Lenze 8200 Vector Selection

Lenze 8200 Vector Inverter System Selection and Engineering Application Guide

Modular design: create systems instead of individual devices

The Lenze 8200 vector frequency converter series covers a wide power range of 0.25 kW to 90 kW and supports 230V (single-phase/three-phase), 400V, and 500V power systems. The core concept is "to create as a system": the inverter body (Base Controller) is combined with functional modules (I/O expansion), communication modules, operation panels, filters, and brake accessories, which can adapt to various application scenarios from simple single machine speed regulation to complex fieldbus networking.

This series supports multiple open-loop/closed-loop modes such as V/f linear/square characteristics, vector control, and sensorless torque control. The output frequency is up to 650 Hz, and the overload capacity is up to 180% of the rated torque for 60 seconds (210% torque for 3 seconds for models above 15 kW), meeting the requirements of high dynamic applications.

Quick Selection Guide: Distinguishing between Normal Operation and Capacity Expansion Operation

Lenze offers two selection paths:

Normal operation: The rated power of the frequency converter matches the rated power of the motor, and is suitable for the vast majority of constant torque or variable torque loads.

Increased rated power operation: allows the use of higher power motors (such as square torque loads for pumps and fans), but must meet specific conditions: specified power supply voltage range, only allows 2 kHz or 4 kHz carrier frequency, and must use approved incoming reactors, fuses, and cable cross-sections.

In the selection table, users need to determine the specific inverter model based on the power supply voltage (1-230V, 3-230V, 3-400V, 3-500V), whether it is equipped with an integrated EMC filter, and the installation method (standard cabinet, cold plate technology, push through technology).

2.1 230V single-phase system (0.25~2.2 kW)

Standard models such as E82EV251K2C200 (0.25kW, without EMC filter) or E82EV251K2C (with integrated filter). For single-phase inputs above 1.5 kW, an incoming reactor (such as ELN1-0250H018) must be used to limit harmonics. During capacity expansion operation, a 0.37 kW frequency converter can drive a 0.75 kW motor, but it needs to be downgraded and used in conjunction with specific reactors.

2.2 400V/500V three-phase system (0.55~90 kW)

The 400V level is the most widely used range. Low power (≤ 11 kW) models such as E82EV551K4C200 to E82EV113K4C200 can use integrated EMC filters or external filters. Medium power (15~45 kW) models such as E82EV153K4B201 typically require an external power filter (such as E82ZN22334B230) or an internal power filter (EZN3Axxxx). High power (55~90 kW) models require the use of ELN3 series incoming line reactors and dedicated brake choppers (EMB9352-E).

Special precautions for 500V system: When the power supply voltage is between 484V~550V, a braking resistor (such as ERBM470R100W, etc.) must be used, otherwise the frequency converter is not allowed to operate (limited version of integrated EMC filter). Therefore, for a 500V power grid, it is recommended to prioritize the use of models without integrated filters (K4C2xx), or confirm that braking resistors have been configured.

Technical data interpretation and derating conditions

3.1 Rated current and overload capacity

The rated output current (Ir) of the frequency converter varies with the carrier frequency. Taking the 400V 7.5 kW model E82EV752K4C as an example:

Ir=16.5 A at 2 kHz, 60 second overload Imax=24.8 A

Ir=10.7 A at 8 kHz, 60 second overload Imax=16.0 A

At 16 kHz, Ir further decreases, and when the radiator temperature approaches the upper limit (-5 ° C margin), it will automatically downshift to 4 kHz.

Engineers must confirm whether the continuous current at the actual carrier frequency can meet the rated current of the motor when selecting, and consider the overload period (1 minute overload+2 minutes base load).

3.2 Environmental derating

When the ambient temperature exceeds 40 ° C, the rated output current needs to be reduced by 2.5%/° C.

When the installation altitude exceeds 1000 meters, the rating will decrease by 5% for every 1000 meters increase.

The frequency converter must be installed vertically, with a ventilation gap of at least 100mm above and below, and can be arranged side by side (with a spacing of 3mm).

