.9 6.0 18
E94_090T4~_X -- 12.0 9.0 27
(1) The first “_” equals “P” for the 940 encoder based drive or “R” for the 941 resolver based drive.
When the 10th digit is marked by “~”, “N” = No line filter or “F” = Integrated line filter
The second “_” equals “E” for incremental encoder (must have E94P drive) or “R” for the standard resolver
(must have E94R drive).
(2) Mains voltage for operation on 50/60 Hz AC supplies (48 Hz -0% … 62Hz +0%).
(3) Connection of 120VAC (45 V … 132 V) to input power terminals L1 and N on these models doubles the voltage
on motor output terminals U-V-W for use with 230VAC motors.

(4) Connection of 240VAC or 120VAC to input power terminals L1 and L2 on these models delivers an equal voltage
as maximum to motor output terminals U-V-W allowing operation with either 120VAC or 230VAC motors.

(5) Drive rated at 8kHz Carrier Frequency. Derate Continuous current by 17% at 16kHz.
(6) Peak RMS current allowed for up to 2 seconds. Peak current rated at 8kHz. Derate by 17% at 16kHz.
Applies to all models:
Acceleration Time Range (Zero to Max Speed) 0.1 … 5x106 RPM/sec
Deceleration Time Range (Max Speed to Zero) 0.1 … 5x106 RPM/sec
Speed Regulation (typical) ± 1 RPM
Input Impedance (AIN+ to COM and AIN+ to AIN-) 47 kΩ
Power Device Carrier Frequency (sinusoidal commutation) 8,16 kHz
Encoder Power Supply (max) +5 VDC @ 300 mA
Maximum Encoder Feedback Frequency 2.1 MHz (per channel)
Maximum Output Frequency (to motor) 400Hz
Resolver Carrier Frequency 4.5 - 5.5kHz (5kHz nominal)
Resolver Turns Ratio between Reference and SIN/COS signal 2:1

S94P01D 
2.2 Power Ratings
Power Loss at Power Loss at
Output Power
Rated Output Rated Output
Type(1) at Rated Output Leakage Current
Current Current
Current (8kHz)(2)
(8kHz) (16 kHz)(3)
Units kVA mA Watts Watts
E94_020S1N_X 0.8 19 21
E94_040S1N_X 1.7 29 30

E94_020S2F_X 0.8 19 21
E94_040S2F_X 1.7 29 30
E94_080S2F_X 3.3 61 63
E94_100S2F_X 4.2 80 85

E94_020Y2N_X 0.8 Typically >3.5 mA. 19 21

E94_040Y2N_X 1.7 Consult factory for 29 30
E94_080Y2N_X 3.3 applications requiring 61 63
<3.5 mA.
E94_120Y2~_X 5.0 114 129
E94_180T2~_X 7.5 171 195

E94_020T4N_X 1.7 31 41
E94_040T4N_X 3.3 50 73
E94_050T4N_X 4.2 70 90
E94_060T4~_X 5.0 93 122
E94_090T4~_X 7.5 138 182

2.3 Fuse Recommendations

AC Line Input
AC Line Miniature
Fuse (4) or DC Bus Input
Type(1) Input Fuse Circuit Breaker(6)
Breaker (5) Fuse(7)
(1ø/3ø) (1ø/3ø)
(N. America)
Amp Ratings
E94_020S1N_X M20/M10 C20/C10 20/10 10
E94_040S1N_X M32/M20 C32/C20 30/20 20

E94_020S2F_X M20 C20 20 15

E94_040S2F_X M20 C20 20 20
E94_080S2F_X M32 C32 32 40
E94_100S2F_X M40 C40 40 45

E94_020Y2N_X M20/M16 C20/C16 20/15 15

E94_040Y2N_X M20/M16 C20/C16 20/15 20
E94_080Y2N_X M32/M20 C32/C20 30/20 40
E94_120Y2~_X M50/M32 C50/C32 50/30 55
E94_180T2~_X M40 C40 40 80

E94_020T4N_X M10 C10 10 10

E94_040T4N_X M10 C10 10 20
E94_050T4N_X M16 C16 15 25
E94_060T4~_X M20 C20 20 30
E94_090T4~_X M25 C25 25 40

(1) The first “_” equals “P” for the Model 940 encoder based drive or “R” for the Model 941 resolver based drive.
When the 10th digit is marked by “~”, “N” = No line filter or “F” = Integrated line filter
The second “_” equals “E” for incremental encoder (must have E94P drive) or “R” for the standard resolver (must have E94R drive).

(2) At 240 VAC line input for drives with suffixes “S1N”, “S2F”, “Y2N”. At 480 VAC line input for drives with suffixes “T4N”.
a. The output power is calculated from the formula: output power (kVA)=sqrt(3) x ULL x I rated

b. The actual output power depends on the motor in use due to variations in power factor.
(3) At 16 kHz, de-rate continuous current by 17%
(4) Installations with high fault current due to large supply mains may require a type D circuit breaker.
(5) UL Class CC or T fast-acting current-limiting type fuses, 200,000 AIC, preferred. Bussman KTK-R, JJN, JJS or equivalent.
(6) Thermal-magnetic type breakers preferred.
(7) DC-rated fuses, rated for the applied voltage. Examples Bussman KTM or JJN as appropriate.

10 S94P01D
2.4 Digital I/O Ratings
Scan Input Voltage
Linearity Temperature Drift Offset Current
Times Impedance Range
Units ms % % % mA Ohm VDC
Digital Inputs(1) 0.02(2) Depend on load 2.2 k 5-24
Digital Outputs 0.052(2) 100 max N/A 30 max
Analog Inputs 0.052 ± 0.013 0.1% per °C rise ± 0 adjustable Depend on load 47 k ± 18
Analog Outputs 0.052 0.1% per °C rise ± 0 adjustable 10 max N/A ± 10
(1) Inputs do not have scan time. Their values are read directly by indexer program statement.
De-bounce time is programmable and can be set as low as 0. Propagation delay is typical 20 us
(2) Time when output has an assigned function.

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

2.6 Operating Modes

Torque
Reference ± 10 VDC 16-bit; scalable
Torque Range 100:1
Current-Loop Bandwidth Up to 3 kHz
Velocity
Reference ± 10 VDC or 0…10 VDC; scalable
Regulation ± 1 RPM
Velocity-Loop Bandwidth Up to 400 Hz
Speed Range 5000:1 with 5000 ppr encoder
Position
Reference 0…2 MHz Step & Direction or 2 channels quadrature input; scalable
Minimum Pulse Width 500 nanoseconds
Loop Bandwidth Up to 200 Hz
Accuracy ±1 encoder count for encoder feedabck
±1.32 arc-minutes for resolver feedback (14-bit resolution)

2.7 Connections and I/O

Mains Power 4-pin removable terminal block (P1)
Ethernet Port Standard RJ45 Connector (P2)
I/O Connector Standard 50-pin SCSI. (P3)
- Buffered Encoder Output In 50-pin SCSI controller connector (P3)
- Digital Inputs 11 programmable, 1 dedicated (5-24V) (P3)
- Digital Outputs 4 programmable, 1 dedicated(5-24V @ 100mA) (P3)
- Analog Input 2 differential; ±10 VDC (one16 bit, one 10 bit) (P3)
- Analog Output 1 single ended; ±10 VDC (10-bit) (P3)
Encoder Feedback (E94P drive) Feedback connector, 15-pin D-shell (P4)
Resolver Feedback (E94R drive) Feedback connector, 9-pin D-shell (P4)
24VDC Power “Keep Alive” 2-pin removable terminal block (P5)
Regen and Bus Power 5-pin removable terminal block (P6)
Motor Power 6-pin pin removable terminal block (P7)
Resolver feedback (option bay) Option module with standard 9-pin D-shell (P11)
Encoder Feedback (option bay) Option module with standard 9-pin D-shell (P12)
Comm Option Bay Optional Comm Modules (CAN, RS485) (P21)
Windows® Software: MotionView (Windows 98, NT, 2000, XP)

S94P01D 11
3 Dimensions
3.1 PositionServo Dimensions
() Y^V 2 )#*,

&'

9 7

&'
)#*,
&* (-

8 6 S923

Type (1)
A (mm) B (mm) C (mm) D (mm) Weight (kg)
E94_020S1N_X 67 190 190 182 1.1
E94_040S1N_X 69 190 190 182 1.2
E94_020S2F_X 67 190 235 182 1.3
E94_040S2F_X 69 190 235 182 1.5
E94_080S2F_X 88 190 235 182 1.9
E94_100S2F_X 103 190 235 182 2.2
E94_020Y2N_X 67 190 190 182 1.3
E94_040Y2N_X 69 190 190 182 1.5
E94_080Y2N_X 95 190 190 182 1.9
E94_120Y2~_X 67 190 235 182 1.5
E94_180T2~_X 67 242 235 233 2.0
E94_020T4N_X 69 190 190 182 1.5
E94_040T4N_X 95 190 190 182 1.9
E94_050T4N_X 115 190 190 182 2.2
E94_060T4~_X 67 190 235 182 1.4
E94_090T4~_X 67 242 235 233 2.0

(1) The first “_” equals “P” for the Model 940 encoder based drive or “R” for the Model 941 resolver based drive.
When the 10th digit is marked by “~”, “N” = No line filter, “F” = Integrated line filter or “C” = Cold plate drive.
The second “_” equals “E” for incremental encoder (must have E94P drive) or “R” for the standard resolver
(must have E94R drive).

12 S94P01D
3.2 Clearance for Cooling Air Circulation

3'*bb
3(bb

3'*bb

S924

S94P01D 13
4 Installation
Perform the minimum system connection. Please refer to section 8.1 for minimum
connection requirements. Observe the rules and warnings below carefully:
DANGER!
Hazard of electrical shock! Circuit potentials are up to 480 VAC above
earth ground. Avoid direct contact with the printed circuit board or
with circuit elements to prevent the risk of serious injury or fatality.
Disconnect incoming power and wait 60 seconds before servicing drive.
Capacitors retain charge after power is removed.
STOP!
• The PositionServo must be mounted vertically for safe operation
and to ensure enough cooling air circulation.
• Printed circuit board components are sensitive to electrostatic
fields. Avoid contact with the printed circuit board directly. Hold
the PositionServo by its case only.
• Protect the drive from dirt, filings, airborne particles, moisture,
and accidental contact. Provide sufficient room for access to the
terminal block.
• Mount the drive away from any and all heat sources. Operate
within the specified ambient operating temperature range.
Additional cooling with an external fan may be recommended in
certain applications.
• Avoid excessive vibration to prevent intermittent connections
• DO NOT connect incoming (mains) power to the output motor
terminals (U, V, W)! Severe damage to the drive will result.
• Do not disconnect any of the motor leads from the PositionServo
drive unless (mains) power is removed. Opening any one motor
lead may cause failure.
• Control Terminals provide basic isolation (insulation per EN
61800-5-1). Protection against contact can only be ensured by
additional measures, e.g., supplemental insulation.
• Do not cycle mains power more than once every 2 minutes.
Otherwise damage to the drive may result.

WARNING!
For compliance with EN 61800-5-1, the following warning applies.
This product can cause a d.c. current in the protective earthing conductor.
Where a residual current-operated protective (RCD) or monitoring
(RCM) device is used for protection in case of direct or indirect contact,
only an RCD or RCM of Type B is allowed on the supply side of this
product.

UL INSTALLATION INFORMATION
• Suitable for use on a circuit capable of delivering not more than
200,000 rms symmetrical amperes, at the maximum voltage
rating marked on the drive.
• Use Class 1 wiring with minimum of 75ºC copper wire only.
• Shall be installed in a pollution degree 2 macro-environment.

14 S94P01D
4.1 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 5.1.1 for Power wiring specifications.

4.2 Shielding and Grounding

4.2.1 General Guidelines
Lenze recommends the use of single-point grounding (SPG) for panel-mounted controls.
Serial grounding (a “daisy chain”) is not recommended. The SPG for all enclosures
must be tied to earth ground at the same point. The system ground and equipment
grounds for all panel-mounted enclosures must be individually connected to the SPG
for that panel using 14 AWG (2.5 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 drive cables provided by
Lenze. If you specify cables other than those provided by Lenze, please make certain
all cables are shielded and properly grounded.
It may be necessary to earth ground the shielded cable. Ground the shield at both the
drive end and at the motor end.
If the PositionServo drive continues to pick up noise after grounding the shield, it may
be necessary to add an AC line filtering device and/or an output filter (between the drive
and servo motor).

S94P01D 15
EMC
Compliance with EN 61800-3:2004
In a domestic environment this product may cause radio interference. The user may
be required to take adequate measures
Noise emission Installation according to EMC
Drive Models ending in the suffix “2F” are in Requirements
compliance with class A limits according to
EN 55011 if installed in a control cabinet and
the motor cable length does not exceed 10m.
Models ending in “N” will require an appropriate D
line filter.

A Screen clamps
B Control cable
F
C Low-capacitance motor cable
(core/core < 75 pF/m, core/screen < 150 pF/m)
D Earth grounded conductive mounting plate
A
E Encoder Feedback Cable
F Footprint or Sidemount Filter (optional)
B E C S930

4.2.2 EMI Protection

Electromagnetic interference (EMI) is an important concern for users of digital
servo control systems. EMI will cause control systems to behave in unexpected and
sometimes dangerous ways. Therefore, reducing EMI is of primary concern not only
for servo control manufacturers such as Lenze, but the user as well. Proper shielding,
grounding and installation practices are critical to EMI reduction.

4.2.3 Enclosure
The panel in which the PositionServo is mounted must be made of metal, and must be
grounded using the SPG method outlined in section 4.2.1.
Proper wire routing inside the panel is critical; power and logic leads must be routed in
different avenues inside the panel.
You must ensure that the panel contains sufficient clearance around the drive. Refer to
section 3.2 suggested cooling air clearance.

