Lenze 9300 Servo Replacement Guide

Overview

For over two decades, the Lenze 9300 series servo inverters (including EVS9300, EVF9300, and EVG9300 legacy lines) have been workhorses within manufacturing, packaging, and converting lines globally. However, these legacy drives have reached end-of-life (EOL) status, making spare parts acquisition highly critical and expensive. High-production lines now face severe obsolescence risks.

This guide outlines the technical roadmap for migrating legacy Lenze 9300 servo drives to the modern Lenze i950 Cabinet series. Since this transition is not a simple pull-and-replace procedure, control engineers must carefully coordinate parameter mapping, power sizing, encoder feedback signals, physical space considerations, and network changes to ensure a successful retrofit without extending planned downtime.

Legacy Product Information

The Lenze 9300 series includes specialized units for distinct positioning and speed applications, typically identified by prefixes such as EVS9321-ES through EVS9332-ES (ranging from 0.37 kW to 75 kW). These older digital servo inverters relied on a custom built-in CANopen-based interface (known as system bus or CAN on X4) for standard inter-drive communication.

Key characteristics of the 9300 legacy family include:

• Configuration Software: Global Drive Control (GDC) or Drive PLC Developer Studio (DDS) via serial adapters (EMF2102IB PC system bus adapter) or CAN card setups.
• Hardware Feedback: Resolvers (plugs into terminal group X7), Incremental Encoders (terminal group X8), or SinCos Encoders.
• Communication Slots: Proprietary AIF expansion slots accepting modules like the EMF2133IB (PROFIBUS-DP), EMF2125IB (Interbus), or EMF2141IB (DeviceNet).
• Control Philosophy: Closed-loop vector control utilizing discrete external parameters and rigid user configuration tables.

Recommended Replacements

The direct, factory-supported successor to the legacy 9300 series is the Lenze i950 Cabinet Servo Inverter. For multi-axis applications where a common DC bus system is preferred, the Lenze i700 series is recommended.

• Primary Axis Replacement: Lenze i950 (Power ranges: 0.55 kW to 110 kW).
• Direct Model Cross-Reference Examples:
  • Legacy EVS9322-ES (0.75 kW, 2.5 A continuous output) -> i950-C0.75/400-3 (0.75 kW, 2.5 A continuous output).
  • Legacy EVS9326-ES (4.0 kW, 9.5 A continuous output) -> i950-C4.0/400-3 (4.0 kW, 9.5 A continuous output).

The i950 drive series employs the standardized IEC 61131-3 CODESYS V3 programming architecture (via Lenze PLC Designer software) instead of GDC, providing standardized motion control profiles (PLCopen) directly onboard the device.

Compatibility Considerations

Transitioning from the legacy 9300 to the modern i950 requires precise verification of several engineering properties:

1. Mechanical Footprints

Older 9300 frames are wider and shallower than the modern i950 book-style frame profiles. For instance, an EVS9322-ES measures 240mm (H) x 78mm (W) x 250mm (D). The equivalent i950-C0.75 is narrower physically but typically requires slightly more depth inside the enclosure for ventilation space and cabling bends. Backplate adaptation plates or DIN-rail offset spacing must be planned before layout preparation.

2. Motor Feedback Integration

The 9300 drive dedicated specific physically separate terminals for Resolver (X7) and TTL/SinCos Encoder (X8) inputs. The modern i950 consolidates these functions into multi-encoder ports (typically X11 or external accessory cards). To reuse legacy MCS-series, MDFQA-series, or SDS-series Lenze motors, you must evaluate the feedback connector standard. Adapter cables or custom terminal pinning conversions are frequently required to connect an old Sub-D 9-pin feedback plug to the RJ45/M12 encoder inputs on the i950.

3. Industrial Communications

Legacy 9300 installations utilizing fieldbus networks must be updated:

• PROFIBUS to PROFINET: Legacy system-to-PLC interfaces built on PROFIBUS-DP (EMF2133IB) will require migrating the master PLC networks to PROFINET (onboard the i950) or installing inline gateway devices standardizing legacy signals.
• CANopen/EtherCAT: The i950 natively implements high-speed EtherCAT, EtherNet/IP, PROFINET, or Modbus TCP protocols. Note that old 9300 standard CAN setups cannot directly map to industrial Ethernet without writing standard physical transport loops.

Upgrade Benefits

Migrating to the i950 Cabinet series introduces significant efficiency and performance enhancements to legacy machinery:

• Precision Automation: Loop times are significantly shortened, boosting positioning accuracy for high-speed cutters, tension controls, and filling lines.
• Integrated Dynamic Safety: Legacy 9300 units relied on external safety contactors for power isolation. The i950 features integrated Safe Torque Off (STO) to meet SIL 3 / PL e requirements without additional control relays, reducing panel wiring overhead.
• Standardized Programming: Eliminates obsolete GDC configuration tools in favor of Lenze EASY Starter and PLC Designer (CODESYS V3 platform). This supports modern, transportable IEC 61131 programming structures.
• Predictive Maintenance Data: The i950 includes comprehensive integrated web servers and diagnostic interfaces, providing real-time data metrics over standard network architecture.

Common Migration Challenges

Engineers performing direct replacements must prepare for several technical hurdles:

• Parameter Logic Migration: Parameter sets from GDC (extension .gdc or .g81) do not directly convert to i950 format. Application setups such as electronic cams (CAM profiles), winders, and custom internal function block logic must be completely re-authored in PLC Designer.
• Dynamic Tuning Differences: Loop-gain constants, integral time variables, and current control algorithms differ structurally between the processors. The auto-tune routine (using Lenze EASY Starter) must be rerun during commissioning with the coupled mechanical load.
• 24V Control Supply: The 9300 legacy drive required a 24V supply to terminals X5 or internal boards. The i950 requires dedicated external 24V control power on terminal X1 to keep the control portion alive when the main three-phase mains input power is completely isolated.
• Braking Resistors: Existing thermal braking resistors must be measured and verified. If the legacy resistance value ($

FAQ

Q: Can I control the modern i950 drive using my old Global Drive Control (GDC) software?

A: No. GDC is legacy software compatible up to the 9300 series. The i950 acts as a modern controller programmed with EASY Starter (for basic parameterizing and configuration) and PLC Designer (for complete logic configuration and IEC 61131-3 programs).

Q: What should I do with my legacy 9300 PROFIBUS network during a migration?

A: The i950 does not feature a native modular AIF slot for legacy PROFIBUS modules. If you cannot upgrade your master PLC network interface to PROFINET or EtherCAT, you must install an protocol converter gateway (e.g., EtherCAT-to-PROFIBUS bridge) or specify an i950 model complete with dedicated PROFIBUS card accessories where available.

Q: Are the power terminals labeled the same on the 9300 and the i950?

A: No. Legacy terminals on the 9300 used specific configurations like +UG and -UG for DC bus terminals, and U, V, and W for motor outputs. The i950 uses modern standardized labeling (L1, L2, L3 for Mains, U, V, W for Motor, and +UG/ -UG for DC-bus connection), requiring precise terminal re-verification before applying power.

Q: Can my existing Lenze MCS motor with a resolver work directly with the i950?

A: Yes, the i950 supports legacy resolver feedback options. However, because the connector forms are different, you must purchase a resolver feedback adapter cable or adapt the legacy D-Sub connection to the terminal layout pinouts specified in the i950 instruction manual.