Lenze EVS9325-ESV004 9300 Servo Positioning Controller 5.5kW
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Product Information
The Lenze EVS9325-ESV004 is a 5.5 kW servo positioning controller from the Lenze 9300 Series, designed for multi-axis synchronized motion, electronic gearing, and dynamic positioning applications. Operating across a 3-phase supply voltage range of 320 to 528 V AC (rated 3x 400 / 480 V AC), this IP20-rated drive supplies a continuous output current of 13 A with a short-term peak current capability of 19.5 A at an 8 kHz switching frequency. With embedded motion control function blocks built into the controller, positioning tasks and complex motion profiles can be executed locally without requiring additional external motion control hardware.
Interfacing the EVS9325-ESV004 into an automated production line relies on its integrated CAN System Bus running at speeds up to 500 kbps alongside dedicated feedback connectors, including X7 for resolvers and X8 for incremental or absolute encoders such as SinCos and Hiperface. The unit also features an Automation Slot (A-Slot) that accommodates fieldbus expansion modules such as the EMF2102IB PROFIBUS, EMF2178IB PROFINET, or EMF2177IB EtherCAT. Bringing a replacement unit into service requires loading the target application parameters; up to four parameter sets are retained in internal EEPROM memory and can be backed up and transferred tool-free using an EMZ9371BC operating keypad or uploaded via Lenze Global Drive Control (GDC) software. ABC Industrial Parts can support maintenance teams with replacement drives and configuration transfer requirements to ensure smooth setup.
System status and active operational faults are signaled directly through onboard status LEDs, where a solid red TRIP LED indicates an active drive fault and a green LED indicates controller ready or enabled status. Detailed fault diagnosis is accessible via the EMZ9371BC keypad display, GDC online monitoring, or by examining the C0161 and C0168 history memory buffers over the CAN System Bus. Standard troubleshooting involves verifying input mains voltage for undervoltage (LU) or overvoltage (OU), checking motor and cabling for short circuits (OC1) or ground faults (OC2), inspecting feedback cables on connectors X7 and X8 for signal loss (Sd2, Sd3), and confirming CAN bus termination and node addresses (CE0). Internal circuit board errors such as H05 or persistent EEPROM failures (EEr) indicate hardware issues that cannot be repaired in the field, making a tested replacement or unit repair through ABC Industrial Parts the most reliable solution to resume production.
Technical Specifications
| Rated Power | 5.5 kW |
| Supply Voltage | 3x 400 / 480 V AC |
| Supply Voltage Range | 320 - 528 V AC |
| Continuous Output Current | 13 A |
| Peak Output Current | 19.5 A |
| Switching Frequency | 8 kHz |
| Protection Rating | IP20 |
| Digital Inputs | 6 |
| Digital Outputs | 4 |
| Analog Inputs | 2 |
| Analog Outputs | 2 |
| Integrated System Bus | CAN / CANopen (500 kbps) |
Programming and Configuration
The Lenze EVS9325-ESV004 features embedded motion function blocks that execute positioning tasks, velocity control, electronic gearing, and master-slave indexing directly on the drive. System setup and axis tuning are carried out using Lenze Global Drive Control (GDC) software, which connects to the drive for real-time parameter configuration, function block linking, and online signal trace monitoring.
Parameter management is supported through four independent internal non-volatile EEPROM parameter sets stored within the drive. Operators can copy complete parameter sets directly into an optional plug-in EMZ9371BC operating keypad. This memory function allows maintenance technicians to restore or clone entire drive configurations in the field without needing a PC on site.
Communication and System Integration
For multi-axis motion synchronization, the EVS9325-ESV004 integrates an onboard CAN System Bus interface supporting transmission rates up to 500 kbps. This internal fieldbus enables rapid cyclic data exchange for master-slave drive cascading, position target distribution, and electronic shaft synchronization across coordinated packaging or material handling lines.
Higher-level control network integration is accomplished using the integrated Automation Slot (A-Slot). This expansion interface supports plug-in communication modules including the EMF2102IB PROFIBUS module, EMF2178IB PROFINET module, and EMF2177IB EtherCAT module, allowing seamless integration into diverse PLC-based automation architectures.
Diagnostics and Status Indication
Diagnostic monitoring on the EVS9325-ESV004 is provided by two front status LEDs alongside digital display methods. A solid red TRIP LED alerts personnel to active inverter faults or safety trips, while the green Operation LED indicates operational states, flashing when the controller is ready or inhibited and remaining solid green when the controller is fully enabled and active.
Detailed troubleshooting is supported via the EMZ9371BC keypad, which presents active fault descriptions and accesses historic fault records. Diagnostic codes are also accessible over the CAN System Bus through parameter buffers C0161 and C0168, or monitored remotely using the diagnostic window in Lenze Global Drive Control software.