16 S94P01D
4.3 Line Filtering
In addition to EMI/RFI safeguards inherent in the PositionServo design, external filtering
may be required. High frequency energy can be coupled between the circuits via radiation
or conduction. The AC power wiring is one of the most important paths for both types
of coupling mechanisms. In order to comply with IEC61800-3:2004, an appropriate filter
must be installed within 20cm of the drive power inputs.
Line filters should be placed inside the shielded panel. Connect the filter to the
incoming power lines immediately after the safety mains and before any critical control
components. Wire the AC line filter as close as possible to the PositionServo drive.

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

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

4.4 Heat Sinking

The PositionServo drive contains sufficient heat sinking within the specified ambient
operating temperature in its basic configuration. There is no need for additional heat
sinking. However, the user must ensure that there is sufficient clearance for proper
air circulation. As a minimum, an air gap of 25 mm above and below the drive is
necessary.

4.5 Line (Mains) Fusing

External line fuses must be installed on all PositionServo drives. Connect the external
line fuse in series with the AC line voltage input. Use fast-acting fuses rated for 250
VAC or 600 VAC (depending on model), and approximately 200% of the maximum RMS
phase current. Refer to section 2.3 for fuse recommendations.

S94P01D 17
5 PositionServo Connections
The standard PositionServo drive contains seven connectors: four quick-connect
terminal blocks, one SCSI connector and one subminiature type “D” connector. These
connectors provide communications from a PLC or host controller, power to the drive,
and feedback from the motor. Prefabricated cable assemblies may be purchased from
Lenze to facilitate wiring the drive, motor and host computer. Contact your Lenze Sales
Representative for assistance.
As this manual makes reference to specific pins on specific connectors, we will use the
convention PX.Y where X is the connector number and Y is the pin number.

5.1 External Connectors

5.1.1 P1 & P7 - Input Power and Output Power Connections
P1 is a 3 or 4-pin quick-connect terminal block used for input (mains) power. P7 is a
6-pin quick-connect terminal block used for output power to the motor. P7 also has a
thermistor (PTC) input for motor over-temperature protection. The tables in this section
identify the connector pin assignments.

DANGER!
Hazard of electrical shock! Circuit potentials are up to 480 VAC above
earth ground. Avoid direct contact with the printed circuit board or with
circuit elements to prevent the risk of serious injury or fatality. Disconnect
incoming power and wait 60 seconds before servicing drive. Capacitors
retain charge after power is removed.
STOP!
DO NOT connect incoming power to the output motor terminals (U, V,
W)! Severe damage to the PositionServo will result.
Check phase wiring (U, V, W) and thermal input (T1, T2) before powering
up drive. If miswired, severe damage to the PositionServo will result.
All conductors must be enclosed in one shield with a jacket around them. The shield on
the drive end of the motor power cable should be terminated to the conductive machine
panel using screen clamps as shown in section 4.2. The other end should be properly
terminated at the motor shield. Feedback cable shields should be terminated in a like
manner. Lenze recommends Lenze cables for both the motor power and feedback.
These are available with appropriate connectors and in various lengths. Contact your
Lenze representative for assistance.
Wire Size
Current Terminal Wire Size
A (rms) Torque (lb-in)
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)

18 S94P01D
 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)

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)

5.1.2 P2 - Ethernet Communications Port

P2 is a RJ45 Standard Ethernet connector that is used to communicate with a host
computer via Ethernet TCP/IP.
P2 Pin Assignments (Communications)

Pin Name Function

1 + TX Transmit Port (+) Data Terminal
2 - TX Transmit Port (-) Data Terminal
3 + RX Receive Port (+) Data Terminal
4 N.C.
5 N.C.
6 - RX Receive Port (-) Data Terminal
7 N.C.
8 N.C.

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

S94P01D 19
5.1.3 P3 - Controller Interface
P3 is a 50-pin SCSI connector for interfacing to the front-end of the controllers. It is
strongly recommended that you use OEM cables to aid in satisfying CE requirements.
Contact your Lenze representative for assistance.
P3 Pin Assignments (Controller Interface)
Pin Name Function
1 MA+ Master Encoder A+ / Step+ input (2)
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)
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 (max 10 mA)
24 AIN1+ Positive (+) of Analog signal input
25 AIN1 - Negative (-) of Analog signal input
26 IN_A_COM Digital input group ACOM terminal (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 5.1.7 - Connector and Wiring Notes
(2)
See Note 2, Section 5.1.7 - Connector and Wiring Notes
3)
See Note 3, Section 5.1.7 - Connector and Wiring Notes

20 S94P01D
5.1.4 P4 - Motor Feedback / Second Loop Encoder Input
For encoder-based 940 drives, P4 is a 15-pin DB connector that contains connections
for an incremental encoder with Hall emulation tracks or Hall sensors. For synchronous
servo motors, Hall sensors or Hall emulation tracks are necessary for commutation. If
an asynchronous servo motor is used, it is not necessary to connect Hall sensor inputs.
For pin assignments, refer to the table P4A. Encoder inputs on P4 have 26LS32 or
compatible differential receivers for increased noise immunity. Inputs have all necessary
filtering and line balancing components so no external noise suppression networks are
needed.
For resolver-based 941 drives, P4 is a 9-pin DB connector for connecting resolver
feedback and thermal sensor. For pin assignments, refer to the table P4B.
All conductors must be enclosed in one shield with a jacket around them. Lenze
recommends that each and every pair (for example, EA+ and EA-) be twisted. In order
to satisfy CE requirements, use of an OEM cable is recommended. Contact your Lenze
representative for assistance.
The PositionServo buffers encoder/resolver feedback from P4 to P3. For example, when
encoder feedback is used, channel A on P4, is Buffered Encoder Output channel A on
P3. For more information on this refer to section 5.2.2 “Buffered Encoder Outputs”.

STOP!
Use only +5 VDC encoders. Do not connect any other type of encoder to
the PositionServo reference voltage terminals. When using a front-end
controller, it is critical that the +5 VDC supply on the front-end controller
NOT be connected to the PositionServo’s +5 VDC supply, as this will
result in damage to the PositionServo.
Note
• The PositionServo encoder inputs are designed to accept differentially
driven hall signals. Single-ended or open-collector type hall signals
are also acceptable by connecting “HA+”, “HB+”, “HC+” and leaving
“HA-,HB-,HC-” inputs unconnected. The user does not need to supply
pull-up resistors for open-collector hall sensors. The necessary pull-
up circuits are already provided.
• Encoder connections (A, B and Z) must be full differential. The
PositionServo does not support single-ended or open-collector type
outputs from the encoder.
• An encoder resolution of 2000 PPR (pre-quadrature) or higher is
recommended.
Using P4 as second encoder input for dual-loop operation.
P4 can be used as a second loop encoder input in situations where the motor is equipped
with a resolver as the primary feedback. If such a motor is used, the drive must have a
resolver feedback option module installed. A second encoder can then be connected to
the A and B lines of the P4 connector for dual loop operation. Refer to section 8.4, “Dual
loop feedback operation” for details.

S94P01D 21
 P4A Pin Assignments (Encoder Feedback - E94P Drives)
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 (2)
11 HA+ Hall Sensor A+ Input (2)
12 HB+ Hall Sensor B+ Input (2)
13 HC+ Hall Sensor C+ Input (2)
14 HB- Hall Sensor B- Input (2)
15 HC- Hall Sensor C- Input (2)
(1) See Note 1, Section 5.1.7 - Connector and Wiring Notes
(2) For asynchronous servo motor, an incremental encoder without Hall effect sensors (commutation tracks) can be used.

P4B Pin Assignments (Resolver Feedback - E94R Drives)

Pin Name Function
1 Ref +
Resolver reference connection
2 Ref -
3 N/C No Connection
4 Cos+
Resolver Cosine connections
5 Cos-
6 Sin+
Resolver Sine connections
7 Sin-
8 PTC+
Motor PTC Temperature Sensor
9 PTC-

5.1.5 P5 - 24 VDC Back-up Power Input

P5 is a 2-pin quick-connect terminal block that can be used with an external 24 VDC
(500mA) power supply to provide “Keep Alive” capability: during a power loss, the logic
and communications will remain active. Applied voltage must be greater than 20VDC.
P5 Pin Assignments (Back-up Power)

Pin Name Function

1 +24 VDC Positive 24 VDC Input
4 Return 24V power supply return

WARNING!
Hazard of unintended operation! The “Keep Alive” circuit will restart the
motor upon restoration of mains power when the enable input remains
asserted. If this action is not desired, then the enable input must be
removed prior to re-application of input power.

22 S94P01D
5.1.6 P6 - Braking Resistor and DC Bus
P6 is a 5-pin quick-connect terminal block that can be used with an external braking
resistor (the PositionServo has the regen circuitry built-in). The Brake Resistor connects
between the Positive DC Bus (either P6.1 or 2) and P6.3.
P6 Terminal Assignments (Brake Resistor and DC Bus)
Pin Terminal Function
1 B+
Positive DC Bus / Brake Resistor
2 B+
3 BR Brake Resistor
4 B-
Negative DC Bus
5 B-

DANGER!
Hazard of electrical shock! Circuit potentials are up to 680 VAC above
earth ground. Avoid direct contact with the printed circuit board or
with circuit elements to prevent the risk of serious injury or fatality.
Disconnect incoming power and wait 60 seconds before servicing the
drive. Capacitors retain charge after power is removed.

5.1.7 Connectors and Wiring Notes

Note 1 - Buffered Encoder Inputs
Each of the encoder output pins on P3 is a buffered pass-through of the corresponding
input signal on P4, Refer to section 5.2.2 “Buffered Encoder Outputs”. This can be
either from a motor mounted encoder/resolver, (primary feedback), or from an auxiliary
encoder/resolver when an optional feedback module is used.
Via software, these pins can be re-programmed to be a buffered pass through of the
signals from a feedback option card. This can be either the second encoder option
module (E94ZAENC1) or an encoder emulation of the resolver connected to the resolver
option module (E94ZARSV2 or E94ZARSV3).
Note 2 - Master Encoder Inputs or Step/Direction Inputs
An external pulse train signal (“step”) supplied by an external device, such as a PLC or
stepper indexer, can control the speed and position of the servomotor. The speed of the
motor is controlled by the frequency of the “step” signal, while the number of pulses that
are supplied to the PositionServo determines the position of the servomotor. Direction
input controls direction of the motion.
Note 3 - Digital Input
For the drive to function, an ENABLE input must be wired to the drive, and should be
connected to IN_A3, (P3.29), which is, by the default the ENABLE input on the drive.
This triggering mechanism can either be a switch or an input from an external PLC or
motion controller. The input can be wired either sinking or sourcing (section 5.2.3). The
Enable circuit will accept 5-24V control voltage.

5.1.8 P11 - Resolver Interface Module (option module)

PositionServo drives can operate motors equipped with resolvers from either the (P4)
connection, for a resolver-based (E94R) drive, or from the Resolver option module for
an encoder-based (E94P) drive. The option module connections are made to a 9 pin
D-shell female connector (P11) on the resolver option module E94ZARSV2 (scalable)
or E94ZARSV3 (standard). When the motor profile is loaded from the motor database
or from a custom motor file, the drive will select the primary feedback source based on
the motor data entry.

S94P01D 23
The E94ZARSV3 has a fixed resolution of 1024 PPR prequadrature or 4096
postquadrature. The E94ZARSV2 has a selectable set of 15 resolutions. The resolution
refers to the pulses per revolution (PPR) of the Buffered Encoder Outputs (P3-7 to P3-
12) if the Encoder Repeat Source is set as “Optional Feedback Input” in MotionView.
When using the E94ZARSV2, the default resolution is 1024 PPR prequadrature.
Depending on the hardware/software revision of the E94ZARSV2 module, the available
PPRs are different. Refer to the table below for the Dip Switch settings for SW1 and the
different resolutions.
SW1 DIP Switch Settings
Dip Switch SW1 PPR prequadrature(1)
Position 1 Position 2 Position 3 Position 4 Hardware/Software Hardware/Software
Revision(2) 1A10, Revision(2) 1C12
1A11, 1B11, 1C11 and higher
OFF OFF OFF OFF 250 1024 (default)
OFF OFF OFF ON 256 256
OFF OFF ON OFF 360 360
OFF OFF ON ON 400 400
OFF ON OFF OFF 500 500
OFF ON OFF ON 512 512
OFF ON ON OFF 720 720
OFF ON ON ON 800 800
ON OFF OFF OFF 1000 1000
ON OFF OFF ON 1024 (default) 1024 (default)
ON OFF ON OFF 2000 2000
ON OFF ON ON 2048 2048
ON ON OFF OFF 2500 2500
ON ON OFF ON 2880 2880
ON ON ON OFF 4096 250
ON ON ON ON 4096 4096
(1) For PPR postquadrature, multiply by 4.
(2) Hardware/Software Revision can be found on the dataplate label attached to the plastic cover of the module.
For example, the revision in the example below is 1B11.

TYPE: E94ZARSV2
ID NO: 13127865
Made in USA
P11

SN 13127865012345678
94/940 E94ZARSV2000XX1B11
Scalable Resolver
Feedback Option

Setting the Dip Switches

To change the DIP SWITCH SETTING
1. Loosen the three set screws on the module
2. Detach the PCB board from the plastic cover
3. Change the SW1 positions according to the table above
4. Put the PCB board back in the plastic cover
5. Tighten the three set screws

24 S94P01D
When using a Lenze motor with resolver feedback and a Lenze resolver cable, the
pins are already configured for operation. If a non-Lenze motor is used, the resolver
connections are made as follows:
P11 Pin Assignments (Resolver Feedback)
Pin Name Function
1 Ref +
Resolver reference connection
2 Ref -
3 N/C No Connection
4 Cos+
Resolver Cosine connections
5 Cos-
6 Sin+
Resolver Sine connections
7 Sin-
8 PTC+
Motor PTC Temperature Sensor
9 PTC-

STOP!
Use only 10 V (peak to peak) or less resolvers. Use of higher voltage
resolvers may result in feedback failure and damage to the resolver
option module.

