Lenze i500

The Lenzei500 is the newest frequency inverter from Lenze and is available in the 0.33 to 60 horsepower power range. The Lenze i500 features a streamlined design, scalable functionality, and exceptional user-friendliness. Lenzei500 provides a high-quality frequency inverter that already conforms to future standards in accordance with the EN 50598-2 efficiency classes (IE). Overall, the Lenze i500 provides a reliable and future-proof drive for a wide range of machine applications.

The functions and power of the new range of Lenze i500 frequency inverters can be tailored to virtually any machine application and industrial environment. Lenze i500 inverters are compliant with efficiency class IE2. Lenze i500 inverters feature a slim design and peak energy efficiency in the 0.33 to 60 Hp power range. Lenze set out to bundle cutting edge control technologies into a customized IE2-compliant package for machine builders. All of the Lenze i500 components are stringently designed for optimal energy efficiency, which boosts the value for machine builders by increasing power density while allowing for a smaller design. The compact, modular Lenze i500 frequency inverter features a lower housing depth along with a sophisticated cooling system to reduce heat losses and allow side-by-side installation with minimal wiring in a smaller control cabinet. Lenze i500 inverters for control cabinet installation feature IP20 and IP31-rated protection. Delivering functional scalability and integrated safety, the Lenze i500 power section is structurally separate from the control unit, and contains different forms of field bus communication, including Ethernet, multiple I/O interfaces, and plug options for a keypad, a USB interface or a wireless LAN module. These interfaces provide users with greater flexibility and ease of commissioning, parameter setting, maintenance and diagnostics. The wireless LAN module can communicate with a PC or via a smart phone keypad application.

Lenze i500 Advantages

  • Space saving design: 2.36 in. (60 mm) wide, 5.12 in. (130 mm) deep, also zero-clearance mounting.
  • Innovative interface options enable set-up times faster than ever before.
  • The wide-ranging modular system enables various product configurations depending on machine requirements.
  • The i500 is recommended in applications for pumps and fans, conveyors, formers, winders, traveling drives, tool and hoist drives.

Lenze is a global manufacturer of electrical and mechanical drives, motion control and automation technology. As a global specialist in Motion Centric Automation, Lenzeoffers products, drive solutions, complete automation systems, engineering services and tools from a single source. Lenze isa leading provider of automation solutions to the packaging industry, and our other focus industries include automotive, material handling and logistics, robotics, and commercial pumps/fans. With a global network of engineers, sales representatives, and manufacturing facilities, Lenze is well-positioned to meet the motion control needs of customers worldwide.

The new Lenze i500 frequency inverters are structured and built to give machine builders the ultimate in energy savings, integration and design flexibility to specify precisely the features they need. To learn more about Lenze i500 frequency inverters, visit the Lenze Website. For Lenze i500 frequency inverter quotes, contact Precision Electric.

Inverter Repair

Most inverterrepair can be prevented with routine maintenance. Inverter repair costs and lead times can also be reduced with routine maintenance. Inverterrepair can be expensive and also cost manufacturers production downtime while the inverter repair is in process.Most manufacturers stock spare inverter modulesto prevent production downtime in the event of an inverter failure.Components used forinverter modules are often cheaply made and prone to failure. Knowledgeable inverter repair shops should replace cheaply made components with high quality components during the inverter repair process. Using high quality components in an inverter repair ensures a higher chance of success and a longer lifespan during production.

Checkingconnections is a step many people miss or do incorrectly during the inverterrepair process. Heat cycles and mechanical vibration can lead to sub-standard connections, as can standard preventative maintenancepractices. Reusing torque screws is not a good Idea, and further tightening an already tight connection can ruin the connection.Bad connections eventually lead to arcing. Arcing at the inverterinput could result in nuisance over voltage faults, clearing of input fuses, or damage to protective components. Arcing at the inverteroutput could result in over-current faults or even damage to the power components.

Loose connections can cause erratic operation. Loose START/STOP signal wires can cause uncontrollable inverterstarting and stopping. A loose speed reference wire can cause the drive speed to fluctuate, resulting in scrap, machine damage, or personnel injury.

Conduct Diode and IGBT Tests
There are a number of methods to test the input and output power sections of an inverter, and this step is essential prior to applying power to the inverterunit. If for any reason there is a short on the input side or output side of the inverter, further damage can be caused to the unit if power is applied to it.

For this reason, Precision Electric uses meters to properly test the input and output power sections of the inverter prior to applying power to the actual unit. If a short is found, the unit can be disassembled and the cause of the short can be diagnosed and quoted for repair. If the repair is too costly, then a replacement is offeredto the customer.

