Lenze EVS9328-EPV004 9300 Servo Position Controller 22kW
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Product Information
The Lenze EVS9328-EPV004 is a high-power 22 kW servo position controller from the Lenze 9300 Servo family, engineered for dynamic motion control and positioning applications in industrial machinery. Operating on a 3-phase supply voltage range from 320 V AC to 528 V AC, the drive supplies a continuous output current of 47 A with an 8 kHz switching frequency. To support demanding dynamic acceleration phases, the controller features a 150% overload capacity (70.5 A) for up to 60 seconds and a peak output current limit of 200% (94 A).
Connecting and installing a replacement EVS9328-EPV004 requires proper alignment of field interfaces and drive parameters. Primary motor feedback connects via resolver input at terminal X7 or through encoder formats including TTL, HTL, SinCos, and Hiperface absolute encoders at terminal X8. Fieldbus communication relies on an onboard CANopen system bus for multi-axis setpoint distribution, alongside an Automation Interface (AIF) slot that supports option cards for PROFIBUS-DP, DeviceNet, INTERBUS, or LECOM. Commissioning a replacement unit involves transferring parameters via the EMZ9371BC keypad module or downloading parameter archives through Global Drive Control (GDC) software version 4.x or higher. If backup files are unavailable, parameter extraction from a faulty donor unit can assist in restoring machine operations with support from ABC Industrial Parts.
System status and operating conditions are displayed directly on the unit through green and red diagnostic status LEDs. A solid green light indicates operational readiness with controller enable, while a blinking green light shows the drive is ready and awaiting an enable signal; blinking or solid red lights indicate fault warnings, TRIP conditions, or internal hardware lockouts. Detailed diagnostics can be accessed through parameter code C0168 for active faults and C0170 for the last eight logged fault events using the keypad menu or GDC software. First-line field checks should verify AC supply line voltages, motor phase insulation resistance, feedback cabling, and CAN bus termination resistors (120 Ohm). When facing unresolvable internal micro-controller or gate drive failure codes such as H05 or H10, board-level faults are not field-serviceable, making tested exchange units or professional repair from ABC Industrial Parts the most reliable path back to production.
Technical Specifications
| Rated Power | 22 kW |
| Supply Voltage Range | 320 V AC to 528 V AC |
| Rated Continuous Output Current | 47 A |
| Max Output Current (60s Overload) | 70.5 A |
| Peak Output Current | 94 A |
| Switching Frequency | 8 kHz |
| Digital Inputs | 8 |
| Digital Outputs | 4 |
| Analog Inputs | 2 |
| Analog Outputs | 2 |
Programming and Configuration
The Lenze EVS9328-EPV004 relies on dedicated EP software firmware designed for dynamic multi-axis positioning. Drive setup and parameter management are supported through Lenze Global Drive Control (GDC) software version 4.x or higher using a computer connected via an EMF2177IB USB-CAN interface adapter. Alternatively, local configuration can be performed using the plug-in EMZ9371BC keypad operating module.
The operating module allows full parameter modification, live diagnostic monitoring, and fault history inspection. The keypad unit can store up to four complete parameter sets directly in its internal memory, facilitating parameter transfer between identical drives during servicing. To clear unrecoverable configuration errors or reset settings, parameter C0002 can be set to 1 to restore factory default parameters.
Communication and System Integration
System integration on the Lenze EVS9328-EPV004 is centered around the integrated CANopen system bus interface. This onboard fieldbus allows fast, multi-axis setpoint distribution and coordinated motion control without requiring external communication cards. Up to 8 digital inputs, 4 digital outputs, 2 analog inputs, and 2 analog outputs handle discrete machine signals and setpoints directly at the terminal strip.
Modular fieldbus integration is provided by the unit's Automation Interface (AIF) slot. Inserting optional modules such as the EMF2133IB PROFIBUS module enables connection to PROFIBUS-DP networks, as well as optional cards for DeviceNet, INTERBUS, or serial LECOM communications. Master frequency inputs and outputs also enable direct master-slave encoder emulation for synchronized multi-axis production lines.
Diagnostics and Status Indication
Operational state and diagnostic fault tracking on the EVS9328-EPV004 are signaled via dual front-panel status LEDs. The green LED indicates operational readiness or standby status, while the red LED communicates warning states, active TRIP conditions, or major internal system faults.
For thorough diagnostic evaluation, parameter C0168 displays active error codes, while parameter C0170 logs the fault history memory containing the last eight fault events. Technicians can review these parameters directly through the EMZ9371BC keypad error menu or by utilizing the real-time diagnostic and oscilloscope view built into Global Drive Control (GDC) software.