Key points of attachment configuration

4.1 Incoming Reactor (Mains Choke)

Incoming reactors can reduce input current harmonics, minimize pollution to the power grid, and extend the lifespan of DC bus electrolytic capacitors. Some models (such as 230V single-phase 1.5 kW and above, 400V 7.5 kW and above) require the use of incoming line reactors. The "Mains choke required" column in the selection table clearly indicates. Commonly used reactors include ELN1-0900H005 (230V single-phase, 9 mH, 5 A) or ELN3-0088H035 (400V, 0.88 mH, 35 A).

4.2 EMC Filters and EMC Grades

The RF interference generated by the frequency converter needs to be suppressed by a filter to achieve Class A (industrial environment) or Class B (residential environment) as specified in EN 55011. Lenze offers three types of filters:

LL type (low leakage current): leakage current<3.5 mA, suitable for non fixed installation systems, limited to 230V single-phase and motor cable ≤ 5 m.

SD type (short distance): low leakage current, can be used for 30 mA leakage protection switches, supports motor cables up to 20 meters long.

LD type (long distance): used in situations where long motor cables are required and meet A/B level limits, with a motor filter that can reach up to 200 meters.

In addition, models above 15 kW can use integrated power filters (Mains filter A/B), which integrate incoming reactors and RFI filtering functions to simplify wiring.

4.3 Braking unit and braking resistor

Integrated braking transistors cover models ranging from 0.25 to 11 kW, and external braking resistors can achieve energy efficient braking. Low power braking resistors such as ERBM470R100W (470 Ω, 100W) are suitable for 0.55 kW 400V frequency converters; High power requires the use of ERBD series grid resistors (such as ERBD047R01K2) and external brake chopper EMB9352-E (suitable for 15~90 kW).

When multiple frequency converters share a DC bus, DC fuses (such as EFSGRxxxxAYHN) and DC bus bars (EWZ0036/EWZ0037) must be used to provide short-circuit protection.

4.4 Motor Filter

When the motor cable exceeds 50 meters (shielded) or 100 meters (unshielded), or the motor insulation is not suitable for supplying power to the frequency converter, a motor filter (such as E82ZM2223B) should be used. The motor filter can limit du/dt ≤ 500 V/μ s and limit the motor terminal overvoltage to below 1 kV to protect the motor winding.

4.5 Operation and Parameterization Tools

Keypad XT (EMZ9371BC): Text display, menu structure, parameter copying function, can be installed on control cabinet doors or handheld.

Global Drive Control easy (GDC easy): A free PC software for parameter settings, diagnostics, and file management, supporting serial or CAN adapter connections.

I/O and Communication Module Configuration

The 8200 vector provides two expansion slots (three slots for models above 15 kW), which can be combined with functional modules and communication modules.

5.1 Standard I/O PT (E82ZAFSC010)

Provide 1 analog input (0-10V, 0-20mA, 4-20mA, ± 10V), 1 analog output (0-10V), 4 digital inputs, 1 digital output, and 1 relay output. Suitable for basic speed regulation and start stop control.

5.2 Application I/O PT (E82ZAFAC010)

Provide 2 analog inputs, 2 analog outputs, 6 digital inputs, 2 digital outputs, and 1 frequency output (0~100 kHz single/dual channels), which can be connected to an incremental encoder to achieve closed-loop speed control.

5.3 Fieldbus module

CAN PT (E82ZAFCC010): CANopen protocol, supports master/slave, up to 500 kbit/s.

PROFIBUS-DP PT (E82ZAFC010): DP slave, automatic baud rate detection, maximum 12 Mbit/s.

INTERBUS PT (E82ZAFIC010): Remote bus slave station, 500 kbit/s.

LECOM-B PT (E82ZALC010): RS485, Lenze proprietary protocol.

AS Interface PT (E82ZAFFC010): AS-i bus used for simple digital signals.

The communication module (such as EMF2133IB PROFIBUS, EMF2175IB CANopen/DeviceNet) can be inserted into the top slot of the frequency converter and used in combination with functional modules.