Power Up Unit
If the input and output power sections test healthy during this step of the inverter repair process, Precision Electric will power the unit and perform amp reading and output frequency tests. Precision Electric prefers to slowly increase power voltage to the unit until the rated input voltage of the inverter is achieved.

Depending on whether or not the inverter provides a display will determine what further action(s) will be taken. If display is unavailable, dis-assembly and diagnosis of the internal power supply of the control section of the inverter is likely necessary to further evaluate cause of failure and establish costand lead time for the inverter repair.

Run A Motor
If the previous three tests have passed during the inverter repair process, then it is time to run a basic jog function of the inverter with a simple template program. Often when an inverter comes into our facility, we make sure to backup whatever program is currently stored in the inverterprior to inputting a template program and running a test procedure. This ensure we have a backup copy of the program.

The best method for backing up depends on the brand of drive, but after it has been backed up, we either reset the inverterto factory defaults through the keypad and recommission a basic start, stop and job application or closed loop if an encoder is involved. If the motor will not run, it will be necessary to checkthe output voltages and current ratings going to the motor to see if the inverteris functioning properly to rotate the motor.

Contact Customer
At this point we have determined the cause of failure, estimated lead time and costof the inverterrepair. If the inverter has tested good entirely, then further underlying issues are communicated with the customer. This is when Precision Electricwill gather application specific information from the customer to establish whether or not it may be some outside issue associated with the system including, but not limited to, PLC communications, faulty IO, bad wiring or even bad cabling. There is no single way to do this step, as it really depends on a wide variety of variables.

Send Service Tech
If the customer cannot establish failure on any other aspect of the machine and the inverterappears to test fine, then it may be necessary to send a field service technician on site to establish cause of failure. Field service technicians should betrained to troubleshoot any issue ranging from standard inverterrepair, to advanced robotics, PLCs and more. Field technicians should also be trained to establish cause of failure and come up with solutions as quick as possible.

Inverter repair should be taken with extreme caution. Inverterrepair should only be performed by technicians who have required training and experience to work with electrical equipment. Precision Electric strongly recommends to consult an expert in the field when repairing or installinginverterequipment.Many invertercontrollers have an internal DC bus that retains a charge after power has been cut to the drive, as a result, it does not mean it’s safe to work with. Technicians working with inverter repair must always take extra precautions to ensure proper safety measures are taken, or injury or even death may occur.

For inverterrepair and inverter replacement quotes, contact Precision Electric.

ABB Motor Control Applications

ABBmotor control applications can be seen in every industry and in all power ranges. ABB motor control applications are compatible with virtually all processes, automation systems, users, and businessrequirements. The innovation behind ABB motor control applications isanarchitecture that simplifies operation, optimizes energy efficiency and helps maximize process output. ABB motor control applications in this article consist of ABB ACS880 single drives, ABB multi-drives and ABB drive modules.

ACS880 Multi-Drives

ABBACS880 multi-drives simplify industrial processes without limiting possibilities. ABB motor control applications using the ACS880 multi-drives can be built-to-order to meet customer needs and technical challenges through a wide selection of options; options that are all mountable within the drive cabinet. A single supply and DC bus arrangement with multipleACS880 multi-drives reduce line power, cabinet size and total investment costs. The features and options include extended I/O, field bus options, EMC filtering, brake options, fuses and main switch. Several ingress protection (IP) classes with IP22 and IP42 offering solutions for different environments are also available for ABB ACS880 multi-drives. ABB ACS880 multi-drives support induction motors, synchronous motors and induction servo motors as standard, without any additional software. ABB ACS880 multi-drives can control motors in either open loop or closed loop, through its high precision motor control platform, Direct Torque Control (DTC).

ACS880 Drive Modules

ABBACS880 drive modules are designed to be built into a control cabinet by machine builders and system integrators. With inverter power up to 3200 kW, ABB drivemodules are used to build multi-drive and high power single drive configurations. Everything that is required for a complete drive including rectifiers, inverters, brake options, EMC filters, du/dt filters, I/O options, communication options and documentation is available. ABB motor control applications using the ABB ACS880 drivemodules is versatile; and are used in industries such as metals, oil and gas, mining, marine, offshore, material handling machines, pulp and paper, automotive, food and beverage, cement, power, water and wastewater.

