Complete Guide to Lenze ECS Servo System

For example, the system has 4 ECSx016 axis modules, each with an internal capacitance of 165 μ F and a total capacitance of 660 μ F; If the average total power is 5kW, then k=six hundred and sixty/five=one hundred and thirty-two>one hundred k=660/5=132>100， No capacitor module is required. If the capacitance is only 300 μ F, the power is 6kW, and k=50<100, then the installation of ECSZK capacitor module should be considered.

Installation method and heat dissipation design

There are three installation forms for ECS servo system, and engineers should choose based on the control cabinet space and heat generation:

Built in: The module is directly installed on the control cabinet mounting board, and all heat is dissipated inside the cabinet. Suitable for situations with low power or good ventilation inside the cabinet.

Push through technology: The heat sink of the module passes through the back panel of the control cabinet and is exposed to the external environment of the cabinet. About 65% of the losses are dissipated through external heat sinks, with only 35% remaining inside the cabinet. It can significantly reduce the temperature rise inside the cabinet, and even eliminate the need for air conditioning or fans. When ordering, the corresponding model (such as ECSxX032-PT) should be selected.

Cold plate: The module does not come with a heat sink and relies on the user's system's cooling plate (such as a water-cooled plate or large metal structure) for heat dissipation. Suitable for high-density integration or extreme environments.

Key dimension reference (ECSx032):

Built in: height 247mm, width 88mm, depth 176mm, weight 2.2kg

Cold plate: height 287mm, width 88mm, depth 121mm

Installation gap requirement: Maintain a ventilation distance of at least 100mm up and down. In the push through technology, the opening size of the control cabinet must strictly follow the cutting diagram in the product manual to ensure the IP54 protection level (radiator side).

Braking energy management

When the motor decelerates or the load is lowered, energy is fed back to the DC bus, causing an increase in bus voltage. The ECS power module is equipped with a built-in brake chopper, which automatically turns on the external brake resistor when the bus voltage exceeds the threshold (typical value of 765V), converting excess energy into heat consumption.

4.1 Selection of Braking Resistors

Lenze offers three types of braking resistor series:

ERBD: IP20 protection, installed inside the control cabinet, suitable for general occasions.

ERBS：IP65， Can be installed outside the cabinet to avoid temperature rise inside the cabinet.

ERBM：IP50， Specially designed for cold plate power modules, with the same size and internal resistance as the module.

Selection suggestion: Select the corresponding resistor based on the rated DC bus current of the power module. For example, ECSEE012 recommends using ERBD047R01K2 (47 Ω, 1200W continuous, heat capacity 174kWs) or ERBS039R01K6 (39 Ω, 1600W). For high vibration environments such as stacker cranes, the anti vibration ERBDV series should be selected.

Minimum resistance limit: When using external braking resistors, the resistance value must not be lower than the minimum value specified by the power module (usually 27 Ω± 10%). A low resistance value can cause overcurrent damage to the chopper tube.

4.2 Continuous braking power and thermal capacity

In the technical parameters of braking resistors, "continuous power" (P) represents the long-term tolerable power, and "thermal capacity" (CB) represents the short-term energy absorption ability. For intermittent braking conditions, it is necessary to calculate the energy of each braking operation（

E=zero point five×Cbus×(Umax two−Umin two)

E=0.5×C bus×(U max two−U mintwo）Add motor kinetic energy and ensure that the single braking energy does not exceed the CB value of the resistor, and the average power does not exceed P.

For example, ECSEE012 with ERBD047R01K2, CB=174kWhs. If the braking energy is 50kWs, it is completely within the safe range. The average power needs to be verified during frequent braking.

EMC Countermeasures and Filter Configuration

Servo systems are typical sources of interference. The Lenze ECS system provides graded EMC solutions for different electromagnetic environments.

5.1 Power side filter

According to EN 61800-3 standard:

Class C1: Used for public low-voltage power grids (residential areas). ECSZZ series RFI filters are required, allowing for a maximum length of 25m shielded motor cables (up to 10 axes).

Class C2: Used in industrial areas, but may affect residential areas. Generally, Lenze standard power filters can be used.

Specific configuration: When using ECSEE power modules, ECSZZ020X4B (20A) or ECSZZ040X4B (40A) RFI filters should be matched. The filter should be installed close to the power module and well grounded.

5.2 Incoming Reactor (Main Reactor)

Even if strict EMC is not required, it is strongly recommended to connect the incoming line reactor (ELN3 series) in series in the main circuit. Its functions include: