Lenze POSITIONSERVO 940 User Manual
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Lenze POSITIONSERVO 940 User Manual

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S929
Model 940 USERS MANUAL
S94P01B

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Summary of Contents for Lenze POSITIONSERVO 940

  • Page 1 S929 Model 940 USERS MANUAL S94P01B...
  • Page 2 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...

  • Page 3: Table Of Contents

    Line (Mains) fusing..........14 PositionServo 940 Connections ....... . . 14 External Connectors .
  • Page 4 Programmable Features and Parameters ......35 Parameters storage and EPM operation ......35 6.1.1 Parameter’s storage .
  • Page 5 6.10 Tools Group ........... . 44 6.10.1 Oscilloscope tool .
  • Page 6 Safety Information All safety information given in these Operating Instruction have the same layout: Signal Word! (Characteristics the severity of the danger) Note (describes the danger and informs on how to proceed) Signal Words Icon DANGER! Warns of impending danger. Warning of hazardous Consequences if disregarded:...

  • Page 7: General Information

    These drives have the suffix “S1N”. The PositionServo 940 will accept feedback from an incremental encoder (that includes Hall channel information) or from a resolver. It accepts commands from a variety of sources, including analog voltage, RS485 interface (PPP and Modbus RTU), Ethernet interface, CANopen interface, digital pulse train, and master encoder reference.

  • Page 8: Scope Of Supply

    • 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.

  • Page 9: Specifications

    2 Specifications 2.1 Electrical Characteristics Single-Phase Models 1~ Mains 1~ Mains Rated Output Peak Output Current Current Type Mains Voltage Current Current (doubler) (Std.) E94P020S1N 120V or 240V E94P040S1N 16.8 E94P020S2F E94P040S2F 120 / 240V (80 V -0%...264 V +0%) E94P080S2F 15.0 E94P100S2F...

  • Page 10: Environment

    2.2 Environment Vibration 2 g (10 - 2000 Hz) Ambient Operating Temperature Range 0 to 40ºC Ambient Storage Temperature Range -10 to 70ºC Temperature Drift 0.1% per ºC rise Humidity 5 - 90% non-condensing Altitude 1500 m/5000 ft [derate by 1% per 300m (1000 ft) above 1500m (5000 ft)] 2.3 Operating Modes Torque...

  • Page 11: Dimensions

    3 Dimensions 3.1 Model 940 Dimensions �� �� ��� � �� �� �� � � S923 Type A (mm) B (mm) C (mm) Weight (kg) E94P020S1N E94P040S1N E94P020S2F E94P040S2F E94P080S2F E94P100S2F E94P020Y2N E94P040Y2N E94P080Y2N E94P100Y2N E94P120Y2N E94P020T4N E94P040T4N E94P050T4N E94P060T4N S94P01B...

  • Page 12: Clearance For Cooling Air Circulation

    3.2 Clearance for Cooling Air Circulation ����� ���� ����� S924 S94P01B...

  • Page 13: Installation

    Disconnect incoming power and wait 60 seconds before servicing drive. Capacitors retain charge after power is removed. STOP! • The PositionServo 940 must be mounted vertically for safe operation and enough cooling air circulation. • Printed circuit board components are sensitive to electrostatic fields.

  • Page 14: Wiring

    It may be necessary to earth ground the shielded cable. Ground the shield at both the drive end and at the motor end. If the PositionServo 940 drive continues to pick up noise after grounding the shield, it may be necessary to add an AC line filtering device and/or an output filter (between drive and servo motor).

  • Page 15: Emi Protection

    4.2.3 Enclosure The panel in which the PositionServo 940 is mounted must be made of metal, and must be grounded using the SPG method outlined in section 4.2.1. Proper wire routing inside the panel is critical; power and logic leads must be routed in different avenues inside the panel.

  • Page 16: Heat Sinking

    The end user must use the compatible filter to comply with CE specifications. The OEM may choose to provide alternative filtering that encompasses the PositionServo 940 drive and other electronics within the same panel. The OEM has this liberty because CE requirements are for the total system.
  • Page 17 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.

  • Page 18: P2 - Serial Communications Port

    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)

  • Page 19: P4 - Motor Feedback / Second Loop Encoder Input

    All conductors must be enclosed in one shield and jacket around them. Lenze recommends that each and every pair (for example, EA+ and EA-) be twisted. In order to satisfy CE requirements, use of an OEM cable is recommended.
  • Page 20 PositionServo 940 reference voltage terminals. When using a front-end controller, it is critical that the +5 VDC supply on the front- end controller NOT be connected to the PositionServo 940’s +5 VDC supply, as this will result in damage to the PositionServo 940.