ACS880 Single Drives

ABBACS880single drives are compatible with a wide range of motor control applications in a broad range of industries such as oil and gas, mining, metals, chemicals, cement, power plants, material handling, pulp and paper, sawmills and marine. At the heart of the drive is Direct Torque Control (DTC), ABBs premier motor control technology. The extensive range of options include EMC filters, encoders, resolvers and brake resistors, remote monitoring tool, as well as application-specific software. Built in safety features reduce the need for external safety components. CODESYS programming capability is embedded inside the drive for making the application run more efficiently, without a separate programmable controller. Multiple drives can be daisy-chained for synchronized drive-to-drive communication. The drive offering includes two enclosure ratings, UL Type 1 (IP21) and UL Type 12 (IP55), for dusty environments. ABB ACS880 single drives also offer built-in service features.


ABB motor control applications can run in either open loop or closed loop, through their high precision motor control platform, Direct Torque Control (DTC).ACS880 motor control applications also have built-in safety features to reduce the need for external safety components. ABB motor control applications using the ACS880 support the CODESYS programming environment according to IEC 61131-3.ABB motor control applications have a common architecture that features the same control panel, parameter menu structure, universal accessories and engineering tools. The new control panel is equipped with an intuitive and high-resolution control display that enables easy navigation.ABB motor control applications using the energy optimizer control mode ensures maximum torque per ampere, reducing energy drawn from the supply.

To learn more about ABB motor control applications, visit theABB Website. Call Precision Electric for ABB repair or ABB replacement quotes.

Inverter Drives

Inverterdrives are also known as variable frequency drives, VFD’s, variable speed drives, adjustable frequency drives, AFD’s, adjustable speed drives and ASD’s. Inverterdrives are solid state motor control systems used to regulatethe speed of alternating (AC) electric motors. Inverter drives are mainly used to reduce energy consumption on electric motors for industrial manufacturers.

Inverterdrives operate as load controls within applications that may accomplish up to 50% reduction in energy costsby speed reduction on applications where the full speed (RPM) of the electric motor is not required. Inverterdrives are used in AC Servo Systems, Air Compressors, Conveyor Systems, Lathes, Mills, Plastic Extrusion, Slitter Lines, Food Processing, Waste Water Treatment Systems, Submersible Pumps, HVAC Fans and Blowers, and many more AC motor applications.

Many manufacturers apply inverterdrives withrotating equipment toreduce amperage spikes upon start up of large electric motors.Choosing the right inverterdrive for an application will benefit rotating equipment by providing less wear on the electric motors where applied; by adjusting the acceleration and deceleration time of electric motors, an electric motor’s lifespan is extended significantly. Inverter drives provide the ability to control the frequency of starting and stopping of an AC electric motor.This ability provides a means by which an AC electric motor is only operating when needed for the equipment it’s rotating, and electric motors have a longer lifespan if they are not continuously operating when they don’t need to be.

Approximately one third of the world’s electrical energy is supplied by electric motors in fixed-speed centrifugal pump, fan, and air compressor applications. These fixed-speed applications hardly ever require the full load speed (RPM) of the electric motor they’re operating. By installing inverter drives to these applications, the motor speeds are reduced, and power costs can be reduced by 50% or more. Technology has reduced cost and physical size of inverterdrives, and has improved performance through advances in semiconductor switching devices, simulation, control techniques, and control hardware and software.

Power Savings With Inverter Drives

The majority of inverter drives in the market today contain electronic circuitry that converts 60 Hertz Line power into direct current. The inverterdrive converts this line power into a pulsed output voltage that duplicates varying alternating current to a desired frequency (speed).A properly applied inverterdrive when paired with an AC electric motor, will significantly reduce operating costs. This is particularly true for variable torque loads such asFans,Blowers, andPumps.Blowers, for example, are often used with dampers to control air flow. These dampers may operate either manually or automatically. When dampers are closed, 50% of the electric motor current will drop to approximately 60% of Full Load nameplate current. By utilizing an AC variable frequency drive in this application, current draw in the motor will be reduced 30% for every 10% drop in speed. The same electric motor operating froman inverterdrive at 50% speed, will draw approximately 20% of the full load current.

Types Of Inverter Drives

Volts Per Hertz inverter drives are the most common type of drive and areknown as a V/Hz drives, or volts by hertz drives. V/Hz inverterdrives are used inapplications such as fans, pumps, air compressors, and other related applications wherehigh starting torque is not required. V/Hz drive applications typically do not require full torque when the AC motor is operating at less than the base speed (RPM) of the electric motor. V/Hz drives are the most inexpensive type of variable frequencydrive. V/Hz drives do not provide full motor torque at low RPM.