5.1.9 P12 - Second Encoder Interface Module (option bay 2)

PositionServo drives can support a second incremental encoder interface for dual-
loop systems. Regardless of what the motor’s primary feedback type is, encoder or
resolver, a 2nd Encoder Option Module, E94ZAENC1, can be installed at Option Bay
2, (P12). Once installed the optional feedback card can be selected as the primary
encoder repeat source from the “Parameter” folder in MotionView. The 2nd Encoder
Option Module includes a 9 pin D-shell male connector. When using a Lenze motor
with encoder feedback and a Lenze encoder cable, the pins are already configured
for operation. If a non-Lenze motor is used, the encoder connections are made as
follows:
P12 Pin Assignments (Second Encoder Feedback)
Pin Name Function
1 E2B+ Second Encoder Channel B+ Input
2 E2A- Second Encoder Channel A- Input
3 E2A+ Second Encoder Channel A+ Input
4 +5v Supply voltage for Second Encoder
5 COM Supply common
6 E2Z- Second Encoder Channel Z- Input
7 E2Z+ Second Encoder Channel Z+ Input
8 N/C No Connection
9 E2B- Second Encoder Channel B- Input
The second encoder needs to be enabled using MotionView software. Refer to section
8.4, “Dual-loop feedback” for details.

STOP!
Use only +5 VDC encoders. Do not connect any other type of encoder to
the option module. Otherwise, damage to drive’s circuitry may result.

S94P01D 25
5.2 Digital I/O Details
5.2.1 Step & Direction / Master Encoder Inputs (P3, pins 1-4)
You can connect a master encoder with quadrature outputs or a step and direction pair
of signals to control position in step / direction operating mode (stepper motor emulation).
These inputs are optically isolated from the rest of the drive circuits and from each other.
Both inputs can operate from any voltage source in the range of 5 to 24 VDC and do not
require additional series resistors for normal operation.

HI:E

9>G:8I>DC
8L 88L
S904
Timing characteristics for Step And Direction signals

8L 88L
S905

Timing characteristics for Master Encoder signals

Input type/ output compatibility Insulated, compatible with Single-ended or

differential outputs (5-24 VDC)
Max frequency (per input) 2 MHz
Min pulse width (negative or positive) 500nS
Input impedance 700 Ω (approx)

+%%7 &%%7
B6 $HI:E
B7 $9>G

*#+K
B6"$HI:E"
B7"$9>G"
S906
Master encoder/step and direction input circuit

Differential signal inputs are preferred when using Step and Direction. Single ended
inputs can be used but are not recommended. Sinking or sourcing outputs may also be
connected to these inputs. The function of these inputs “Master Encoder” or “Step and
Direction” is software selectable. Use the MotionView set up program to choose the
desirable function.

26 S94P01D
5.2.2 Buffered Encoder Output (P3, pins 7-12)
There are many applications where it is desired to close the feedback loop to an external
device. This feature is built into the PositionServo drive and is referred to as the “Buffer
Encoder Output”. If a motor with encoder feedback is being used, the A+, A-, B+, B-, Z+
and Z- signals are directly passed through the drive through pins 7-12 with no delays,
up to a speed of 25MHz. If a motor with resolver feedback is being used a simulated
encoder feedback is transmitted. The default resolution of the simulated encoder is
1024 pulses per revolution, pre-quad. If a different resolution is desired refer to section
6.3.22 “Resolver Tracks”.

5.2.3 Digital Outputs

There are a total of five digital outputs (“OUT1” - “OUT4” and “RDY”) available on the
PositionServo drive. These outputs are accessible from the P3 connector. Outputs are
open collector type that are fully isolated from the rest of the drive circuits. See the
following figure for the electrical diagram. These outputs can be either used via the
drives internal User Program or they can be configured as Special Purpose outputs.
When used as Special Purpose, each output (OUT1-OUT4) can be assigned to one of
the following functions:
• Not assigned
• Zero speed
• In-speed window
• Current limit
• Run-time fault
• Ready
• Brake (motor brake release)
Please note that if you assign an output as a Special Purpose Output then that output
can not be utilized by the User Program. The “RDY” Output has a fixed function,
“ENABLE”, which will become active when the drive is enabled and the output power
transistors becomes energized.

Digital outputs electrical characteristics

Circuit type Isolated Open Collector
Digital outputs load capability 100mA
Digital outputs Collector-Emitter max voltage 30V

The inputs on drive can be wired as either sinking (NPN) or sourcing (PNP),
as illustrated in wiring examples mb101 and mb102.

CEC H^c`^c\ ')K ECE HdjgX^c\ ')K

DJI &"8 DJI &"8

). ).

)) ))

DJI &": DJI &":

DJI '"8 DJI '"8

)* )*

)+ )+

DJI '": DJI '":

<cY <cY
mb101 mb102

S94P01D 27
5.2.4 Digital Inputs
IN_Ax, IN_Bx, IN_Cx (P3.26-30, P3.31-35, P3.36-40)
The PositionServo Drive has 12 optically isolated inputs. These inputs are compatible
with a 5 - 24V voltage source. No additional series resistors are needed for circuit
operation. The 12 inputs are segmented into three groups of 4, Inputs A1 - A4, Inputs
B1 - B4, and Inputs C1 - C4. Each group, (A, B and C) have their own corresponding
shared COM terminal, (ACOM, BCOM and CCOM). Each group or bank can be wired
as sinking or sourcing. Refer to wiring examples mb103 and mb104. All inputs have
a separate software adjustable de-bounce time. Some of the inputs can be set up as
Special Purpose Inputs. For example inputs A1 and A2 can be configured as limit inputs,
input A3 is always set up as an Enable input and input C4 can be used as a registration
input. Refer to the PositionServo Programming Manual (PM94P01) for more detail.

ECE HdjgX^c\

')K ', '#' `

>C 6&

'- '#' `

>C 6'

'+

>C 6 8DB
<cY
9^\^iVa ^cejih X^gXj^i#
mb103
CEC H^c`^c\

<cY ', '#' `

>C 6&

'- '#' `

>C 6'

'+

>C 6 8DB

')K mb104
9^\^iVa ^cejih X^gXj^i#

5.3 Analog I/O Details

5.3.1 Analog Reference Input
AIN1+, AIN1- (P3.24 and P3.25)
The analog reference input can accept up to a ±10V analog signal across AIN1+ and
AIN1-. The maximum limit with respect to analog common (ACOM) on each input is
±18VDC. The analog signal will be converted to a digital value with 16 bit resolution (15
bit plus sign). This input is used to control speed or torque of the motor in velocity or
torque mode. The total reference voltage as seen by the drive is the voltage difference
between AIN1+ and AIN1-. If used in single-ended mode, one of the inputs must
be connected to a voltage source while the other one must be connected to Analog
Common (ACOM). If used in differential mode, the voltage source is connected across
AIN1+ and AIN1- and the driving circuit common (if any) needs to be connected to the
drive Analog Common (ACOM) terminal. Refer to wiring examples mb105 and mb106.

28 S94P01D
Reference as seen by drive: Vref = (AIN1+) - (AIN1-) and -10V < Vref < +10V

:miZgcVa GZ[ZgZcXZ
(Differential Configuration)
940 Servo Drive
6cVad\ 8dbbVcY Djieji E(#') 6>C

Bdi^dc 6cVad\ 8dbbVcY GZijgc 6>C

E(#'*
8dcigdaaZg

68DB E(#''

68DB

Analog Input
Analog input +
Edhi^dcHZgkd
Analog input - 9g^kZ

mb105

H^c\aZ"ZcYZY 8dc[^\jgVi^dc

6Dji E(#'% 6>C

E(#'& 6>C

68DB

E(#''

As the dancer arm goes up and down 68DB

a 0 - 10 volt signal is transmitted
to the PositionServo Drive.
Edh^i^dcHZgkd
9g^kZ
mb106

AIN2+, AIN2- (P3.20 and P3.21)

The analog reference input can accept up to a ±10V analog signal across AIN2+ and
AIN2-. The maximum limit with respect to analog common (ACOM) on each input is
±18VDC. The analog signal will be converted to a digital value with 10 bit resolution
(9 bit plus sign). This input is available to the User’s program. This input does not have
a predefined function. Scaling of this input is identical to AIN1.

5.3.2 Analog Output

AO (P3.23)
The analog output is a single-ended signal (with reference to Analog Common (ACOM)
which can represent the following motor data:
• Not Assigned • Phase U Current • Iq Current

• RMS Phase Current • Phase V Current • Id Current

• Peak Phase Velocity • Phase W Current •

• Motor Velocity

MotionView Setup program can be used to select the signal source for the analog
output as well as its scaling.
If the output function is set to “Not Assigned” then the output can be controlled directly
from user’s program. Refer to the PositionServo Programming Manual (PM94P01) for
programming details.

S94P01D 29
5.4 Communication Interfaces
5.4.1 Ethernet Interface (standard)
Programming and diagnostics of the drive are performed over the standard Ethernet
communication port. The Drives IP address is addressable from the drive’s front
panel display. The interface supports both 100 BASE-TX as well as 10 BASE-T. This
configuration allows the user to monitor and program multiple drives from MotionView.
Refer to section 6.4.1 for PC configuration information.

5.4.2 RS485 Interfaces (option module)

PositionServo drives can be equipped with an RS485 communication interface option
module (E94ZARS41) which is optically isolated from the rest of the drive’s circuitry. This
option module can be used for two functions: drive programming and diagnostics using
MotionView from a PC (with RS485 port) or as a Modbus RTU slave. The PositionServo
drives support 7 different baud rates, ranging from 2400 to 115200. Drives are
addressable with up to 32 addresses from 0-31. The factory setting for the baud rate is
38,400 with a node address of “1”. The drives address must be set from the front panel
display of the drive. When used with MotionView software, the communication speed
is also set from the front panel display. Please note that the baud rate and address
are applied to both RS232 and RS485 interfaces in this case. If used for Modbus RTU
communications, the Modbus baud rate is set as a parameter within MotionView.
Pin Assignments (RS485 interface)
Pin Name Function
1 ICOM Isolated Common
2 TXB Transmit B(+)
3 TXA Transmit A(-)

5.4.3 RS485 Communication Setup

When establishing communication between MotionView and a PositionServo drive, a
communication method must be selected. The connection choice can be either “UPP
over RS485/RS232” or “Ethernet”. The “UPP over RS485/RS232” selection establishes
a RS485 connection between MotionView and the first drive on the network. Multiple
drives can then be added to the network via RS485. Each drive on the network will
have a different Node Address. When setting up communications the node address of
the target drive must be set. MotionView will then send out a communications packet to
the first drive on the network, via the RS485 connection. If the node address set in this
packet doesn’t match the node address of the drive, the drive will resend the packet, via
RS485, to the next drive on the network. This process will continue until the target drive
is reached. The following message, “Device with address # not present in the network”
will appear If the target node could not be found.

5.4.4 MODBUS RTU Support

As a default, the Ethernet, RS485 interfaces are configured to support MotionView
program operations. In addition, the Ethernet port can be configured to support
MODBUS TCP/IP slave protocals and the RS485 interface can be configured to
support the MODBUS RTU slave protocol. These interfaces are configured through the
MotionView program environment. When configured for MODBUS operation, the baud
rate for RS485 is set by the parameter “Modbus baud rate” in MotionView. NOTE: if the
RS485 port is configured for MODBUS operation, then the command repeat function,
(see 5.4.3), is unavailable even if baud rates are set the same for both interfaces.
MODBUS RTU requires 8 data bits.
The MODBUS RTU slave interface protocol definitions can be found in the MotionView
help menu under “Product Manuals”.
30 S94P01D
5.5 Motor Selection
The PostionServo drive is compatible with many 3-phase AC synchronous servo motors
as well as 3-phase AC asynchronous servo motors. MotionView is equipped with a
motor database that contains over 600 motors for use with the PositionServo drive.
If the desired motor is in the database, no data to set it up is needed. Just select the
motor and click “OK”. However, if your motor is not in the database, it can still be used,
but some electrical and mechanical data must be provided to create a custom motor
profile. The auto-phasing feature of the PositionServo drive allows the user to correctly
determine the relationship between phase voltage and hall sensor signals, eliminating
the need to use a multi-channel oscilloscope.

5.5.1 Motor Connection

Motor phase U, V, W (or R, S, T) are connected to terminal P7. It is very important
that motor cable shield is connected to Earth ground terminal (PE) or the drive’s case.
The motor’s encoder/resolver feedback cable must be connected to terminal P4. If a
resolver option module is used, connect to terminal P11, and if a second encoder option
module is used, connect to terminal P12.

5.5.2 Motor Over-temperature Protection

If using a motor equipped with an encoder and PTC thermal sensor, the encoder
feedback cable will have flying leads exiting the P4 connector to be wired to the P7.1
(T1) and P7.2 (T2) terminals. If using a motor equipped with a Resolver and a PTC
sensor, the thermal feedback is pased directly to the drive via the resolver 9-pin D shell
connector.
Use parameter “Motor PTC cut-off resistance” (refer to section 6.3.12) to set the
resistance that corresponds to maximum motor allowed temperature. The parameter
“Motor temperature sensor” must also be set to ENABLE. If the motor doesn’t have a
PTC sensor, set this parameter to DISABLE. This input will also work with N.C. thermal
switches which have only two states; Open or Closed. In this case “Motor PTC cut-off
resistance” parameter can be set to the default value.

5.5.3 Motor Setup

Once you are connected to the PostionServo via MotionView a “Parameter Tree” will
appear in the “Parameter Tree Window”. The various parameters of the drive are shown
here as folders and files. If the “Motor” folder is selected, all motor parameters can
be viewed in the “Parameter View Window”. To view selected motor parameters or to
select a new motor click the section marked “CLICK HERE TO CHANGE”.