  • Page 21: P5 - 24 Vdc Back-Up Power Input

    The speed of the motor is controlled by the frequency of the “step” signal, while the number of pulses that are supplied to the PositionServo 940 determines the position of the servomotor. “DIR” input controls direction of the motion.

  • Page 22: P11 - Resolver Interface Module (Option Module)

    file, the drive will select the primary feedback source based on the motor data entry. When using a Lenze motor with resolver feedback and a Lenze resolver cable, the pins are already configured for operation. If a non-Lenze motor is used, the resolver...

  • Page 23: P12 - Second Encoder Interface Module (Option Bay 2)

    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...

  • Page 24: Digital I/O Details

    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.

  • Page 25: Digital Outputs

    There are a total of five digital outputs (“OUT1” - “OUT4” and “RDY”) available on the PositionServo 940 drive. These outputs are accessible from the P3 connector. Outputs are open collector type that are fully isolated from the rest of the drive circuits.

  • Page 26: Digital Inputs

    Digital inputs IN_Ax, IN_Bx, IN_Cx (P3.26-30, P3.31-35, P3.36-40 ). The PositionServo 940 Drive has 12 optically isolated inputs. These inputs are compatible with a 5 -24V voltage source. No additional series resistors are needed for circuit operation. The 12 inputs are segmented into three groups of 4, Inputs A1 - A4, Inputs B1 - B4, and Inputs C1 - C4.

  • Page 27: Analog I/O Details

    5.3 Analog I/O details 5.3.1 Analog reference input AIN+, AIN1- (P3.24 and P3.25) The analog reference input can accept up to a ±10V analog signal across AIN1+ and AIN2-. The maximum limit with respect to analog common (ACOM) on each input is ±18VDC.

  • Page 28: Communication Interfaces

    5.4.2 RS485 interface (option module) PositionServo 940 drives can be equipped with an RS485 communication interface option module (E94ZARS41) which is optically isolated from the rest of the drive’s circuitry. This option module can be used for two functions: drive programming and diagnostics using MotionView from a PC (with RS485 port) or as a Modbus RTU slave.

  • Page 29: Modbus Rtu Support

    5.4.4 MODBUS RTU support As a default, the RS232 and RS485 interfaces are configured to support MotionView program operations. In addition, the RS485 interface can be configured to support the MODBUS RTU slave protocol. The interface can be configured through the MotionView program.

  • Page 30: Motor Set-Up

    5.5.3 Motor set-up Once you are connected to the PostionServo 940 via MotionView a “Parameter Tree” will appear in the “Parameter Tree Window”. The various parameters of the drive are shown here as folders and files. If the “Motor” folder is selected, all motor parameters can be viewed in the “Parameter View Window”.

  • Page 31: Using A Custom Motor

    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”. •...

  • Page 32: Autophasing

    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”).
  • Page 33 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.
  • Page 34 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.
  • Page 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.
  • Page 36 Otherwise (if B leads A ) check B leads A for CW box. Note Lenze convention references the shaft direction of rotation from the front (shaft end) of the motor. Some manufacturers’ timing diagrams are CW when viewed from the “rear” of the motor.

  • Page 37: Programmable Features And Parameters

    The White EPM is the only acceptable EPM for the PositionServo 940 drive. If a white EPM is detected, the drive compares data in the EPM to that in its internal memory. In order for the drive to operate, the contents of the drive’s memory and EPM must be the same.

  • Page 38: Epm Fault

    6.1.3 EPM fault If the EPM fails during operation or the EPM is removed from the EPM Port the drive will generate a fault and will be disabled (if enabled). The fault is logged to the drives memory. Further operation is not possible until the EPM is replaced (inserted) and the F_EP drive’s power is cycled.

  • Page 39: Drive Pwm Frequency

    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. (See Programmer’s manual for details). P3.1-4 inputs can be configured for two types of signals: step and direction and Master encoder quadrature signal.

  • Page 40: Accel/Decel Limits (Velocity Mode Only)

    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.

  • Page 41: Regen Duty Cycle

    6.3.14 Regen duty cycle This parameter sets the maximum duty cycle for the brake (regen) resistor. This parameter can be used to prevent brake resistor overload. Use the following formula to set the correct value for this parameter. D = P * R / (Umax) * 100% where: D (%)

  • Page 42: Enable Switch Function

    6.5 Analog I/O Group 6.5.1 Analog output The PositionServo 940 has one analog output with 10-bit resolution on P3.23. The signal is scaled to ± 10V. The analog output can be assigned to following functions: • Not Assigned • Phase current RMS •...

  • Page 43: Analog Output Current Scale (Volt / Amps)

    Analog input offset parameter Allows you to adjust the offset voltage at AIN1+ and AIN1- (P3.24 and P3.25). 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”...

  • Page 44: Hard Limit Switch Action

    6.6.2 Hard limit switch action Digital inputs IN_A1-IN_A2 can be used as limit switches if their function is set to “Fault” or “Stop and Fault”. Activation of this input while the drive is enabled will cause the drive to Disable and go to a Fault state. The “Stop and Fault” action is available only in Position mode when the “Reference”...

  • Page 45: Compensation Group

    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.

  • Page 46: Second Encoder I-Gain (Integral)

    6.10.1 Oscilloscope tool The oscilloscope tool gives real time representation of different signals inside the PositionServo 940 drive and is helpful when debugging and tuning drives. Operation of the oscilloscope tool is described in more detail in the MotionView Software User’s Manual.

  • Page 47: Display And Diagnostics

    7 Display and Diagnostics 7.1 Diagnostic display The PositionServo 940 drives are equipped with a diagnostic LED display and 3 push buttons to select displayed information and to edit a limited set of parameter values. Parameters can be scrolled by using the “UP” and “DOWN” ( ) buttons.

  • Page 48: Diagnostic Leds

    7.2 Diagnostic LEDs The PositionServo 940 has five diagnostic LEDs mounted on the periphery of the front panel display as shown in the drawing below. These LEDs are designed to help monitor system status and activity as well as troubleshoot any faults.

  • Page 49: Faults

    7.3 Faults 7.3.1 FAULT CODES Below are fault codes mostly caused by hardware operations. Additional fault codes are listed in Programmer’s manual. Fault Code Fault Description Drive bus voltage reached the maximum level, typically due F_OU Over voltage to motor regeneration Resolver signal lost or at least one motor hall sensor is F_FB Feedback error...

  • Page 50: Operation

    8.2 Configuration of the PositionServo Regardless of the mode in which you wish to operate, you must first configure the PositionServo 940 for your particular motor, mode of operation, and additional features if used. Drive configuration consists of following steps: •...
  • Page 51 To configure drive: Ensure that the control is properly installed and mounted. Refer to Section 4 for installation instructions. Perform wiring to the motor and external equipment suitable for desired operating mode and your system requirements. Connect the serial port P2 on the drive to your PC serial port. Make sure that the drive is disabled.

  • Page 52: Position Mode Operation (Gearing)

    8.3 Position mode operation (gearing) In position mode the drive will follow the master reference signals at the P3. 1-4 inputs. The distance the motor shaft rotates per each master pulse is established by the ratio of the master signal pulses to motor encoder pulses (in single loop configuration).

  • Page 53: Enabling The Positionservo

    8.5 Enabling the PositionServo Regardless of the selected operating mode, the PositionServo must be enabled before it can operate. A voltage in the range of 5-24 VDC connected between P3.26 and 3.29 (input IN_A3) is used to enable the drive. There is a difference in the behavior of input IN_A3 depending on how the “Enable switch function”...
  • Page 54 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.

  • Page 55: Tuning In Position Mode

    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.
  • Page 56 S933 Continue to increase the P-gain until the position error stop decreasing. You will need to increase the D-gain again while increasing the P-gain to suppress the oscillations. 10. Stop the program. 11. The above method is suggested as a general guideline for position tuning. You will have to experiment with the gains to achieve the performance and stability needed for your individual application.

  • Page 57: Sample Motor Responses To Gain Settings

    9 Sample Motor Responses to Gain Settings 9.1 Motor response to gain settings (Velocity mode) Initial settings: S934 S94P01B...

  • Page 58: P-Gain

    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.
  • Page 59 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).

  • Page 60: I-Gain

    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 in your application a high and more flat response is expected then leave this value so that the overshoot is no more then 10%.

  • Page 61: Abnormal Gains. Velocity Mode

    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.

  • Page 62: Motor Response To Gain Settings (Position Mode)

    9.2 Motor response to gain settings (Position Mode) 9.2.1 P-gain selection Position P-gain 2500 Position D-gain Position I-gain Position I-limit 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.

  • Page 63: Optimal P-Gain / D-Gain Settings

    S943 9.2.2 Optimal P-gain / D-gain settings Position P-gain 8700 Position D-gain 16000 Position I-gain Position I-limit 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.
  • Page 64 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 = Position I-limit = Positive effect: Oscillation stopped and stability is increased S946 S94P01B...

  • Page 65: Troubleshooting

    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.
  • Page 66 Notes S94P01B...
  • Page 68 AC Technology Corporation member of the Lenze Group 630 Douglas Street Uxbridge, MA 01569 Telephone: (508) 278-9100 Facsimile: (508) 278-7873 Document: S94P01B...

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