Lenze 00450899 EVS9328-KHV531 9300 Servo Inverter
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Product Information
The Lenze 00450899 (model EVS9328-KHV531) is a 22 kW vector-controlled servo inverter within the Lenze 9300 Servo family, engineered for high-torque precision motion control in automated machinery and KUKA KRC series robot controller main axis drive systems under KUKA part number 00-103-118. Operating on a 3-phase AC input voltage from 320 V AC to 528 V AC, the drive delivers a nominal DC bus voltage of 565 V DC, a continuous rated output current of 47 A at an 8 kHz switching frequency, and a maximum output frequency of 480 Hz. To accommodate heavy robot arm acceleration and dynamic load spikes, the unit features a 150% overload capability that provides up to 70.5 A peak current for up to 60 seconds.
System connectivity and motion feedback are managed through an onboard CAN system bus interface on connector X4 operating at 500 kbit/s, a Sub-D resolver input on connector X7, and incremental encoder input and output interfaces on connectors X8 and X9. An integrated Automation Interface slot accepts optional fieldbus cards such as the EMF2133IB PROFIBUS-DP or EMF2102IB Interbus module. Commissioning a spare unit requires matching drive parameters stored in internal EEPROM memory, which holds up to four independent parameter sets. Settings can be uploaded or modified using Lenze Global Drive Control software or a Keypad XT handheld module. When replacing an operational drive, parameter backup and alignment with the KUKA controller are required to ensure correct axis synchronization, where ABC Industrial Parts can assist with parameter extraction from donor or damaged units.
Status monitoring is provided by front-panel LEDs: a green LED signals operational readiness and active running state, a yellow LED indicates active current limiting or warning thresholds, and a red TRIP LED alerts personnel to fault conditions. Diagnostics can also be monitored via the Keypad XT display, online status screens in Global Drive Control software, or by reviewing the trip memory buffer in parameter C0168. First-line field checks involve testing 3-phase input lines, measuring DC bus voltage at terminals +UG and -UG, and verifying CAN bus wiring and termination resistors. Internal hardware failures, EEPROM corruptions, or power module short circuits cannot be repaired in the field, making unit replacement or specialized repair through ABC Industrial Parts the most effective route to resume operation.
Technical Specifications
| Manufacturer | Lenze |
| Part Number | 00450899 |
| Model / Type Code | EVS9328-KHV531 |
| KUKA Cross-Reference | 00-103-118 |
| Product Family | 9300 Servo |
| Component Type | Servo Inverter |
| Rated Power | 22 kW |
| Supply Voltage Range | 320 - 528 V AC |
| Rated Output Current | 47 A |
| Peak Output Current | 70.5 A (60 seconds) |
| Nominal DC Bus Voltage | 565 V DC |
| Switching Frequency | 8 kHz |
| Maximum Output Frequency | 480 Hz |
Programming and Configuration
Parameter management and setup for the Lenze 00450899 EVS9328-KHV531 are conducted via Lenze Global Drive Control (GDC) software or using the Keypad XT (EMF2171IB) operator module. The inverter incorporates non-volatile internal EEPROM memory capable of retaining up to four separate parameter sets, allowing versatile multi-profile configuration and straightforward backup.
When commissioning a spare drive within a KUKA KRC robot control system, the specific OEM motor maps, feedback parameters, and axis velocity settings must be loaded into the active parameter set. Diagnostic history and active fault logs are monitored directly through parameter C0168 (TRIP history buffer), enabling technicians to assess previous drive events prior to re-commissioning.
Communication and System Integration
System-level motion integration is provided by the onboard CAN system bus interface on connector X4, operating at a high-speed baud rate of 500 kbit/s for real-time cyclic communication with host controllers. Dedicated motor feedback ports include a Sub-D resolver connector (X7) alongside incremental encoder input (X8) and output (X9) interfaces.
For integration into external fieldbus networks, the drive features a built-in Automation Interface (AIF) slot. This expansion slot accommodates optional communication modules such as the EMF2133IB PROFIBUS-DP module or the EMF2102IB Interbus module, allowing seamless connection into broader plant automation architectures.
Diagnostics and Status Indication
The EVS9328-KHV531 provides real-time diagnostic feedback using front-panel LED indicators and internal system monitors. Technicians can analyze operational status using the Keypad XT display, GDC software online diagnostic tools, CANbus network monitoring, or physical voltage measurements across the +UG and -UG DC bus terminals.
Status LED Indicators
| LED | Color/Status | Meaning |
|---|---|---|
| Red LED (TRIP) | Red - Solid / Blinking | Active drive trip condition or fault present. Blinking patterns indicate fault group or severe failure state. |
| Green LED (Ready/Run) | Green - Solid / Flashing | Drive active and operational status. Solid green indicates power stage enabled; flashing green indicates drive ready with power stage disabled. |
| Yellow LED | Yellow - Solid | Warning state or current limit reached (Imax / limit active). |
Replacement and Spare Part Considerations
The Lenze 00450899 (EVS9328-KHV531) is customized for KUKA robotics applications under part number 00-103-118. When sourcing a replacement, confirm both the Lenze hardware code (EVS9328) and the OEM firmware revision suffix (KHV531) to guarantee compatibility with KUKA KRC robot controller software and main axis motor characteristics.
Replacing an active unit involves transferring parameter sets saved in the internal EEPROM using Global Drive Control (GDC) software or a Keypad XT module. Ensure that optional fieldbus cards (such as PROFIBUS EMF2133IB or Interbus EMF2102IB) are transferred from the old unit, correctly seated in the AIF slot, and verified. Inspect resolver cabling at connector X7 and confirm that 120 Ohm termination resistors are present at the CAN bus X4 port.
Error Codes & Fault Codes
The following error codes may be displayed during operation or diagnostics:
| Code | Name | Description | Possible Cause | Recommended Action |
|---|---|---|---|---|
| OC1 | Short circuit / Earth fault | Short circuit on motor output terminals or earth fault in power section. | Motor cable short circuit, motor phase insulation failure, damaged power IGBT module. | Check motor and output wiring for short circuit or earth fault. If fault occurs immediately on power-up with motor disconnected, internal hardware fault — return unit for repair. |
| OC2 | Earth fault during operation | Ground fault detected in output phases during drive operation. | Moisture in motor terminal box, defective motor insulation, cable shield breakdown. | Check motor winding resistance and cable insulation resistance against ground. |
| OC3 | Overcurrent during acceleration | Output current exceeded trip limit during motor acceleration. | Acceleration ramp too steep, mechanical axis jammed, incorrect motor data. | Increase acceleration time, check motor parameter settings, verify mechanical movement. |
| OC4 | Overcurrent at constant load | Output current limit exceeded during steady-state operation. | Sudden mechanical load surge, axis collision, motor overload. | Inspect mechanical motion and motor loading. |
| OC5 | Overcurrent during deceleration | Output current limit exceeded during deceleration ramp. | Deceleration ramp too steep, high load inertia. | Increase deceleration time or check brake resistor function. |
| OU | Overvoltage DC bus | DC bus voltage exceeded upper voltage threshold (~770 V DC). | Excessive braking energy, brake chopper defect, missing or open-circuit braking resistor, mains input voltage too high. | Check braking resistor connection and resistance value, check mains supply voltage. |
| LU | Undervoltage DC bus | DC bus voltage dropped below minimum threshold (~430 V DC). | Mains supply line failure, blown supply fuse, input voltage too low. | Check 3-phase AC input voltage and line fuses. |
| OH | Heatsink overtemperature | Drive heatsink temperature exceeded allowable operating limit (>85°C/90°C). | Fan failure, blocked heatsink airflow, ambient cabinet temperature too high, heavy continuous overload. | Clean heatsink cooling fins, verify cabinet cooling fan operation, reduce ambient temperature. |