S911

S94P01D 31
MotionView’s “Motor Group” folder and its contents
Note
If the drive is ENABLED, a new motor cannot be set. You can only set a
new motor when the drive is DISABLED.

To View selected motor parameters or to make a new motor selection:

• Click “Click here to change the motor” from the Parameter View Window (see figure
above). If just viewing the motor parameters click Cancel on the Motor Parameters
dialog box when done to dismiss the box.
• Select motor Vendor from the right list box and desired motor from the left list
box.
• If you will be using a “custom” motor (not listed in our motor database) go to ”Using
a custom motor” topic in the next section.
• Finally, click the OK button to dismiss the dialog box and return to MotionView’s main
program.
Note
To help prevent the motor from drawing to much current and possibility
overheating it is recommended that the drives “Current Limit” be checked
against the motors “Nominal Phase Current” and set accordingly.

5.6 Using a Custom Motor

You can load a custom motor from a file or you can create a new custom motor.
• To create a custom motor click “CREATE CUSTOM” and follow the instructions in
the next section “Creating custom motor parameters”.
• To load a custom motor click “OPEN CUSTOM” button then select the motor file
and click the “OPEN“ button to select or click the “CANCEL“ button to return to the
previous dialog box.
• Click OK to load the motor data and return to the main MotionView menu or Cancel
to abandon changes. When clicking OK for a custom motor, a dialog box will
appear asking if you want to execute “Autophasing” (refer to section 5.6.2).

5.6.1 Creating Custom Motor Parameters

STOP!
Use extreme caution when entering custom parameters! Incorrect
settings may cause damage to the drive or motor! If you are unsure of
the settings, refer to the materials that were distributed with your motor,
or contact the motor manufacturer for assistance.
1. Enter custom motor data in the Motor Parameters dialog fields. Complete all
sections of dialog: Electrical, Mechanical, Feedback. Refer to section 5.6.3
for explanation of motor parameters and how to enter them.
Note
If unsure of the motor halls order and encoder channels A and B
relationship, leave “B leads A for CW”, “Halls order” and “inverted” fields
as they are. You can execute autophasing (refer to section 5.6.2) to set
them correctly.
2. Enter motor model and vendor in the top edit boxes. Motor ID cannot be
entered, this is set to 0 for custom motors.
3. Click “Save File” button and enter filename without extension. Default
extension .cmt will be given when you click OK on file dialog box.

32 S94P01D
 Note
Saving the file is necessary even if the autophasing feature will be used
and some of the final parameters are not known. After autophasing is
completed the corrected motor file can be updated before loading it to
memory.
4. Click OK to exit from the Motor Parameters dialog.
5. MotionView will ask if you want to autophase your custom motor. If you
answer “No”, the motor data will be loaded immediately to the drive’s
memory. If you answer “Yes”, the motor dialog will be dismissed and
the drive will start the autophasing sequence. Refer to section 5.6.2 for
autophasing information.
6. If you answered “Yes” for autophasing, you will be returned to the same
motor selection dialog box after autophasing is complete. For motors with
incremental encoders, the fields “B leads A for CW”, “Halls order” and
“inverted” will be assigned correct values. For motors with resolvers, the
fields “Offset in degree” and “CW for positive” will be assigned correct values.
7. Click “Save File” to save the custom motor file and then click “OK” to exit the
dialog box and load the data to the drive.
5.6.2 Autophasing
The Autophasing feature determines important motor parameters when using a motor
that is not in MotionView’s database. For motors equipped with incremental encoders,
Autophasing will determine the Hall order sequence, Hall sensor polarity and encoder
channel relationship (B leads A or A leads B for CW rotation). For motors equipped
with resolvers, Autophasing will determine resolver angle offset and angle increment
direction (“CW for positive”).
To perform autophasing:
1. Complete the steps in the previous section “Setting custom motor
parameters”. If the motor file you are trying to autophase already exists,
simply load it as described under “Using a custom motor” at the beginning of
this section.
2. Make sure that the motor’s shaft is not connected to any mechanical load
and can freely rotate.
STOP!
Autophasing will energize the motor and will rotate the shaft. Make sure
that the motor’s shaft is not connected to any mechanical load and can
freely and safely rotate.

3. Make sure that the drive is not enabled.

4. It is not necessary to edit the field “Hall order” and check boxes “inverted”
and “B leads A for CW” as these values are ignored for autophasing.
5. Click OK to dismiss motor selection dialog. MotionView responds with the
question “Do you want to perform autophasing?”
6. Click OK. A safety reminder dialog appears. Verify that it is safe to run the
motor then click “Proceed” and wait until autophasing is completed.
Note
If there is a problem with the motor connection, hall sensor connection
or resolver connection, MotionView will respond with an error message.
Problems commonly occur with power, shield and ground terminations
or when an improper cable is used. Correct the wiring problem(s) and
repeat steps 1 - 6.
If the error message repeats, exchange motor phases U and V (R and
S) and repeat. If problems persist, contact the factory.

S94P01D 33
 7. If autophasing is completed with no error then MotionView will return to the
motor dialog box. For motors with incremental encoders, the parameter field
“Hall order” and the check boxes “inverted”, “B leads A for CW” will be filled
in with correct values. For resolver equipped motors, fields “Offset ” and “CW
for positive” will be correctly set.
8. Click “Save File” to save the completed motor file (you can use the same
filename as you use to save initial data in step 1) and click OK to load the
motor data to the drive.
5.6.3 Custom Motor Data Entry
A Custom Motor file is created by entering motor data into the “Motor Parameters”
dialog box. This box is divided up into the following three sections, or frames:
Electrical constants
Mechanical constants
Feedback
When creating a custom motor you must supply all parameters listed in these sections.
All entries are mandatory except the motor inertia (Jm) parameter. A value of 0 may be
entered for the motor inertia if the actual value is unknown.

5.6.3.1 Electrical constants

Motor Torque Constant (Kt).
Enter the value and select proper units from the drop-down list.

Note
Round the calculated result to 3 significant places.
Motor Voltage Constant (Ke)
The program expects Ke to be entered as a phase-to-phase Peak voltage. If you have
Ke as an RMS value, multiply this value by 1.414 for the correct Ke Peak value.

Phase-to-phase winding Resistance (R) in Ohms

This is also listed as the terminal resistance (Rt). The phase-to-phase winding
Resistance (R) will typically be between 0.05 and 200 Ohms.

Phase-to-phase winding Inductance (L)

This must be set in millihenries (mH). The phase-to-phase winding Inductance (L) will
typically be between 0.1 and 200.0 mH.

Note
If the units for the phase-to-phase winding Inductance (L) are given in
micro-henries (µH), then divide by 1000 to get mH.
Nominal phase current (RMS Amps)
Nominal continuous phase current rating (In) in Amps RMS. Do not use the peak current
rating.

Note
Sometimes the phase current rating will not be given. The equation
below may be used to obtain the nominal continuous phase-to-phase
winding current from other variables.
In= Continuous Stall Torque / Motor Torque Constant (Kt)

34 S94P01D
The same force x distance units must be used in the numerator and denominator in the
equation above. If torque (T) is expressed in units of pound-inches (lb-in), then Kt must
be expressed in pound-inches per Amp (lb-in/A). Likewise, if T is expressed in units of
Newton-meters (N-m), then units for Kt must be expressed in Newton-meters per Amp
(N-m/A).
Example:
Suppose that the nominal continuous phase to phase winding current (In) is not
given. Instead, we look up and obtain the following:
Continuous stall torque T = 3.0 lb-in
Motor torque constant Kt = 0.69 lb-in/A
Dividing, we obtain:
In = 3.0 lb-in / 0.69 lb-in/A =4.35 (A)
Our entry for (In) would be 4.35.
Note that the torque (lb-in) units are cancelled in the equation above leaving just
Amps (A). We would have to use another conversion factor if the numerator and
denominator had different force x distance units.
Nominal Bus Voltage (Vbus)
The Nominal Bus Voltage can be calculated by multiplying the Nominal AC mains
voltage supplied by 1.41. When using a model with the suffix “S1N” where the
mains are wired to the “Doubler” connection, the Nominal Bus Voltage will be
doubled.
Example:
If the mains voltage is 230VAC, Vbus = 230 x 1.41 = 325V
This value is the initial voltage for the drive and the correct voltage will be
calculated dynamically depending on the drive’s incoming voltage value.
Rotor Moment of Inertia (Jm)
From motor manufacturer or nameplate.

Note
Round the calculated result to 3 significant places.
Maximum Motor Speed in RPM
This is also listed as “Speed @ Vt” (motor speed at the terminal voltage rating). The
maximum motor speed will typically be a round even value between 1000 and 6000
RPM.
Number of Poles
This is a positive integer number that represents the number of motor poles, normally
2, 4, 6 or 8.

5.6.3.2 For Incremental Encoder - Equipped Motors Only

Encoder Line Count
The Encoders for servomotors normally have Line Counts of 1000, 1024, 2000, 2048,
4000, or 4096. The Encoder Line Count must be a positive integer and must be pre-
quadrature.
Index pulse offset. Enter 0 (zero)
Index marker pulse position. This field is reserved for backward compatibility. All
PositionServo drives determine actual marker pulse position automatically.

S94P01D 35
Halls Order
Each hall signal is in phase with one of the three phase-phase voltages from the motor
windings. Hall order number defines which hall sensor matches which phase-phase
voltage. Motor phases are usually called R-S-T or U-V-W or A-B-C. Phase-Phase
voltages are called Vrs, Vst, Vtr. Halls are usually called HALL-A, HALL-B, HALL-C or
just Halls 1, 2, 3. A motor’s phase diagram is supplied by motor vendor and usually can
be found in the motor data sheet or by making a request to the motor manufacturer. A
sample phase diagram is illustrated in Figure S912.

S912

The Halls Order is obtained as follows:

1. Look at the “Vrs” Output Voltage and determine the Hall Voltage that is lined
up with (or in phase with) this voltage. To determine which Hall Voltage is in
phase with the Vrs Output Voltage draw vertical lines at those points where
it crosses the horizontal line (zero). The dashed lines at the zero crossings
(above) indicate that Hall B output is lined up with (and in phase with) the Vrs
Output Voltage.
2. Look at the “Vst” Output Voltage. Determine which Hall Voltage is in phase
with this Voltage. Per Figure S912, the Hall C output is in phase with the Vst
Output Voltage.
3. Look at the “Vtr” Output Voltage. Determine which Hall Voltage is in phase
with this Voltage. Per Figure S912, the Hall A output is in phase with the Vtr
Output Voltage.
Note
If hall sensors are in phase with the corresponding phase voltage
but are inverted 180 degrees (hall sensor waveform edge aligns with
the phase-phase voltage waveform but the positive hall sensor cycle
matches the negative phase-phase waveform or visa-versa), you must
check the “Inverted” check box.
4. The phases that correspond to the Vrs, Vst and Vtr voltages are Hall B then
Hall C then Hall A or Halls number 2 then 3 then 1. Referring to the following
table, we find that 2-3-1 sequence is Halls Order number 3. We would then
enter 3 for the Halls Order field in the motor dialog box.

36 S94P01D
 Hall Order Numbers for Different Hall Sequences
Halls Order Hall Sequence
0 1-2-3
1 1-3-2
2 2-1-3
3 2-3-1
4 3-1-2
5 3-2-1

Note
Each Hall Voltage is in phase with one and only one Output Voltage.

B leads A for CW
This is the encoder phase relationship for CW/CCW shaft rotation. When you obtain the
diagram for your motor phasing similar to shown above, it’s assumed by the software
that the motor shaft rotates CW when looking at the mounting face of the motor. For that
rotation Encoder phase A must lead phase B. If it does leave the check box unchecked.
Otherwise (if B leads A), check B leads A in the CW box.

Note
Lenze convention references the shaft direction of rotation from the
front (shaft end) of the motor. Some manufacturer’s timing diagrams
are CW when viewed from the “rear” of the motor.

5.6.3.3 For Resolver Equipped Motors Only

If parameter “Resolver” is checked, following parameters appear on the form:
Offset in degree (electrical )
This parameter represents offset between resolver’s “0 degree” and motor’s windings
“0 degree”.
CW for positive
This parameter sets the direction for positive angle increment.
“Offset in degree” and “CW for positive” will be set during Auto-Phasing of the motor.
5.6.3.4 For Asynchronous Servo Motors Only
Four additional parameters need to be defined for asynchronous motors:
Power Factor Cos Phi (cos f)
The power factor is defined as the ratio of the active (true or real) power to apparent
power. The power factor range is from 0 to1.
Base Frequency in Hz
The motor base frequency defines the output frequency, when operating at rated
voltage, rated current, rated speed, and rated temperature.
Velocity Nominal in RPM
Also called rated velocity or speed, velocity nominal is obtained when the motor is
operated at the base frequency, rated current, rated voltage, and rated temperature.
Velocity Max in RPM
This is the maximum speed of the motor. The maximum velocity is usually limited by
mechanical construction.

S94P01D 37
6 Programmable Features and Parameters
The PositionServo drive is configured through an RS485 or Ethernet interface. The
drive has many programmable features and parameters accessible via a universal
software called MotionView. Refer to the MotionView Manual for details on how to
make a connection to the drive and change parameter values. This chapter covers the
PositionServo’s programmable features and parameters in the order they appear in
the Parameter Tree of MotionView. Programmable parameters are divided into groups.
Each group holds one or more user adjustable parameters.
All drives can execute a User Program in parallel with motion. Motion can be specified
by variety of sources and in three different modes:
• Torque
• Velocity
• Position
In Torque and Velocity mode Reference can be taken from Analog Input AIN1 or from
the User Program by setting a particular variable (digital reference). In Position mode,
the reference could be taken from MA/MB master encoder/step and directions inputs
(available in terminal P3) or from trajectory generator. Access to the trajectory generator
is provided through the User Program’s motion statements, MOVEx and MDV. Refer to
the PositionServo Programming Manual for details on programming.
Whether the reference comes from an external device, (AIN1 or MA/MB ) or from the
drives internal variables (digital reference and trajectory generator) will depend on the
parameter settings. Refer to “Parameters” group in MotionView.