Special installation techniques

6.1 Cold plate technology

Suitable for high protection level control cabinets above IP54 or in situations with water/oil cooling conditions. The frequency converter does not come with heat sinks and is directly installed on the cooling body provided by the user through a heat-conducting plate. The ordering model starts with E82CV. It is necessary to ensure that the contact surface is flat (deviation ≤ 0.05 mm) and the thermal resistance (Rth) meets the requirements (e.g. Rth ≤ 0.13 K/W for 11 kW models).

6.2 Push through Technology

Install the heat sink of the frequency converter outside the control cabinet, and there is almost no heat accumulation inside the cabinet. Suitable for applications with high heat generation and sensitive cabinet environment. The ordering model starts with E82DV. Randomly provide seals and installation frames to achieve IP65 protection level.

6.3 Safe Stop Version

To meet the requirements of EN 954-1 control category 3 and EN 1037 for "prevention of accidental start-up", Lenze offers special versions with safety relays (model suffix 040 or 241). External 24V power supply to safety relay, cutting off the power supply of IGBT driven optocoupler. Compared with the external motor contactor scheme, this scheme reduces wiring, saves space, and does not interrupt the motor cable shielding.

6.4 IT System Version

Used for ungrounded power supply systems (IT systems) to prevent insulation monitoring devices from malfunctioning. The ordering model ends with B101 (such as E82EV153K4B101). This version has improved the insulation strength of the frequency converter and will not damage the equipment in the event of a single phase to ground fault.

Summary of Application Cases

7.1 Speed adjustment (potentiometer given)

Use standard I/O modules, connect 1k~10k potentiometers externally to terminals 7/8/9, and connect terminal 28 to the start switch. Acceleration/deceleration ramp time can be set.

7.2 Fixed Frequency Selection (JOG)

Select three preset frequencies (such as 20 Hz, 30 Hz, 40 Hz) through two digital inputs (such as terminals 11/12), suitable for multi speed applications.

7.3 Pressure Control (PID)

Using an internal process controller, the pressure setting value is provided by a 4-20 mA signal from the PLC, and the actual pressure is fed back by a 0-10 V sensor. Configurable manual/automatic switching, night time voltage reduction operation (fixed frequency), minimum frequency anti dry rotation, frequency hopping to avoid mechanical resonance.

7.4 Group drive (parallel connection of multiple motors)

In V/f control mode, one frequency converter can drive multiple parallel motors. The total current shall not exceed the rated current of the frequency converter. Each motor needs to be connected in series with a thermal switch (NC contact) connected to the PTC input terminal (terminals T1/T2) of the frequency converter to achieve collective protection.

7.5 Sequential switching

For example, two refrigeration compressors: compressor 1 is controlled by a frequency converter for speed regulation, and when the demand increases, compressor 2 is directly started by outputting K1 through a relay (power frequency). Utilize the programmable relay delay function of the application I/O module to avoid frequent switching.

Common selection errors and precautions

Neglecting the requirements for incoming reactors: Some models (such as single-phase 230V 1.5 kW or above) must use reactors, otherwise it may damage the rectifier or cause harmonic exceedance.

Blind increase in carrier frequency: Increasing the carrier frequency can reduce motor noise, but it will significantly reduce the output current capability. Priority should be given to using 8 kHz (Lenze default), and only increase to 16 kHz and downgrade when necessary.

Improper selection of braking resistor: It is necessary to confirm that the resistance value is not lower than the minimum value allowed by the frequency converter (such as 0.55 kW 400V minimum 455 Ω), and the continuous power and thermal capacity need to match the braking cycle.

Improper filter combination: When using LD type RFI filters, motor filters must be used simultaneously to achieve the EMC limit for long cables. The Mains filter already includes an incoming reactor and does not require an external reactor.

Insufficient thermal resistance of cold plate technology: The thermal resistance of the user's own radiator must be less than the specified value, otherwise the frequency converter will be protected against overheating.