Open-Loop vector inverter drives are also known as “sensorless vector” drives. Open loop vector drives adapted the name “sensorless vector” because they do not use an external encoder for speed feedback to the motor.Open loop vector drives are used in applications where high starting torque and full torque at low speed (RPM) is required. Open-Loop vector drives operating a motor a zero RPM should not be used on crane or hoist applications. Most open-loop vector drives are used on CNC machines, mixers, mills, lathes, and other applications where high starting torque or full torque at low RPM is needed.Open loop vector drives are usually more expensive than V/Hz inverterdrives.

Closed-Loop vector drives are used in applications where precise speed control (0.01%) is needed, or in applications where extensive programming is needed. Closed-Loop vector drives use an encoder on the motor to provide constant shaft position indication to the drive’s microprocessor. The encoder feedback allows the drive microprocessor to constantly control torque no matter how many RPM the motor is operating at. Closed-Loop vector drives are used to provide the motor to operate at full torque even at zero RPM. Closed-Loop vector drives are commonly used on hoist and crane applications because crane and hoist motors must produce full torque prior to it’s brake being released, or the load will drop and it will not be able to stop.

To learn more about inverterdrives or for inverter drive repair and replacement quotes, contact Precision Electric, Inc.

ABB ACS355 Emergency Stop

fig1+estopABB ACS355 emergency stop is usedfor applications that require risk reduction from unexpected and hazardous movement. The aim to integrate drive-based safety functions is to createmachines that are safe to use. This safety function example is presented to install ABB ACS355 emergency stop but these same functions can be implemented with other ABB drives with few modifications. ACS355 machinery drives offer a safe torque off (STO) safety function as a standard integrated feature. STO eliminates the need to use contactors, which means that the drive is not disconnected from the power during safe stopping. This again enables fast restart of the drive and the machine. STO is also offered as standard in many ABB drive types for easy integration of functional safety.

Overview of the Safety Function

ABB ACS355 emergency stop, stop category 1 (Figure 1), stops the drive with a controlled deceleration ramp before disabling the drives output to the motor. In this example, the deceleration ramp is time monitored. The safety function can be used in an application where a synchronized stop of multiple axes is required.

Design of the Safety Function

fig2+estopThe design of theABB ACS355emergency stop consists of an emergency stop button as an activating switch, a safety timer relay as a logic unit and a safe torque off (STO) -circuit inside the ACS355 drive. The drive acts as an actuator to bring the motor into a nontorque state after the deceleration. See circuit diagram (Figure 2) for connection details.

Operation of the safety function When the emergency stop button is pressed, the safety relay detects the button signal and opens its non-delayed contacts to inform the drive todecelerate. Simultaneously, the relays timer for the time delay contacts starts counting. After the time delay has elapsed, the contacts open, activating the STO function, which disables the drives power output to the motor. To continue drive operation after an emergency stop, the emergency stop button is released (pulled up), which causes the contacts of the relay to close. This deactivates the STO function. The drive is restarted by a separate start command. The drive is configured not to start automatically.

The safety relay is used to provide diagnostics for the emergency stop button wiring. The relay also enables the use of a separate reset button, if required (reset button is not shown in this example since it is not required by the standard). Ensuring the required safety performance The safety function has to fulfil the required safety performance determined by a risk assessment. ABBs Functional safety design tool (FSDT-01) is used to design the desired safety function.

This is carried out according to the Following Steps:

1. Evaluate the risks to establish target safety performance (SIL/PL level) for the safety function.

2. Design the safety function loop and verify the achieved performance (PL) or safety integrity level (SIL) for the safety function loop (according to EN ISO 13849-1 or EN/IEC 62061, respectively), utilizing the device safety data and the application specific characteristics.

3. Generate a report for the machine documentation. Report should contain all the calculation results as well as all assumptions made during the application design.

Safety function verification and validation In addition to the safety calculations for the achieved safety performance (SIL/PL), the safety function needs to be functionally verified as well. Finally the implemented safety function is validated against the risk assessment to ensure that the implemented safety function actually reduces the targeted risk.

General considerations Achieving machinery safety requires a systematic approach beyond the physical implementation of a safety function. The overall machinery safety generally covers the following areas:

  • Planning for and managing functional safety during the life cycle of the machine
  • Assuring compliance to local laws and requirements (such as the Machinery directive/CE marking)
  • Assessing machine risks (analysis and evaluation)
  • Planning the risk reduction and establishing safety requirements
  • Designing the safety functions
  • Implementing and verifying the safety functions
  • Validating the safety functions
  • Documenting the implemented functions and results of risk assessment, verification and validation

For more information concerning the ABBACS355 emergency stop function, visit the ABB Website.For ABB drive repair quotes or ABB drive replacement quotes, contact Precision Electric.