6.1 Parameter Storage and EPM Operation

6.1.1 Parameter Storage
All settable parameters are stored in the drive’s internal non-volatile memory.
Parameters are saved automatically when they are changed. In addition, parameters
are copied to the EPM memory module located on the drive’s front panel. In the unlikely
event of drive failure, the EPM can be removed and inserted into the replacement drive,
thus making an exact copy of the drive being replaced. This shortens down time by
eliminating the configuration procedure. The EPM can also be used for replication of
the drive’s settings.

6.1.2 EPM Operation

When the drive is powered up it first checks for a white EPM in the EPM Port. If the EPM
Port is empty, no further operation is possible until a white EPM is installed into the EPM
Port. The drive will display “-EP-” until an EPM is inserted.
If a different color EPM is inserted the drive may appear to function however, some
operations will not be correct and the drive may hang. The white EPM is the only
acceptable EPM for the PositionServo drive. If a white EPM is detected, the drive
compares data in the EPM to that in its internal memory. In order for the drive to operate,
the contents of the drive’s memory and EPM must be the same. If “FEP?” is displayed
press the enter button to load the EPM’s data to the drive, this will take a moment.

STOP!
If the EPM contains any data from an inverter drive, that data will be
overwritten during this procedure.

38 S94P01D
6.1.3 EPM Fault
If the EPM fails during operation or the EPM is removed from the EPM Port, the drive
will generate a fault and will be disabled (if enabled). The fault is logged to the drives
fault history. Further operation is not possible until the EPM is replaced (inserted) and
the drive’s power is cycled. The fault log on the display shows “F_EP” fault.

6.2 Motor Group

The motor group shows the data for the currently selected motor. Refer to section 5.5
for details on how to select another motor from the motor database or to configure a
custom motor.

6.3 Parameters Group

6.3.1 Drive Operating Modes
The PositionServo has 3 operating mode selections: Torque, Velocity and Position.
For Torque and Velocity modes the drive will accept an analog input voltage on the
AIN1+ and AIN1- pins of P3 (refer to section 5.3.1). This voltage is used to provide a
torque or speed reference.
For Position mode the drive will accept step and direction logic signals or a quadrature
pulse train on pins P3.1- P3.4.
6.3.1.1 Torque Mode
In torque mode, the servo control provides a current output proportional to the
analog input signal at input AIN1, if parameter “Reference” is set to “External”.
Otherwise the reference is taken from the drive’s internal variable. (Refer to the
PositionServo Programming Manual for details)
For analog reference “Set Current”, (current the drive will try to provide), is
calculated using the following formula:
Set Current(A) = Vinput(Volt) X Iscale (A/Volt)
where:
• Vinput is the voltage at analog input
• Iscale is the current scale factor (input sensitivity) set by the Analog input
(Current Scale) parameter (section 6.5.5).
6.3.1.2 Velocity Mode
In velocity mode, the servo controller regulates motor shaft speed (velocity)
proportional to the analog input voltage at input AIN1, if parameter “Reference” is
set to “External”. Otherwise the reference is taken from the drive’s internal variable.
(Refer to the PositionServo Programming Manual for details).
For analog reference, Target speed (set speed) is calculated using the following
formula:
Set Velocity (RPM) = Vinput (Volt) x Vscale (RPM/Volt)
where:
• Vinput is the voltage at analog input (AIN1+ and AIN1-)
• Vscale is the velocity scale factor (input sensitivity) set by the Analog input
(Velocity scale) parameter (section 6.3.6).

S94P01D 39
6.3.1.3 Position Mode
In this mode the drive reference is a pulse-train applied to P3.1-4 terminals, if the
parameter “Reference” is set to “External”. Otherwise the reference is taken from
the drive’s internal variable. (Refer to the PositionServo Programming Manual for
details).
P3.1-4 inputs can be configured for two types of signals: step and direction and
Master encoder quadrature signal. Refer to section 5.2.1 for details on these inputs
connections. Refer to section 8.3 for details about positioning and gearing.
When the Reference is set to Internal, the drives reference position, (theoretical
or Target position), is generated by trajectory generator. Access to the trajectory
generator is provided by motion statements, MOVEx and MDV, from the User
Program. (Refer to the PositionServo Programming Manual for details).

6.3.2 Drive PWM frequency

This parameter sets the PWM carrier frequency. Frequency can be changed only when
the drive is disabled. Maximum overload current is 300% of the drive rated current when
the carrier is set to 8kHz. It is limited to 250% at 16kHz.

6.3.3 Current Limit

The CURRENT LIMIT setting determines the nominal currents, in amps RMS per phase,
which output to the motor phases. To prevent the motor from overloading, this parameter
is usually set equal to the motor nominal (or rated) phase current. If MotionView (6.04)
or higher is used, the Current Limit is set equal to the nominal motor phase current
by default when a motor model is selected. To modify this parameter, refer to section
6.3.23.

6.3.4 Peak Current Limit (8 kHz and 16 kHz)

Peak Current Limit sets the motor RMS phase current that is allowed for up to 2
seconds. After this two second limit, the drive output current to motor will be reduced
to the value set by the Current Limit parameter. When the motor current drops below
nominal current for two seconds, the drive will automatically re-enable the peak current
level. This technique allows for high peak torque on demanding fast moves and fast
start/stop operations with high regulation bandwidth. If 8 kHz is used for Drive PWM
frequency, use the parameter 8 kHz Peak Current Limit, otherwise, use 16 kHz Peak
Current Limit.
If MotionView (6.04) or higher is used, the Peak Current Limit is set equal to 2.5 times
the nominal motor phase current by default when a motor model is selected. To prevent
motor from overloading, the Peak Current Limit shall be set no higher than the maximum
motor current. Otherwise, the motor may be damaged due to overheating. To modify
this parameter, refer to section 6.3.23.

6.3.5 Analog Input Scale (current scale)

This parameter sets the analog input sensitivity for current reference used when the
drive operates in torque mode. Units for this parameter are A/Volt. To calculate this
value use the following formula:
Iscale = Imax / Vin max
Imax maximum desired output current (motor phase current RMS)
Vin max max voltage fed to analog input at Imax
Example: Imax = 5A (phase RMS)
Vin max = 10V
Iscale = Imax / Vin max
= 5A / 10V = 0.5 A / Volt (value to enter)

40 S94P01D
6.3.6 Analog Input Scale (velocity scale)
This parameter sets the analog input sensitivity for the velocity reference used when the
drive operates in velocity mode. Units for this parameter are RPM/Volt. To calculate this
value use the following formula:
Vscale = VELOCITYmax / Vin max
VELOCITYmax maximum desired velocity in RPM
Vin max max voltage fed to analog input at Velocitymax
Example: VELOCITYmax = 2000 RPM
Vin max = 10V
Vscale = VELOCITYmax / Vin max
= 2000 / 10V
= 200 RPM / Volt (value to enter)

6.3.7 ACCEL/DECEL Limits (velocity mode only)

The ACCEL setting determines the time the motor takes to ramp to a higher speed.
The DECEL setting determines the time the motor takes to ramp to a lower speed. If
the ENABLE ACCEL/DECEL LIMITS is set to DISABLE, the drive will automatically
accelerate and decelerate at maximum acceleration limited only by the current limit
established by the PEAK CURRENT LIMIT and CURRENT LIMIT settings.

6.3.8 Reference
The REFERENCE setting selects the reference signal being used by the drive. This
reference signal can be either External or Internal. An External Reference can be one
of three types, an Analog Input signal, a Step and Direction Input or an Input from a
external Master Encoder. The Analog Input reference is used when the drive is either
in torque or velocity mode. The Master Encoder and Step and Direction reference is
used when the drive is in position mode. An Internal Reference is used when the motion
being generated is derived from drive’s internal variable(s), i.e., User Program, (Refer
to the PositionServo Programming Manual).

6.3.9 Step Input Type (position mode only)

This parameter sets the type of input for position reference the drive expects to see.
Signal type can be step and direction (S/D) type or quadrature pulse-train (Master
Encoder / Electronic Gearing). Refer to section 5.2.1 for details on these inputs.

6.3.10 Fault Reset Option

The FAULT RESET OPTION selects the type of action required to reset the drive after
a FAULT signal has been generated by the drive. ON DISABLE clears the fault when
the drive is disabled. This is useful if you have a single drive and motor connected
in a single drive system. The ON ENABLE option clears the fault when the drive is
re-enabled. Choose ON ENABLE if you have a complex servo system with multiple
drives connected to an external controller. This makes troubleshooting easier since the
fault will not be reset until the drive is re-enabled. Thus, a technician can more easily
determine which component of a complex servo system has caused the fault.

6.3.11 Motor Temperature Sensor

This parameter enables / disables motor over-temperature detection. It must be disabled
if the motor PTC sensor is not wired to either P7.1-2 or to the resolver option module
(P11).

S94P01D 41
6.3.12 Motor PTC Cut-off Resistance
This parameter sets the cut-off resistance of the PTC which defines when the motor
reaches the maximum allowable temperature. See section 5.5.2 for details how to
connect motor’s PTC.

6.3.13 Second Encoder

Disables or enables second encoder. Effectively selects single-loop or double-loop
configuration in position mode. The second encoder connects to the Encoder Option
Module (E94ZAENC1) connector P12, refer to section 8.4 for details on dual loop
operation.

6.3.14 Regeneration Duty Cycle

This parameter sets the maximum duty cycle for the brake (regeneration) resistor. This
parameter can be used to prevent brake resistor overload. Use the following formula
to calculate the maximum value for this parameter. If this parameter is set equal to
the calculated value, the regeneration resistor is most effective without overload. One
may set this parameter with a value smaller than the calculated one if the drive will not
experience over voltage fault during regeneration.
D = P * R / (Umax)2 * (1/Dapplication) * 100%
Where:
D (%) regeneration duty cycle
Umax (VDC) bus voltage at regeneration conditions
Umax = 390 VDC for 120/240 VAC drives and 770 VDC for
400/480 VAC drives.
R (Ohm) regeneration resistor value
P (W) regeneration resistor rated power
Dapplication (%) application duty cycle. For the continuous regeneration applications,
use Dapplication = 1. For the intermittent regeneration applications,
use Dapplication = t/T, where t is the duration when regeneration is
needed and T is the time interval between two regenerations.
Both t and T must use the same time unit, e.g., seconds
t, regeneration

T-t, regeneration
is not needed

Note
If calculation of D is greater than 100% set it to 100% value. If calculation
of D is less than 10% then resistor power rating is too low. Refer to
section 5.1.6 for details on braking resistor selection.

6.3.15 Encoder Repeat Source

This parameter sets the feedback source signal for the buffered encoder outputs (P3.7
-P3.12). The source can be the drive’s feedback input (P4) or an optional feedback
module (resolver, second encoder etc.)

42 S94P01D
6.3.16 System to Master Ratio
This parameter is used to set the scale between the reference pulse train (when operating
in position mode) and the system feedback device. In a single loop configuration, the
system feedback device is the motor encoder or resolver. In a dual-loop system the
system encoder is the second encoder. See sections 8.3 and 8.4 for details.

6.3.17 Second to Prime Encoder Ratio

This parameter sets the ratio between the secondary encoder and the primary feedback
device when the drive is configured to operate in dual-loop mode. When the primary
feedback device is a resolver, the pulse count is fixed at 65,536. The resolutions of
encoders are “post quadrature” (PPR x 4). See section 8.4

Note
Post quadrature pulse count is four times the pulses-per-revolution
(PPR) of the encoder.

6.3.18 Autoboot
When set to “Enabled” the drive will start to execute the user’s program immediately
after cold boot (reset). Otherwise the user program has to be started from MotionView
or from the Host interface.

6.3.19 Group ID
Refer to the PositionServo Programming Manual for details. This parameter is only
needed for operations over Ethernet network.

6.3.20 Enable Switch Function

If set to “Run”, input IN_A3 (P3.29) acts as an “Enable” input when the user program
is not executing. If the user program is executing, the function will always be “Inhibit”
regardless of the setting. This parameter is needed so the drive can be Enabled/
Disabled without running a user’s program.

6.3.21 User Units

This parameter sets up the relationship between User Units and motor revolutions.
From here you can determine how many User Units there is in one motor revolution.
This parameter allows the user to scale motion moves to represent a desired unit of
measure, (inches, meters, in/sec, meters/sec, etc).
For example:
A linear actuator allows a displacement of 2.5” with every revolution of the motor’s
shaft.
User Units = Revolutions / Unit
User Units = 1 Revolutions / 2.5 Inches
User Units = 1 / 2.5 Revolutions / inch
User Units = 0.4 Revolutions / inch

S94P01D 43
6.3.22 Resolver Track
The Resolver Track parameter is used in conjunction with the resolver motors and
Buffered Encoder Outputs, (Ref Section 5.2.2). If a motor with resolver feedback is being
used a simulated encoder feedback is transmitted out the Buffered Encoder Outputs,
P3.7 to P3.12. The default resolution of this feedback is 1024 pulses per revolution, pre
quad. If a different resolution is required then the Resolver Track parameter is utilized.
The number entered into this field, 0-15, directly correlates to a different encoder
resolution. Please reference the table below.
Resolver Track Configuration

Resolver Resolution Resolver Resolution

Track Before Quad Track Before Quad
0 1024 8 1000
1 256 9 1024
2 360 10 2000
3 400 11 2048
4 500 12 2500
5 512 13 2880
6 720 14 250
7 800 15 4096
6.3.23 Current Limit Max Overwrite
If this parameter is set to “Disable”, the parameters “Current limit”, “8 kHz peak current
limit” and “16 kHz peak current limit” cannot be overwritten. If you want to overwrite
the above three current limit parameters, this parameter must be set as “Enable”. To
prevent the motor from overloading, the “current Limit”, “8 kHz peak current limit” and
“16 kHz peak current limit” shall be set to values no higher than the corresponding
current limits of the motor in use. Note that this parameter applies to firmware version
(3.06) or higher.