Status LED Indicators
| LED | Color/Status | Meaning |
|---|---|---|
| TRIP / Fault LED | Red - Solid / Active | Inverter TRIP active / Fault state detected |
| Operation / Ready LED | Green - Blinking / Solid | Green blinking = Drive ready / inhibit; Green solid = Controller enabled / running |
Replacement and Spare Part Considerations
When installing a replacement Lenze EVS9325-ESV004, confirm that the rating matches your existing unit, specifically the 5.5 kW output and 13 A continuous current rating. Ensure that any installed option card in the Automation Slot, such as a PROFIBUS or PROFINET module, is transferred to the replacement controller and configured with matching fieldbus network addresses.
A replacement unit will not operate correctly until programmed with the original application parameters. Parameters should be transferred from the original unit using an EMZ9371BC operating keypad backup or uploaded using Global Drive Control (GDC) software. Check feedback connections on X7 (resolver) or X8 (encoder) to prevent feedback faults upon initial power-up.
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 | Short circuit on motor phase output or power stage overcurrent | Short circuit in motor cable or motor winding, ground short, or excessive acceleration rate | Check motor and wiring for short circuits; check power stage. Internal power stage failure requires unit return for repair. |
| OC2 | Earth Fault | Ground fault on output motor lines | Motor cable insulation breakdown, ground leakage in motor windings, excessive line length | Check motor lead insulation to ground; check motor coil resistance. |
| OC5 | Ixt Overload | Inverter I x t overload threshold reached | Drive loaded continuously above rated current rating for extended duration | Reduce mechanical load, increase acceleration/deceleration times, or check motor size. |
| OU | Overvoltage DC Bus | DC bus voltage exceeds upper threshold limit | Excessive regenerative energy during braking, brake chopper defective, or braking resistor open | Extend deceleration time, inspect external braking resistor and braking chopper circuit. |
| LU | Undervoltage DC Bus | DC bus voltage dropped below minimum operating limit | Mains supply voltage drop, phase loss, or weak supply power line | Check mains voltage supply, fuses, and line reactor connection. |
| OH | Heatsink Overtemperature | Inverter heatsink temperature exceeds maximum threshold | Inadequate cabinet cooling, blocked airflow, internal fan failure, ambient temperature too high | Clean heatsink fins, check cabinet ventilation, ensure internal fan functions correctly. |
| OH4 | Motor Overtemperature | Motor temperature sensor trip (PTC / KTY input triggered) | Motor overload, inadequate motor cooling, sensor connection broken | Allow motor to cool down, inspect load mechanism, verify PTC/KTY sensor wiring. |
| CE0 | System Bus (CAN) Communication Fault | Communication failure on integrated CAN System Bus | Bus cabling interrupted, incorrect termination resistors, bus overload, invalid node ID | Verify CAN bus wiring, check 120-ohm termination, check baud rate and node address settings. |
| CE1 | Automation Module Communication Error | Communication fault between drive and A-Slot module | Fieldbus communication failure, module unseated, missing fieldbus master signal | Verify fieldbus cable connection, re-seat communication module, check master PLC configuration. |
| EEr | EEPROM Fault | EEPROM read/write memory failure | Corrupted non-volatile parameter memory or internal EEPROM hardware failure | Re-initialize parameters to factory default. If error persists, internal hardware fault requires unit repair/replacement. |
| H05 | Internal Hardware Error | Hardware failure detected on main processing circuit board | Internal control board component failure | Internal hardware failure — non-field-serviceable. Contact Lenze service or replace unit. |
| Sd2 | Resolver Feedback Fault | Resolver signal fault or cable break detected | Broken feedback cable, defective resolver, or excessive signal noise | Check resolver feedback cable shield and connector X7, test resolver windings. |
| Sd3 | Encoder Signal Fault | Encoder track signal loss or track fault on interface X8 | Incremental/SinCos encoder cable fault or encoder failure | Check encoder wiring at X8 connector, verify encoder supply voltage, inspect encoder. |
| Pr0 | Parameter Error | Invalid parameter set data detected during power-up load | Incomplete parameter transfer or corrupted parameter set | Reload parameter set into drive via GDC software or keypad. |
Frequently Asked Questions
How do I transfer parameters to a spare Lenze EVS9325-ESV004 drive?
Parameters can be saved and transferred using an EMZ9371BC keypad module, which allows tool-free uploading and downloading between drives. Alternatively, parameters can be backed up and reloaded using a PC running Lenze Global Drive Control (GDC) software.
What feedback types are compatible with the EVS9325-ESV004 controller?
The controller features dedicated feedback interfaces supporting standard resolvers via connector X7, as well as incremental encoders and absolute SinCos or Hiperface encoders via connector X8.
What does an OC1 fault mean on the Lenze EVS9325-ESV004?
An OC1 fault indicates a short circuit or power stage overcurrent. This is typically caused by a shorted motor cable, a ground fault in the motor windings, or excessively rapid acceleration rates.
How are fieldbus options like PROFIBUS or EtherCAT added to this drive?
Fieldbus integration is achieved by inserting an optional communication card into the drive's Automation Slot (A-Slot), such as the EMF2102IB for PROFIBUS, EMF2178IB for PROFINET, or EMF2177IB for EtherCAT.
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