Complete Guide to Lenze ECS Servo System

Complete Guide to Lenze ECS Servo System

In the field of modern industrial automation, multi axis high dynamic drive tasks impose strict requirements on the power density, response speed, installation flexibility, and long-term reliability of servo systems. The Lenze ECS servo system is designed for this purpose - it integrates high overload capacity, compact structure, multiple installation forms, and rich software functions, and can be widely used in handling robots, packaging machinery, gantry systems, machining centers, and other occasions. This article systematically elaborates on the hardware selection, power calculation, braking energy management, EMC countermeasures, software configuration, and common troubleshooting methods of Lenze ECS servo system from the perspective of engineering practice, providing a practical technical manual for on-site engineers and technical support personnel.

System Overview: Why Choose ECS Servo System

The Lenze ECS servo system is a multi axis servo drive solution based on DC bus sharing. Its core features include:

Extremely high overload capacity: The peak current of the shaft module can reach 4 times the rated current (such as ECSx032 with a maximum output current of 32A and a rated current of 12.7A), meeting the requirements of rapid acceleration, deceleration, and impact load.

Multiple installation forms: support built-in control cabinet (build in), push through technology (push through, external heat sink), and direct installation of cold plate to adapt to different heat dissipation conditions.

Integrated safety function: All axis modules come standard with the "Safe Torque Off" function, which complies with EN 954-1 control category 3 and allows for safe shutdown without the need for additional safety relays.

Flexible software features: ranging from simple speed/torque control to programmable positioning, electronic cam, winding control, and even preset flying shear and cross cutting solutions, covering various typical processes.

The most common confusion encountered by engineers when facing multi axis systems includes: how to choose the capacity of the power module? How to determine if a capacitor module is needed? What is the appropriate size for the braking resistor? How to suppress encoder interference? This article provides answers one by one.

Hardware selection and power calculation

2.1 Selection steps of axis module

The correct selection of axis modules requires starting from mechanical load data and following the steps below:

Determine load parameters: 

Calculate maximum torque M max

Maximum speed n max

Effective torque Meff

For systems with reducers, a reduction ratio is also required ii。

Select servo motor: Based on the above parameters, choose the appropriate motor from the Lenze MCS (synchronous motor), MDCKS, MCA, or MDFQA (asynchronous motor) series. Specific data can refer to the 'Servo Motor Product Catalog'.

Determine the model of the shaft module: The selection of the shaft module is determined by the maximum current and continuous power. The overload mode of the ECS axis module is: within a 3-minute cycle, the maximum output current during the 1-minute load phase can reach 150% of the rated current (some low-power models can reach 200%), and during the 2-minute recovery phase, it reaches 75% of the rated current.

Rated data of ECS axis module (400V system, 8kHz switching frequency)

Model Rated DC bus current (A) Rated output current (A) Maximum output current (A) Power consumption - Internal module (W) Power consumption - Heat sink (W)

ECSx004 2.5 2.0 4.0 13.3 14

ECSx008 4.9 4.0 8.0 17.3 29

ECSx016 9.8 8.0 16.0 20.7 64

ECSx032 15.6 12.7 32.0 27.5 117

Note: The actual output current can be increased by 26% to 35% under specific control factors.

2.2 Calculation of Power Module and DC Bus Capacity

In a multi axis system, all axis modules share the same DC bus. The power module must provide the sum of the average power of all axes and have sufficient peak power capability. In practice, it is recommended to draw a "time power diagram" of the entire machine cycle, superimposing the transient power of each axis to obtain the total power curve.

Power module model and data

Rated DC bus current of power module (A) Applicable voltage range Integrated braking chopper Continuous braking power (kW)

ECSEE012 12 3 AC 180~550V has 0.1

ECSEE020 20 3 AC 180~550V has 0.1

ECSEE040 38.5 3 AC 180~550V with 0.1

2.3 Criteria for Capacitor Modules

In dynamic multi axis applications, the DC bus may generate significant ripple or even undervoltage due to instantaneous energy exchange. Lenze provides ECS capacitor modules (ECSZK series) for increasing bus capacitance. A simple and practical criterion is as follows:

k=C total P avg

k= P avg C total

among which C total

The sum of the DC bus capacitors inside all axis modules (in μ F),Pavg

The average total power (in kW) of all drives. if k≥one hundred μ F/kW k≥100 μF/kW， Usually, no additional capacitor module is required; Otherwise, it is recommended to install it.