6.4 Communication
6.4.1 Ethernet Interface
Programming and diagnostics of the PositionServo drive are done over the standard
10/100 Mbps Ethernet communication port. All devices on an Ethernet network have an
IP address. Before connecting MotionView software to the PositionServo drive, set up
the IP address of the drive and configure the PC as well.
The IP address of the PositionServo drive is composed of four sub-octets that are
separated by three dots. This conforms to the Class C Subnet structure. The sub-octets
IP_1, IP_2, IP_3 and IP_4 can be found by using “UP” and “DOWN” buttons of the LED
panel and are organized in the following order:
IP_1.IP_2.IP_3.IP_4
where each sub-octet IP_x can be any number between 1-254. On the LED display,
only IP_4 can be changed. IP_1, IP_2 and IP_3 can be changed once the PositionServo
drive is connected to the MotionView software. As shipped from the factory the default
IP address is 192.168.124.120.
If using the default PC Ethernet port on your computer for internal use (email, web
browsing, etc,) AC Tech recommends that you add an additional Ethernet port to
your PC. The most common and cost effective way to do this is by using a USB /
Ethernet dongle or a PCMCIA Ethernet card. Then configure this Ethernet port to the
PositionServo Subnet address and leave your local connection for your internal use.

44 S94P01D
There are two modes to obtain the IP address of the PositionServo drive by setting
DHCP equal to either 0 or 1. These modes are described herein. It is important to know
that the drive must be rebooted after changing any Ethernet settings such as IP address
and DHCP.

6.4.1.1 Manually Obtain the PositionServo Drive’s IP Address

The PositionServo drive can be connected to a local PC or a private network if
setting DHCP=0. In this mode, make sure to set DHCP = 0 via the diagnostic
display LED, refer to section 7.1 for details. One can also verify the IP address
of the drive via the display LED. When shipped from the factory the default IP
address of the PositionServo drive is 192.168.124.120. Before MotionView can
establish communications to the drive, both the PC and the PositionServo drive
must be on the same subnet, but have different addresses. That is, both the PC
and PositionServo drive shall have the same sub-octects IP_1, IP_2 and IP_3 and
different IP_4. When connecting MotionView to a brand-new PositionServo drive
out of box, set the PC’s IP address as 192.168.124.1. Refer to section 6.4.1.3 on
how to set up your PC IP address. Every time dHCP, or any IP sub-octect IP_x
is changed, one must reboot the PositionServo drive so that the change can take
effect.
Once the MotionView software is connected to the PositionServo drive, one can
change the DHCP setting and the drive IP address via the communication option
“Ethernet” – “IP setup” in MotionView. If one wants to configure the PositionServo
drive’s IP address under a specific subnet, for example, 10.135.110.xxx as shown
below. One can pick an available IP_4, e.g., 246 is used below, then click “OK” to
confirm. After this change, make sure to reboot the drive. After the drive reboot, the
IP address stored in the EPM before last power-off will be the drive’s IP address. In
the meantime, one needs to configure the PC’s IP address under the same subnet.
In case, one may choose “Obtain an IP Address Automatically” for the PC or pick
up an available IP address, refer to section 6.4.1.3 for details.

6.4.1.2 Automatically Obtain the PositionServo’s IP Address

To use this mode set dHCP = 1 via the diagnostic display LED (refer to section 7.1
for details). After setting this parameter, cycle the input power to the PositionServo
drive so that the setting can take effect. The LED display will be “----“ if one checks
the IP address octets IP_1, IP_2, IP_3 and IP_4. This means that the drive is still
trying to acquire an IP address from the dHCP server. To obtain the PositionServo
drive’s IP address automatically, there must be a dHCP server available.

S94P01D 45
6.4.1.3 Set the PC’s IP Address
Follow these steps to set up the PC’s IP address:
To display the IP address of your PC, from the Start menu, select “Control Panel”
and then select “Network Connections”.

Select the connection you wish to set: “Local Area Connection”, the PC Default
Port or “Local Area Connection x” your additional Ethernet port. Then double-click
the icon to open the [Connection Status] details. To view the connection properties
click the [Properties] button.

Select [Internet Protocol (TCP/IP)] and click the [Properties] button.

46 S94P01D
 Select “Use the following IP address” and enter [192.168.124.1] for the IP address.
Now enter the subnet mask [255.255.255.0], and then click the [OK] button. Note
that one can use “Obtain an IP address automatically” after the PositionServo
drive’s IP address has been configured under the same subnet to which the PC
is connected.

6.4.2 RS-485 Configuration

This parameter sets how the optional RS485 interface will function. The RS485 interface
can be configured for normal operation (programming and diagnostics using MotionView
software) or as a Modbus RTU slave. See section 5.4 for details on communication
interfaces.

6.4.3 Modbus Baud Rate

This parameter sets the baud rate for RS485 interface in Modbus RTU mode. When
the drive is operating in normal mode the baud rate is set to the same setting as the
RS232 interface.

6.4.4 Modbus Reply Delay

This parameter sets the time delay between the drives reply to the Modbus RTU master.
This delay is needed for some types of Modbus masters to function correctly.

S94P01D 47
6.5 Analog I/O Group
6.5.1 Analog Output
The PositionServo has one analog output with 10-bit resolution on P3 pin 23. The signal
is scaled to ±10V. The analog output can be assigned to following functions:
• Not Assigned
• Phase current RMS
• Phase current Peak
• Motor Velocity
• Phase U current
• Phase V current
• Phase W current
• Iq current (Torque component)
• Id current (Direct component)
6.5.2 Analog Output Current Scale (Volt / amps)
Applies scaling to all functions representing CURRENT values.

6.5.3 Analog Output Current Scale (mV/RPM)

Applies scaling to all functions representing VELOCITY values. (Note: that mV/RPM
scaling units are numerically equivalent to volts/kRPM)

6.5.4 Analog Input Dead Band

Allows the setting of a voltage window (in mV) at the reference input AIN1+ and AIN1-
(P3 pins 24 and 25) such that any voltage within that window will be treated as zero
volts. This is useful if the analog input voltage drifts resulting in motor rotation when
commanded to zero.

6.5.5 Analog Input Offset Parameter

Allows you to adjust the offset voltage at AIN1+ and AIN1- (P3 pins 24 and 25). This
function is equivalent to the balance trim potentiometer found in analog drives. Lenze
recommends that this adjustment be made automatically using the “Adjust analog voltage
offset” button while the external analog reference signal commands zero speed.

6.5.6 Adjust Analog Voltage Offset

This control button is useful to allow the drive to automatically adjust the analog input
voltage offset. To use it, command the external reference source input at AIN1+ and
AIN1- (P3 pins 24 and 25) to zero volts and then click this button. Any offset voltage
at the analog input will be adjusted out and the adjustment value will be stored in the
“Analog input offset” parameter.

48 S94P01D
6.6 Digital I/O
The PositionServo has four digital outputs. These outputs can be either assigned to one
of the following functions, or be used by the drives internal User Program
• Not Assigned No special function assigned. Output can be used by the User
Program.
• Zero Speed Output activated when drive is at zero speed, refer to “Velocity
Limits Group” (section 6.7) for settings.
• In Speed Window Output activated when drive is in set speed window, refer to
“Velocity Limits Group” (section 6.7) for settings.
• Current Limit Output activated when drive detects current limit.
• Run Time Fault A fault has occurred. Refer to section 7.3 for details on faults.
• Ready Drive is enabled.
• Brake Command for the holding brake option (E94ZAHBK2) for
control of a motor with a holding brake. This output is active
10ms after the drive is enabled and deactivates 10ms before
the drive is disabled.
• In position Position mode only. Refer to the PositionServo Programming
Manual for details
6.6.1 Digital Input De-bounce Time
Sets de-bounce time for the digital inputs to compensate for bouncing of the switch or
relay contacts. This is the time during an input transition that the signal must be stable
before it is recognized by the drive.

6.6.2 Hard Limit Switch Action

Digital inputs IN_A1 and IN_A2 can be used as limit switches if their function is set
to “Fault” or “Stop and Fault”. Activation of these inputs while the drive is enabled
will cause the drive to Disable and go to a Fault state. The “Stop and Fault” action is
available only in Position mode when the “Reference” parameter is set to “Internal”, i.e.,
when the source for the motion is the Trajectory generator. Refer to the PositionServo
Programming Manual for details on “Stop and Fault” behavior.

6.7 Velocity Limits Group

These parameters are active in Velocity Mode Only.

6.7.1 Zero Speed

Specifies the upper threshold for motor zero speed in RPM. When the motor shaft
speed is at or below the specified value the zero speed condition is set to true in the
internal controller logic. The zero speed condition can also trigger a programmable
digital output, if selected.

6.7.2 Speed Window

Specifies the speed window width used with the “In speed window” output.

6.7.3 At Speed
Specifies the speed window center used with the “In speed window” output.
These last two parameters specify speed limits. If motor shaft speed is within these
limits then the condition AT SPEED is set to TRUE in the internal controller logic. The
AT SPEED condition can also trigger a programmable digital output, if selected.
For example if “AT SPEED” is set for 1000 RPM, and the “SPEED WINDOW” is set for
100, then “AT SPEED” will be true when the motor velocity is between 950 -1050 RPM.

S94P01D 49
6.8 Position Limits
6.8.1 Position Error
Specifies the maximum allowable position error in the primary (motor mounted)
feedback device before enabling the “Max error time” clock (described next). When
using an encoder, the position error is in post-quadrature encoder counts. When using
a resolver, position error is measured at a fixed resolution of 65,536 counts per motor
revolution.

6.8.2 Max Error Time

Specifies maximum allowable time (in mS) during which a position error can exceed
the value set for the “Position error” parameter before a Position Error Excess fault is
generated.

6.8.3 Second Encoder Position Error

Specifies the maximum allowable error of the second encoder in post quadrature
encoder counts before enabling the “Second encoder max error time” clock (described
next).

6.8.4 Second Encoder Max Error Time

Specifies maximum allowable time (in mS) during which the second encoder’s position
error can exceed the value set for the “Second encoder position error” parameter before
a Position Error Excess fault is generated.

6.9 Compensation Group

6.9.1 Velocity P-gain (proportional)
Proportional gain adjusts the system’s overall response to a velocity error. The velocity
error is the difference between the commanded velocity of a motor shaft and the actual
shaft velocity as measured by the primary feedback device. By adjusting the proportional
gain, the bandwidth of the drive is more closely matched to the bandwidth of the control
signal, ensuring more precise response of the servo loop to the input signal.

6.9.2 Velocity I-gain (integral)

The output of the velocity integral gain compensator is proportional to the accumulative
error over cycle time, with I-gain controlling how fast the error accumulates. Integral
gain also increases the overall loop gain at the lower frequencies, minimizing total error.
Thus, its greatest effect is on a system running at low speed, or in a steady state without
rapid or frequent changes in velocity.

Note
The following four position gain settings are only active if the drive is
operating in Position mode. They have no effect in Velocity or Torque
modes.

6.9.3 Position P-gain (proportional)

Position P-gain adjusts the system’s overall response to position error. Position error is
the difference between the commanded position of the motor shaft and the actual shaft
position. By adjusting the proportional gain, the bandwidth of the drive is more closely
matched to the bandwidth of the control signal, ensuring more precise response of the
servo loop to the input signal.

50 S94P01D
6.9.4 Position I-gain (integral)
The output of the Position I-gain compensator is proportional to accumulative error over
cycle time, with I-gain controlling how fast the error accumulates. Integral gain also
increases overall loop gain at the lower frequencies, minimizing total error. Thus, its
greatest effect is on a system running at low speed, or in a steady state without rapid or
frequent changes in position.

6.9.5 Position D-gain (differential)

The output of the Position D-gain compensator is proportional to the difference between
the current position error and the position error measured in the previous servo cycle. D-
gain decreases the bandwidth and increases the overall system stability. It is responsible
for removing oscillations caused by load inertia and acts similar to a shock-absorber in
a car.

6.9.6 Position I-limit

The Position I-limit will clamp the Position I-gain compensator to prevent excessive
torque overshooting caused by an over accumulation of the I-gain. It is defined in terms
of percent of maximum drive velocity. This is especially helpful when position error is
integrated over a long period of time.

6.9.7 Gain Scaling Window

Sets the total velocity loop gain multiplier (2n) where n is the velocity regulation window.
If, during motor tuning, the velocity gains become too small or too large, this parameter
is used to adjust loop sensitivity. If the velocity gains are too small, decrease the total
loop gain value, by deceasing this parameter. If gains are at their maximum setting and
you need to increase them even more, use a larger value for this parameter.

6.10 Tools Group

6.10.1 Oscilloscope Tool
The oscilloscope tool gives real time representation of different signals inside the
PositionServo drive and is helpful when debugging and tuning drives. Operation of
the oscilloscope tool is described in greater detail in the MotionView User’s Manual
(IM94MV01). The following signals can be observed with the oscilloscope tool:
Phase Current (RMS): Motor phase current
Phase Current (Peak): Motor peak current
Iq Current: Measures the motor Iq (torque producing) current
Motor Velocity: Actual motor speed in RPM
Commanded Velocity: Desired motor speed in RPM (velocity mode only)
Velocity Error: Difference in RPM between actual and commanded
motor speed
Position Error: Difference between actual and commanded position
(Step & Direction mode only)
Bus voltage: DC bus voltage
Analog input: Voltage at drive’s analog input
Absolute position: Absolute position (actual position)
Target position: Requested position
6.10.2 Run Panels
Check Phasing
This button activates the Autophasing feature as described in section 5.6.2. However, in
this panel only the motor phasing is checked, the motor data is not modified.

