FEATURE MACHINE BUILDING, FRAMEWORKS & SAFETY
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BrIngIng MotIon control & IndustrIal autoMatIon to tHe next level
Eric van den Broek, MD EMEA West, Lenze, takes a look at the features and benefits of the i-series decentralised controllers
B
uilding an energy- efficient machine requires looking
beyond just the motor. Lenze understands this well, and therefore its portfolio allows you to assemble the entire drive train from the right components. This article focuses on the decentralised controllers of the i-series, which share the same DNA as Lenze’s IE5 and IE7 motors: innovative, energy- efficient, and user-friendly. Controllers are best suited
for the cabinet (i5 cabinet), wall (i5 protec), or motor/wall (i5/i6 motec) depending on the application. Lenze users don’t have to worry about how to commission and operate the devices. “Because they use the same software, it’s easy to switch,” explained Eric van den Broek, MD EMEA West. “If you know one, you know them all, allowing you to choose the right model for each application.” van den Broek notes that decentralised
solutions are gaining popularity: “The cost and time savings of cabling are a significant advantage of these controllers,” he commented.
More tHan drIves Lenze’s response to this trend is the new i550 and i650 Motec controllers, covering a range from 0.37 to 45 kW. “They are much more than drives. They are solutions for a green future, digitalisation, and quick and easy implementation,” stated van den Broek. He delves into how these motec models
contribute to greater energy efficiency: “Energy- efficient operation is based on three pillars. The dimensioning must be correct, which can save 20 to 30%. This can be done intuitively with the Easy System Designer and, of course, our expertise. Additionally, the selection of motor, gearbox, and controller must be coordinated to achieve high energy efficiency. Finally, regenerative feedback is important: recovering energy by feeding it back into the grid. Our motec perfectly meets these requirements.”
usIng less energy, losIng less energy
The various modes in which the motec can operate help it save energy. van den Broek highlights the VFCeco mode, which is unique
18 DESIGN SOLUTIONS MAY 2025
Feature
to Lenze. “In normal operation with an inverter, the reactive current is kept constant, and the active current is adjusted based on the load. We do it differently: based on the load, we can reduce the reactive current thanks to our know-how,” van den Broek summarised. “The motor then draws less current, resulting
in fewer losses and less heating of the motor. This makes it doubly interesting in, for example, freezer environments. What you don’t heat, you don’t have to cool later, directly saving costs on energy consumption in your freezer warehouse,” he added. Lenze also does energy recovery differently
and better. “We don’t need brake resistors and can continuously feed high-power energy back into the grid,”said van den Broek. This is particularly interesting for applications like pallet lifts in intralogistics projects.”
dIgItal skIlls Lenze has also done its homework in terms of digitalisation. van den Broek explained: "All data from the controllers is sent to a central PC via our Drive Datahub software. Extensive analysis can be performed, and necessary measures can be taken to prevent downtime; very proactive.” Those curious about how this works can see it in practice in Lenze’s automated warehouse. “You don’t need extra sensors; the inverter is
the smartest sensor you can have. Based on the harmonic frequency of the currents, you can detect where and when problems might occur. This is important because reliability is crucial in fully automated warehouses. Additionally, the i550 and i650 motec can be equipped with an
optional IO link master, allowing intelligent IO link sensors to be connected locally, saving costs for our customers as they don’t need additional IO link masters,” added van den Broek.
Integrated posItIonIng and IntellIgence
And then there’s the promised ease of use. They fit within a wide power range and work with the same software. But what else? van den Broek explained: “Firstly, only one
cable, standard with connectors, is needed for 400VAC and 24VDC connection of the i550 or i650 motec. With the provision of 24VDC, communication between the inverter and PLC will remain intact in case of power failure. Secondly, we use M12 connectors for communication, IOs, and safety connections. Everything is plug-and-play for quick implementation and less chance of errors.” van den Broek also mentions two special
features of the i650: integrated positioning and expandable with additional PLC logic. You can locally complete many applications with the i650 controller, reducing bus communication load. The i650 also has extra variants in terms of safety. In addition to the STO version, it can be equipped with additional safety functions such as Limited Speed, Safe Brake control, etc. In addition, a version with extended safety
functions and additional safety IOs will be available. This will be suitable for various communication networks: Profinet-Profisafe, Ethercat-FSoE, and Ethernet-CIP safety.
Lenze
www.Lenze.com
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