Status LED Indicators
| LED | Color/Status | Meaning |
|---|---|---|
| Ready / Operational (Green LED) | Green - Solid / Blinking | Solid Green indicates operational status with controller enabled. Blinking Green indicates drive ready, awaiting enable signal. |
| Fault / Error (Red LED) | Red - Solid / Blinking | Blinking Red indicates active fault warning or TRIP. Solid Red indicates severe TRIP lockout or internal fault. |
Replacement and Spare Part Considerations
When replacing a failed drive with a spare Lenze EVS9328-EPV004, ensure the replacement matches the exact hardware part number and EP position software firmware requirement. Before applying power to the machine, verify that power terminal wiring, feedback cables at terminals X7 or X8, and external dynamic braking resistor connections match the original installation.
Because new or replacement drives carry factory default parameters, the replacement drive must be loaded with the machine-specific parameter set prior to running. Parameters can be copied using the memory transfer capability of an EMZ9371BC keypad or uploaded from a saved GDC archive file. Ensure proper CAN bus node addressing and verify 120 Ohm termination resistors at network ends before restoring full multi-axis operation.
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 | Instantaneous motor phase short circuit or ground/earth fault detected at inverter power stage. | Short circuit in motor cable, motor winding isolation fault, line capacitance excessive, ground contact. | Check motor wiring and insulation resistance with megohmmeter. Inspect motor phases for phase-to-phase or phase-to-earth short circuit. If fault occurs without motor connected, internal power stage is damaged — contact service. |
| OC2 | Overcurrent during Acceleration | Motor current exceeded maximum allowed threshold during speed acceleration ramp. | Acceleration ramp time set too steep, motor size mismatched, mechanical jam/brake closed. | Increase acceleration time (tR), check mechanical motor load and holding brake, verify motor parameters. |
| OC3 | Overcurrent during Deceleration | Motor current exceeded maximum threshold during dynamic braking or speed reduction. | Deceleration time set too short, dynamic brake resistor not connected or undersized. | Increase deceleration time (tF), check dynamic brake chopper circuit and external brake resistor connection. |
| OC4 | Overcurrent at Constant Speed | Motor current exceeded allowable threshold during steady-state constant speed operation. | Sudden load spike, mechanical blockage, gain settings in speed controller too high. | Check drive mechanics for jamming or overload; optimize speed controller gain settings. |
| OC5 | I x t Drive Overload | Continuous overload threshold of the drive inverter (Ixt) exceeded. | Drive operated above rated continuous current (47 A) for too long. | Reduce duty cycle or continuous motor load; check process power requirement against drive size. |
| OU | Overvoltage DC Bus | DC bus intermediate voltage exceeded maximum safety threshold (> 770 V DC). | Regenerative energy from motor during deceleration too high, brake resistor open circuit, brake chopper transistor failed. | Check dynamic brake resistor wiring and resistance value. Extend deceleration ramps. Verify mains input voltage. |
| LU | Undervoltage DC Bus | DC bus intermediate voltage dropped below minimum threshold (< 430 V DC). | Mains supply failure, supply phase missing, mains line voltage too low, transient power loss. | Check AC supply line voltages and fuses. Verify main contactor and line choke wiring. |
| OH | Heatsink Overtemperature | Heat sink temperature exceeded maximum operating limit (> 90 °C). | Cabinet ambient temperature too high, cooling fan defective, heat sink clogged with dust, insufficient airflow. | Clean heat sink cooling fins. Check drive cooling fan operation. Improve control cabinet ventilation. |
| OH3 | Motor Overtemperature (PTC / KTY) | Motor temperature sensor triggered overtemperature fault via terminal X10 input. | Motor thermal overload, cooling fan failure on motor, thermistor cable broken or disconnected. | Allow motor to cool down. Check motor loading and external cooling fan. Measure resistance of PTC/KTY thermistor. |
| OH4 | Drive Inside Temperature Warning / Trip | Internal air temperature inside the drive housing exceeded safety threshold. | Ambient environment in control panel too hot or internal circulation fan failed. | Reduce panel temperature and check control cabinet air conditioning. |
| OH7 | Motor I x t Overload | Calculated thermal load of motor exceeded maximum allowable continuous threshold. | Motor run continuously at high torque at low speeds without forced cooling. | Check motor sizing, reduce continuous load, or add external forced ventilation fan to motor. |
| OEB | Brake Chopper Overload | Internal dynamic braking chopper transistor or brake resistor thermal limit reached. | Extremely frequent braking cycles, braking resistor resistance too low. | Increase braking time, check external braking resistor value and duty cycle rating. |
| CE0 | Communication Error AIF | Communication fault detected at the Automation Interface slot (AIF). | AIF module (e.g. PROFIBUS card) loose, fieldbus cable damaged, master timeout. | Check card mounting in AIF slot, inspect fieldbus cabling and bus termination resistors. |
| CE1 | Communication Error CAN / Systembus | Communication fault on integrated CAN / Systembus interface. | CAN bus cable shorted/open, missing termination resistor (120 Ohm), incorrect baud rate. | Check CAN wiring, verify 120 Ohm termination resistors at both network ends, check baud rate settings. |
| CE4 | CAN Bus Off State | CAN controller switched off due to severe transmit/receive error count threshold. | Heavy electrical interference, ground loops, incorrect shield connection, bad node ID assignment. | Check shield grounding, ensure unique CAN node addresses, inspect cable routing away from power cables. |
| P12 | Position Controller Software Limit Switch | Target position selected is outside configured software limit switch range. | Target position command exceeds maximum or minimum software position limits. | Check motion profile parameters and software limit switch settings in code C1220/C1221. |
| P13 | Following Error / Lag Limit Exceeded | Position deviation between actual position and setpoint command exceeded tolerance threshold. | Mechanical overload, axis binding, position loop gain (Kv) set too low, acceleration too high. | Check mechanics for free movement. Increase position controller gain or adjust following error threshold (C1215). |
| P14 | Homing Sequence Fault | Homing run aborted or home switch signal not detected correctly. | Home proximity switch failed, incorrect homing mode selected, homing direction inverted. | Check homing switch digital input, verify zero pulse from encoder/resolver, review homing configuration. |
| P15 | Hardware Limit Switch Triggered | Hardware positive or negative limit switch digital input activated. | Axis overtravel beyond physical working zone. | Manually jog axis out of limit switch range, inspect limit switch wiring and inputs. |
| EER | EEPROM Memory Error | Checksum or read/write error occurred while accessing internal non-volatile EEPROM memory. | Power supply failure during parameter save, EEPROM hardware defect. | Reload factory default parameter set (C0002 = 1). If error persists after power cycle, internal control board fault — return unit for repair. |
| Sd1 | Resolver Feedback Error | Signal loss or wire break detected on resolver input connector X7. | Resolver cable damaged, plug disconnected, resolver coil fault. | Check resolver cable connection at X7 and motor junction box. Measure resolver coil continuity. |
| Sd2 | Incremental Encoder Fault | Signal error or cable break on incremental encoder input connector X8. | Encoder supply voltage failure, channel A/B signal loss or short circuit. | Inspect encoder cable and shielding. Check encoder power supply voltage setting at code C0421. |
| Sd3 | Absolute Encoder Communication Error | Communication failure with Hiperface / SSI absolute encoder. | Serial data line interrupted, noise interference, encoder power supply fault. | Check absolute encoder connection cable and shielding at X8 interface. |
| H05 | Internal Control Board Hardware Error | Internal micro-controller hardware fault or memory corruption detected during boot. | Internal circuit board failure or component breakdown. | Internal board hardware fault — unit is not field serviceable; replace drive or return unit for repair. |
| H10 | Internal Power Section Fault | Internal driver circuit or gate drive supply fault detected in power inverter section. | Power module fault, gate driver circuit component failure. | Internal hardware failure — return drive to authorized Lenze service center for repair. |
Frequently Asked Questions
What software is required to configure the Lenze EVS9328-EPV004 servo drive?
The drive is configured using Lenze Global Drive Control (GDC) software version 4.x or higher via an EMF2177IB USB-CAN interface adapter, or locally using an EMZ9371BC keypad operating module.
How can I transfer parameters to a replacement EVS9328-EPV004 drive?
Parameters can be transferred by saving and restoring parameter archives using GDC software, or by saving up to four parameter sets onto an EMZ9371BC keypad module and copying them directly to the replacement unit.
What motor feedback types are compatible with this drive?
The controller supports primary 2-pole or multi-pole resolvers on terminal X7, as well as TTL, HTL, SinCos, and Hiperface absolute encoders on terminal X8.
How do I troubleshoot a CAN communication error (CE1 or CE4)?
Verify that CAN wiring is intact, ensure that 120 Ohm termination resistors are present at both ends of the CAN network, confirm unique node addresses, and check baud rate settings.
What does fault code H05 or H10 indicate?
Fault codes H05 and H10 indicate internal microcontroller or power section hardware failures. These internal hardware faults are not field-serviceable and require drive replacement or professional repair.
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