S94P01D 51
6.11 Faults Group
Faults Group loads the fault history from the drive. The 8 most recent faults are displayed
with the newer faults replacing the older faults in a first-in, first-out manner. In all cases
fault # 0 is the most recent fault. To clear the faults history from the drive’s memory click
on the “Reset Fault history” button. Each fault has its code and explanation of the fault.
Refer to section 7.3 for details on faults.

52 S94P01D
7 Display and Diagnostics
7.1 Diagnostic Display
The PositionServo drives are equipped with a diagnostic LED display and 3 push
buttons to select displayed information and to edit a limited set of parameter values.
Parameters can be scrolled by using the “UP” and “DOWN” ( ) buttons. To view
a value, press “Enter”( ). To return back to scroll mode press “Enter” again. After
pressing the ”Enter” button on editable parameters, the yellow LED “C” (see figure in
the next section) will blink indicating that parameter value can be changed. Use “UP”
and “DOWN” buttons to change the value. Press “Enter” to store new setting and return
back to scroll mode.

Display Description
StAt current drive status - to view:
run - drive running
diS - drive disabled
F_XX - drive fault. Where XX is the fault code (section 7.3.2)

Hx.xx Hardware revision (e.g. H2.00)

Fx.xx Firmware revision (e.g. F2.06)

bAUd RS232/RS485(normal mode) baud rate - to set

selects from 2400 to 115200 baudrates

Adr Drive’s address - to set

sets 0 - 31 drive’s address

FLtS Stored fault’s history - to view

scroll through stored faults F0XX - F7XX, “XX” is the fault code (section 7.3.2)

Ht Heatsink temperature - to view

Shows heatsink temperature in ºC if greater than 40ºC. Otherwise shows “LO” (low).

EnC Encoder activity - to view

Shows primary encoder counts for encoder diagnostics activity

HALL Displays motor’s hall sensor states - to view

Shows motor hall states in form XXX , where X is 1 or 0 - sensor logic states.

boot 0 = Autoboot disabled 1 = Autoboot enabled (Feature available in FW 3.50 or higher)

buS Displays drive DC bus voltage - to view

Shows DC bus voltage value

Curr Displays motor’s phase current (RMS)

Shows current value if drive is enabled, otherwise shows “DiS”

CAnb CAN Baudrate

CAnA CAN Address

CAno CAN Operational Mode

CAnd CAN Delay

CAnE CAN Enable/disable

dHCP Ehternet DHCP Configuration: 0=”dHCP” is disabled; 1=”dHCP is enabled.

IP_4 IP Adress Octet 4

IP_3 IP Adress Octet 3

IP_2 IP Adress Octet 2

IP_1 IP Adress Octet 1

S94P01D 53
7.2 Diagnostic LEDs
The PositionServo has five diagnostic LEDs located around the periphery of the front
panel display as shown in the drawing below. These LEDs are designed to help monitor
system status and activity as well as troubleshoot any faults.

S913

LED Function Description

A Enable Orange LED indicates that the drive is ENABLED (running).
B Regen Yellow LED indicates the drive is in regeneration mode.
C Data Entry Yellow LED will flash when changing.
D Comm Fault Red LED illuminates upon a communication fault. (in CANbus only)
E Comm Activity Green LED flashes to indicate communication activity.

7.3 Faults
7.3.1 Fault Codes
Listen herein are fault codes caused mostly by hardware operations. Refer to the
PositionServo Programming Manual for additional fault codes related to programming.

Fault
Code Fault Description
Drive bus voltage reached the maximum level, typically due to
F_OU Over voltage
motor regeneration
Resolver signal lost or at least one motor hall sensor is inoperable
F_FB Feedback error
or not connected.
Drive exceeded peak current limit. Software un-capable to
F_OC Over current regulate current within 15% for more then 20mS. Usually results
in wrong motor data or poor tuning.
F_Ot Over temperature Drive heatsink temperature has reached maximum rating.
EN954-1 Safety The drive is disabled by the EN954-1 Safety Function.
F_EF
Function (applicable only to drives with the EN954 safety circuit option)
F_OS Over speed Motor has reached velocity above its specified limit
F_PE Excess position error Position error has exceeded maximum value.
F_bd Bad motor data Motor profile data invalid or no motor is selected
F_EP EPM failure EPM fails on power up
EP- EPM missing EPM not recognized (connected) on power up
Optional motor temperature sensor (PTC) indicates that the motor
F_09 Motor over temperature
windings have reached maximum temperature
Error in data exchange between processors. Usually occurs when
F_10 Subprocessor failure
EMI level is high due to poor shielding and grounding.
Occurs when the bus voltage level drops below 50% of nominal
F_14 Undervoltage bus voltage while drive is operating. An attempt to enable the
drive with low bus voltage will also result in this fault.
Hardware overload Occurs when the phase current becomes higher than 400% of
F_15
protection total drive’s current capability for more then 5uS.
F_32 Positive Limit Switch Positive limit switch is activated
F_33 Negative Limit Switch Negative limit switch is activated
The drive is disabled while operating or an attempt is made to
Drive Disabled by
F_36 enable the drive without deactivating “Inhibit input”. “Inhibit” input
User at Enable Input
has reverse polarity.

54 S94P01D
7.3.2 Fault Event
When drive encounters any fault, the following events occur:
• Drive is disabled
• Internal status is set to “Fault”
• Fault number is logged in the drive’s internal memory for later interrogation
• Digital output(s), if configured for “Run Time Fault”, are asserted
• Digital output(s), if configured for READY, are de asserted
• If the display is in the default status mode, the LEDs display F_XX where XX is
current fault code.
• “Enable” LED turns OFF
7.3.3 Fault Reset
Fault reset is accomplished by disabling or re-enabling the drive depending on the
setting of the “Reset option” parameter (section 6.3.10).

8 Operation
This section offers guidance on configuring the PositionServo drive for operations in
torque, velocity or position modes without requiring a user program. To use advanced
programming features of PositionServo please perform all steps below and then refer to
the PositionServo Programming Manual for details on how to write motion programs.

8.1 Minimum Connections

For the most basic operation, connect the PositionServo to mains (line) power at
terminal P1, the servomotor power at P7 and the motor feedback as appropriate.

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 at least 60 seconds before servicing drive.
Capacitors retain charge after power is removed.

As a minimum these connections must be made:

• Connect an Ethernet crossover cable between PositionServo’s P2 and your
PC’s Ethernet port. A straight patch cable can be used if using a hub or switch.
• Connect mains power to terminal P1. Mains power must be as defined on the
drive’s data label (see section 2.1).
• When connecting to an encoder-based drive, take the encoder feedback cable
and connect it to the15 pin D-sub connector located at P4. When connecting to
a resolver-based drive, take the resolver feedback cable and connect it to the
9 pin D-sub connector located at P4.
• Connect motor windings U, V, W (sometimes called R, S, T) to terminal P7
according to Section 5.1.1. Make sure that motor cable shield is connected as
described in section 4.2.
• Provide an Enable switch according to Section 8.5.
• Perform drive configuration as described in the next section.

Note
When using an encoder-based drive and operating with a resolver
option module as the primary feedback, a second encoder can be
connected to P4.

S94P01D 55
8.2 Configuration of the PositionServo
Regardless of the mode in which you wish to operate, you must first configure the
PositionServo for your particular motor, mode of operation, and additional features if
used.
Drive configuration consists of following steps:
• Motor Selection
• Mode of operation selection
• Reference source selection (Very Important)
• Drive parameters (i.e. current limit, acceleration / deceleration) setup
• Operational limits (velocity or position limits) setup
• Input / Output (I/O) setup
• Velocity / position compensator (gains) setup
• Optionally store drive settings in a PC file and exit the MotionView program.
To configure drive:
1. Ensure that the control is properly installed and mounted. Refer to section 4
for installation instructions.
2. Perform wiring to the motor and external equipment suitable for desired
operating mode and your system requirements.
3. Connect the Ethernet port P2 on the drive to your PC Ethernet port. If
connecting directly to the drive from the PC, a crossover cable is required.
4. Make sure that the drive is disabled.
5. Apply power to the drive and wait until “diS” shows on the display. For
anything other than this, refer to the chart below before proceeding.
Drive Display Meaning
-EP- EPM missing. Refer to 6.1.2
EPM EPM data. Refer to 6.1.2
---- No valid firmware
----
Monitor mode

6. Confirm that the PC and the drive have the correct IP setting. Refer to
section 6.4.1.1 - Setting Your PC IP Address.
7. Launch MotionView software on your computer.
8. From the MotionView menu, select <Project> <Connection setup>.
9. Select “Ethernet UDP”, then click the OK button.
10. From the MotionView menu, select <Node> <Connect Drive>.
11. Click the Discover button to ping the network for any drives. If a drive
is located the address will appear on the screen. If no address appears
then you can type the IP address in. The default address for the drive is
192.168.124.120. Click the Connect button to connect to the drive.
12. Once MotionView connects to the drive, its node icon will appear in the upper
left-hand corner of the Parameter Tree Window. Refer to the PositionServo
Programming Manual for more details.
Note
MotionView’s “Connection setup” properties need only be
configured the first time MotionView is operated or if the port
connection is changed. Refer to MotionView User’s Manual
for details on how to make a connection to the drive.
13. Double-click on the drive’s icon to expand parameter group’s folders.
14. Select the motor to be used according to the section 5.5.
15. Expand the folder “Parameters” and choose the operating mode for the drive.
Refer to section 6.3.1 for details on operating modes.

56 S94P01D
 16. Click on the “Current limit” parameter, refer to section 6.3.3 and enter current
limit (in Amp RMS per phase) appropriate for the motor.
17. Click on the appropriate “Peak current limit” parameter, refer to section 6.3.4,
based on the “Drive PWM frequency” parameter, refer to section 6.3.2, used
and enter the peak current limit (in Amps RMS per phase) appropriate for
your motor.
18. Set up additional parameters suitable for the operating mode selected in step 17.
19. After you configure the drive, proceed to the tuning procedure if operating
in “Velocity”, or “Position” mode. “Torque” mode doesn’t require additional
tuning or calibration. Refer to section 8.6 for details on tuning.

8.3 Position Mode Operation (gearing)

In position mode the drive will follow the master reference signals at the 1-4 inputs of
P3. The distance the motor shaft rotates per each master pulse is established by the
ratio of the master signal pulses to motor encoder pulses (in single loop configuration).
The ratio is set by “System to Master ratio” parameter (see section 6.3.16).
Example 1.
Problem: Setup the drive to follow a master encoder output where 1 revolution of
the master encoder results in 1 revolution of the motor
Given: Master encoder: 4000 pulses / revolution (post quadrature)
Motor encoder: 8000 pulses / revolution (post quadrature)
Solution: Ratio of System (motor encoder) to Master Encoder is 8000/4000 = 2/1
Set parameter “System to master ratio” to 2:1
Example 2
Problem: Setup drive so motor can follow a master encoder wheel where 1
revolution of the master encoder results in 3 revolutions of the motor
Given: Motor encoder: 4000 pulses / revolution (post quadrature)
Master encoder: 1000 pulses / revolution (post quadrature).
Desired “gear ratio” is 3:1
Solution: Ratio is motor encoder PPR divided by master encoder PPR times the
“gear ratio”:
(Motor PPR / Master PPR)*(3/1) => (4000/1000)*(3/1) => 12/1
Set parameter “System to master ratio” to 12:1

8.4 Dual-loop Feedback

In dual-loop operation (position mode only) the relationship between the Master input
and mechanical system movement requires that two parameters be set:
1. “System to master ratio” sets the ratio between the second encoder pulses (system
encoder) and the master input pulses.
2. “Prime to second encoder ratio” sets the ratio between the second and primary
(motor) encoder. If the motor is equipped with a resolver connected to the resolver
option module, the primary encoder resolution of 65536 (post quadrature) must
be used.
When operating in this mode the second encoder input is applied to integral portion of
the position compensator. Therefore it is important that the Position I-gain and Position
I-limit parameters are set to non 0 values. Always start from very small values of Position
I-limit values.

S94P01D 57
 Note
When using an encoder-based drive and operating with the Resolver
Option Module as the primary feedback, a second encoder can be
connected to P4.

8.5 Enabling the PositionServo

Regardless of the selected operating mode, the PositionServo must be enabled before
it can operate. A voltage in the range of 5-24 VDC connected between P3 pins 26 and
29 (input IN_A3) is used to enable the drive, refer to section 5.1.7, note 3. There is a
difference in the behavior of input IN_A3 depending on how the “Enable switch function”
is set.
When the “Enable switch function” is set to “RUN”:
IN_A3 acts as positive logic ENABLE or negative logic INHIBIT input depending on:
If user program is not running: Activating IN_A3 enables the drive
User program running: Activating IN_A3 acts as negative logic
“Inhibit” and operates exactly as if parameter
“Enable switch function” set to “Inhibit” (see below)
When the “Enable switch function’ set to “Inhibit”:
IN_A3 acts as negative logic INHIBIT input regardless of mode or program status.
Activating input IN_A3 doesn’t enables the drive. The drive can be enabled from the
user’s program or interface only when IN_A3 is active. Attempt to enable drive by
executing the program statement “ENABLE” or from interface will cause the drive to
generate a fault, F_36. Regardless of the mode of operation, if the input is deactivated
while the drive is enabled, the drive will be disabled and will generate a fault, F_36.

WARNING!
Enabling the servo drive allows the motor to operate depending on
the reference command. The operator must ensure that the motor and
machine are safe to operate prior to enabling the drive and that moving
elements are appropriately guarded.
Failure to comply could result in damage to equipment and/or injury to
personnel!