| OH4 | Drive thermal overload (Ixt) | Thermal overload threshold (I x t calculation) of the inverter reached. | Continuous operation above continuous rated current (47 A). | Reduce continuous axis load or duty cycle. |
| OH7 | Motor thermal overload | Motor temperature sensor (PTC/KTY/thermal contact) open-circuit or triggered. | Motor overheated, thermal contact cable broken. | Allow motor to cool, verify motor cooling fan and sensor cabling. |
| OH8 | Heatsink temperature sensor fault | Internal heatsink temperature sensor signal invalid or disconnected. | Internal temperature sensor defect or broken connection on control PCB. | Internal hardware fault — return unit for repair. |
| CE0 | AIF communication fault | Communication failure between inverter control board and plugged AIF module. | AIF module improper seating, electrical interference, defective option module. | Check AIF module seating and screws; replace option module if error persists. |
| CE1 | CAN system bus failure | CANbus communication error on onboard system bus X4 interface. | CAN bus wire broken, incorrect bus termination resistors (120 Ohm missing), baud rate mismatch. | Inspect CAN cabling, verify bus termination at both line ends, check CAN baud rate. |
| EER | EEPROM memory fault | Checksum error detected in internal EEPROM memory during read/write. | Power failure during parameter save operation, corrupted non-volatile memory cell. | Reload factory default parameter set. If fault re-occurs, internal hardware failure — return unit for repair. |
| H05 | Internal hardware error | Internal diagnostic check failed on control board or power PCB. | Control board component failure, internal voltage supply failure. | Internal hardware failure — replace unit or return for repair. |
| SD2 | Resolver signal fault | Loss or distortion of resolver feedback signal on connector X7. | Resolver cable damaged, plug disconnected, strong electromagnetic interference. | Check resolver cable connection and shielding. |
| SD3 | Encoder signal fault | Incremental encoder signal loss or track error on connector X8. | Encoder cable defect, encoder supply voltage missing, track A/B signal loss. | Verify encoder cabling and supply voltage. |
| LP1 | Mains phase failure | Phase loss detected on AC mains supply terminals L1, L2, L3. | Blown main fuse, loose supply line terminal, severe mains imbalance. | Check 3-phase mains voltage at input terminals. |
| PR0 | System error / Microcontroller fault | Firmware execution error or CPU watchdog reset. | Severe electrical noise / EMC disturbance, micro-controller crash. | Power cycle unit. If problem persists, internal hardware fault — return unit for repair. |
Frequently Asked Questions
Which system applications use the Lenze 00450899 EVS9328-KHV531 drive?
This 22 kW servo inverter is specifically engineered for main axis drive control in KUKA KRC series robot controllers under KUKA part number 00-103-118, as well as high-inertia multi-axis automated machinery in automotive and packaging environments.
What tools are needed to transfer parameters to a replacement drive?
Parameter transfer and configuration backup can be completed using Lenze Global Drive Control (GDC) software connected via an interface module or using a handheld Keypad XT (EMF2171IB) module.
What does a solid red TRIP LED indicate on the inverter?
A solid or blinking red TRIP LED indicates an active drive trip condition or severe fault state, such as an overcurrent event, earth fault, overvoltage, or internal hardware error.
What fieldbus option modules can be installed in the AIF slot?
The Automation Interface (AIF) slot supports fieldbus expansion modules including the Lenze EMF2133IB PROFIBUS-DP card and the EMF2102IB Interbus card.
How should an OC1 trip code be diagnosed?
An OC1 code indicates a short circuit or earth fault on the motor output. Check motor wiring, phase resistance, and cable insulation. If OC1 triggers immediately upon applying power with the motor cables disconnected, internal power section damage has occurred and the unit requires repair.
Can hardware fault codes like H05 or EER be resolved in the field?
For an EER code, reloading the factory default parameter set may resolve temporary EEPROM memory corruption. If EER persists or an H05 internal error occurs, the issue is an internal hardware failure that requires unit replacement or professional off-site repair.
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