8.6 Tuning in Velocity Mode

Whether the application requires velocity mode or position mode, the drive has to be
tuned in velocity mode. If the application only requires velocity mode then position
tuning is not required.
1. Make sure that power is applied to the drive and that the drive is connected
to a PC running MotionView software
2. Make sure that the drive is disabled.
3. Select the “Parameters” folder from the node tree. Click on “Reference”
parameter and change it to “Internal”. This will tell drive to use the internally
generated reference.
4. Make sure that “Enable Accel/Decel limits” is set to “Disable”.
5. From the node tree, select “Indexer program”. The drives current program
will appear in the View Window. Click anywhere in the View Window to
activate the tool bar. From the MotionView menu select <Indexer>, <Import
program from file>. Navigate to the following folder MotionView6.xx/Help/
940Examples. Select the TuneV program and click Open. Click on the
compile and download button on the toolbar to load the program to the drive.

58 S94P01D
 6. Select “Oscilloscope” tool from the node tree to engage the oscilloscope.
Check the “Always on top” box, so that the MotionView main window does
not cover the oscilloscope tool.
7. On the Scope tool select:
• Channel 1: “Motor Velocity”
• Scale: 100 Rpm/Volt
• Channel 2: “Phase Current (RMS)”
• Scale: Motor peak current parameter / 3
• Timebase: 50mS
• Trigger: Channel 1, Rising
• Trigger level: 100 Rpm
(Choose closest integer value: if 10A/3=3.33(3) choose 3A)
8. Select “Compensation” from the Node tree. As a starting point, set “Gain
Setting” to “-2” if the motor is equipped with an encoder. If the motor is
equipped with a resolver, set this to “-4”. Refer to section 6.9.8 for more
details.
9. Set the Velocity P-gain to 5000 and the Velocity I-gain to 20.
10. Apply voltage to IN_A3 input and press F5 on the keyboard. Alternatively you
can use menu “Indexer” -> “Run” or use button on the toolbar.
11. If the motor vibrates uncontrollably, disable the drive, rest P-Gain to 1000,
and re-enable the drive.
12. Slowly increase the “Velocity P-gain” and observe the motor velocity
waveform. Increasing the P-gain should increase the angle of the
acceleration edge of the wave form. Continue increasing the P-gain to get
the leading edge of the wave form as vertical as possible and stop once
you start to get a slight overshoot. The current wave form should be spiking
during the acceleration segment of the move. Continue to increase the P-gain
until instability starts to appear in the waveform.

S949

Stop increasing the gain once you see oscillation appearing on either the
current waveform or velocity waveform flat portion. Then lower the P-gain
until the oscillation disappears

S94P01D 59

S951

13. Slowly increase the “Velocity I-gain” and watch for an overshoot on the motor
velocity waveform. Stop increasing the setting when overshoot just starts to
occur or is very narrow. The setting should be less then 5mS or less then
3-5%, if a steep acceleration/deceleration is desired in your servo system. If
stiffness at low velocity or stall torque is desired then the “Velocity I-gain” can
be increased allowing step overshoot up to approximately 15-30%.
14. Check the motor Iq current. Set the oscilloscope Ch1 source to Iq current.
Observe the current waveform to ensure there is no significant oscillation.
15. Click “Indexer” -> “Stop” or alternatively Alt+F5 on the keyboard to stop the
program. Remove voltage from IN_A3 input.
16. Depending on the application you may want to set parameters “Reference”
and “Enable switch function” to appropriate values. Refer to section 6 for
details.

8.7 Tuning in Position Mode

For an application in position mode, it is required to tune the drive in velocity mode and
then in position mode.
1. Perform velocity loop tuning as per section 8.6. Select I-Gain value for
minimum overshoot.
2. Make sure that the drive is disabled.
3. From the node tree select <Indexer program>. The drives current program
will appear in the View Window. Click anywhere in the View Window to
activate the tool bar. From the MotionView Menu select <Indexer>, <Import
program from file>. Navigate to the following folder MotionView6._ _ / Help
/ 940Examples. Select the TuneP program and click Open. Click on the
Compile and download button on the toolbar to load the program to the drive.
4. Select “Tools” then “Oscilloscope” tool from node tree.
5. On the Scope tool select:
• Channel 1: “Position Error”
• Scale: 100 pulses/div
• Channel 2: “Target Position”
• Scale: 0.1 Unit/div
• Timebase: 50mS
• Trigger: Channel 2, Rising
• Trigger level: 0
6. Select “Compensation” from node tree. Set “Position P-gain” to 100 and
“Position D-gain” to 0. Set “Position I-gain” to 0 and “Position I-limit” to 0.
7. Activate IN_A3 and run the “TuneP.txt” program.

60 S94P01D
8. Slowly increase the P-gain while watching the Position Error waveform,
(Ch1). While increasing P-gain you should observe the position error
decrease. At some point you should start to experience high frequency
oscillation noticeable on the Position Error waveform, (see picture below).
Increase D-gain to suppress the oscillations.

S933
9. Continue to increase the P-gain until the position error stops decreasing. To
suppress the oscillations increase the D-gain again while increasing the P-
gain.
10. Stop the program.
11. The above method is suggested as a general guideline for position tuning.
Experiment with the gains to achieve the performance and stability needed
for your individual application.
12. The goal of tuning is to achieve the minimum acceptable position error while
still maintaining stability. By increasing the P-gain you increase the response
to position change and reduce the position error. At the same time a large P-
gain can lead to instability, oscillation. By increasing the D-gain you improve
the stability of the system. Generally, both P-gain and D-gain should be
increased together.
13. While the program is stopped, edit the “TuneP” User Program and set the
Accel and Decel variables to the maximum values your system can accept.
Compile and load the program to the drive.
14. Set oscilloscope channel 1 to “Iq current”. Set the scale to the appropriate
value to see a full current pulse.
15. Observe that current, Iq, waveform. Check to make sure that there isn’t any
significant oscillation at the flat portion of the waveform. If so then decrease
the P-gain to a level where the oscillation either disappears or is very small.
(See pictures in section 9.2).
16. The I-gain comes into play when trying to minimize the position error during
the steady state of the move. The same is true for holding the position
accuracy. Increasing the I-gain will increase the drive’s reaction time while
the I-Limit will set the maximum influence that the I-Gain will have on the
loop. When adjusting the I-gain start with a very small value for both the
I-gain and the I-Limit then increase the I-gain until stand-still reaction is
compensated. Large values of Position I-limit can cause large instability and
unsettled oscillation of the mechanism.
Note
These are only initial settings. Your application will likely require fine-tun-
ing. To optimize settings experiment with combinations of all gains P, I
and D and the I-limit.

S94P01D 61
9 Sample Motor Responses to Gain Settings
9.1 Motor Response to Gain Settings (velocity mode)
Initial settings:

S934

9.1.1 P-gain
Velocity P-gain = 5000
Velocity I-gain = 20
Current didn’t reach maximum possible value. (10A)

S935

Velocity P-gain = 32767 (max value)

Velocity I-gain = 20
Gain Scaling = -2
The P-gain is set to its maximum value, per the (-2) in the Gain Scaling window. The
current value is very close to the maximum but since the P-gain is maxed out we can’t
determine if we have achieved optimum settings.
Also notice that the oscilloscope Time Base is set to 10ms. This allows us to view
the leading edge and current impulse response more clearly. A real-time oscilloscope
is essential when analyzing waveforms in depth and is a distinctive feature of the
PositionServo drives.

62 S94P01D
 S936

To increase the P-gain setting we need to set “Gain Scaling” one notch higher. This is
done by changing the “Gain Scaling” setting from (-2) to (-1).
After changing the “Gain Scaling” setting, set the P-gain to 16000 (approximately
the middle of the scale) and restart the drive. Then slowly increase the P-gain again.
(Reference the next section).
Velocity P-gain = 20322
Velocity I-gain = 20
Gain Scaling = -1
We start to see a small overshoot at the leading edge of the Motor Velocity wave, but
the current doesn’t increase anymore. This is how fast the motor can reach the set
velocity with current limit selected. Any further increase in gain will only increase the
overshoot and will not improve the response.
P-gain should be decreased slightly, (approximately 10%), to remove the overshoot.

The final value for the P-gain should be 18000.

S937

S94P01D 63
9.1.2 I-gain
Velocity P-gain = 18000
Velocity I-gain = 2396
Gain Scaling = -1
I-gain is increased to allow small velocity overshoot, (~10%), as a step response.
This setting is very application dependent. If a high and flat response is expected in
the application, then leave this value so that the overshoot is no more than 10%. If
the application requires stiffness at zero or near zero velocity and long term stability is
desired increase I-Gain so that the overshoot reaches 30% (see next section).

S938
Large I-Gain
I-Gain = 7935
Overshoot = 20%
The I-gain setting is very application dependent. If the application requires a high and
flat response then the I-gain should be set to produce an overshoot of no more than
10%. If the application requires stiffness at zero or near zero velocity and has long term
stability increase the I-Gain so that the overshoot reaches 30% (see below).

S939

64 S94P01D
9.1.3 Abnormal Gains (velocity mode)
Velocity I-Gain is too high
Velocity P-gain = 18000
Velocity I-gain = 12000
Gain Scaling = -1
Notice below that there is a large overshoot and a noticeable oscillation in the flat
portion of the Motor Velocity waveform. The current waveform also has a small trace of
instabilities at the flat portion of the waveform.

S940

Velocity P-gain is too high

Velocity P-gain = 22720
Velocity I-gain = 20
Gain Scaling =0
Notice below that there is a large overshoot and a noticeable oscillation in flat portion of
the Motor Velocity waveform. The current waveform also has some instability on trailing
edge of the current impulse response.

S941

S94P01D 65
9.2 Motor Response to Gain Settings (position mode)
9.2.1 P-gain selection
Position P-gain = 2500
Position D-gain = 0
Position I-gain = 0
Position I-limit = 0
Problem: Insufficient P-gain can cause large position error as motor
changing position rapidly
Treatment: Increase P-gain.
Side effects: Increasing the P-gain might cause oscillations and might require
an increase of the D-gain as well to overcome this problem.

S942

P-gain increase
Position P-gain = 8700
Position D-gain = 0
Position I-gain = 0
Position I-limit = 0
Positive effect: Position error decreased
Problem: Noticeable oscillation (Channel 1). P-gain can’t be set any
higher due to increasing oscillation, (instability).
Treatment: Increase D-gain and then P-gain until position error stops
decreasing
Side effects: Possible high noise produced by excess of D-gain. A
compromise between the D-gain setting and an acceptable
position error must be reached. This will be mainly controlled
by value of P-gain.

66 S94P01D
 S943

9.2.2 Optimal P-gain / D-gain Settings

Position P-gain = 8700
Position D-gain = 16000
Position I-gain = 0
Position I-limit = 0
Positive effect: Position error decreased. Oscillation eliminated by D-gain.
Side effects: Possible high noise produced by high P and D gains at
0 velocity. This problem arises since encoder has finite
resolution. A compromise might have to be made by setting the
P-gain and the D-gain lower to smooth out the operation at 0
velocity.

S944

S94P01D 67
 P and D gains setting check (problem)
Position P-gain = 12673
Position D-gain = 16000
Position I-gain =0
Position I-limit =0
Problem: Noticeable oscillation (Channel 1) on Iq current waveform.
Treatment: Decrease the P-gain setting until oscillation disappears.

S945

P and D gains setting check (corrected)

Position P-gain = 12673
Position D-gain = 16000
Position I-gain = 0
Position I-limit = 0
Positive effect: Oscillation stopped and stability is increased

S946

68 S94P01D
10 Troubleshooting
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 at least 60 seconds before servicing drive.
Capacitors retain charge after power is removed.
Before troubleshooting
Perform the following steps before starting any procedure in this section:
• Disconnect AC or DC voltage input from the PositionServo. Wait at least 60
seconds for the power to discharge.
• Check the PositionServo closely for damaged components.
• Check that no foreign material has fallen or become lodged in the PositionServo.
• Verify that every connection is correct and in good condition.
• Verify that there are no short circuits or grounded connections.
• Check that the drive’s rated phase current and RMS voltage are consistent
with the motor ratings.
For additional assistance, contact your local PositionServo® authorized distributor.
Problem External line fuse blows

Possible Cause Line fuses are the wrong size

Motor leads or incoming power leads are shorted to ground.
Nuisance tripping caused by EMI noise spikes caused by poor
grounding and/or shielding.

Suggested Solution • Check that line fuses are properly sized for the motor being used.
• Check motor cable and incoming power for shorts.
• Check that you follow recommendation for shielding and grounding
listed in section “shielding and grounding” early in this manual.

Problem Ready LED is on but motor does not run.

Suggested Solution If in torque or velocity mode:

Reference voltage input signal is not applied.
Reference signal is not connected to the PositionServo input
properly; connections are open.
In MotionView program check <Parameters> <Reference> set
to <External>
For Velocity mode only:
In MotionView check <Parameters> <Compensation><Velocity
loop filter> P-gain must be set to value more then 0 in order to
run. Without load motor will run with P-gain set as low as 20 but
under load might not. If P-gain is set to 0 motor will not run at all.
In position mode with master encoder motion source (no program)
Reference voltage input signal source is not properly selected.
In MotionView program check <Parameters> <Reference> set
to <External>
In position mode using indexing program
Variables ACCEL, DECEL,MAXV, UNITS are not set or set to
0. Before attempting the move set values of motion parameters
ACCEL, DECEL,MAXV, UNITS

Problem In velocity mode, the motor runs away.

Possible Cause • Hall sensors or encoder mis-wired.

• PositionServo not programmed for motor connected.

Suggested Solution • Check Hall sensor and encoder connections.

• Check that the proper motor is selected..

S94P01D 69
70 S94P01D
NOTES

S94P01D 71
 NOTES

72 S94P01D
 AC Technology Corporation
630 Douglas Street • Uxbridge, MA 01569 • USA
Sales: (800) 217-9100 • Service (508) 278 9100
www.lenze-actech.com

Document
S94P01D