Pump Ready Lenze i500 Pump Solutions

No challenge is too great or single application too small. From industrial plants to OEMs to municipal water and wastewater treatment facilities, Lenze i500 pump solutions are hard at work. Versatile and robust, our industrial drives are cost-effective and low maintenance. Our focus is on variable speed flow and pressure control so whatever your specific application requires, Lenze has the drive to match form, fit, and function.

Communication Options:

• CANopen
• EtherCAT
• EtherNet/IP
• IO-Link
• Modbus
• PROFIBUS
• PROFINET
• ModbusTCP/IP
• POWERLINK

Input Voltage/Power:

• 120 V
• 230 V
• 400/480 V
• 600 V
• 0.33 hp (0.25 kW) to 175 hp (132 kW)

Features:

• Programmability
• Sequencer mode
• Parameters grouped by function
• Hassle-free installation
• Quick commissioning
• Diagnostics
• Quick reset to default or OEM settings

With a wide range of communication options, i500 is also ready to integrate into your choice of upper-level controls vendor. i500 drives are available in IP20, NEMA 1 as well as NEMA 4X versions ready to mount where you need them. NEMA 4X models also feature an optional, lockable disconnect switch to service the motor right at the pump.

The NEMA 4X models can also be equipped with optional 22 mm operators which can be used for functions such as START/STOP and potentiometers for speed control for ease of operation by gloved workers.

The i500 cabinet and protec drives feature 12-Bit analog inputs for PID control with Sleep and Rinse functions so pressure, temperature, flowrate, and dosing applications can all easily be controlled.

Cascade Pump Controller
Example with i550 cabinet frequency inverter:
M - Main drive
A1 - Auxiliary drive 1
A2 - Auxiliary drive 2

Centrifugal pumps are used in a wide range of commercial, industrial, and municipal applications. Pumps are sized for the maximum flow condition; however, most of the time a process will not require 100% of the system’s capacity. Significant energy savings can be accomplished by simply taking advantage of the affinity laws.

Typical applications:

• Chilled and hot water pumps
• Condenser water pumps
• Booster pumps
• Potable water pumps
• Chemical pumps

Centrifugal Pumps:
To reduce the voltage supplied to the motor as a function of speed, i500 drives use a quadratic V/Hz profile following the affinity law (following the torque curve). Compared to throttling valves, the i500 VFD offers greater energy savings. Operating at 75% flow with an i500 drive reduces power demand by over 50%, while a throttling valve requires about 90%.

In centrifugal pump applications, the i500 can have its motor overload programmed to fault the drive in the event of a pump runout/open flow condition. Additionally, loss of load detection or an external sensor can be utilized to prevent pump cavitation.

The i500 also features a built-in cascade pump controller function that allows the drive to control two additional assist pumps to the main pump, giving extra capacity to PID-controlled systems. The two assist pumps can be alternated to balance wear.

Positive Displacement (PD) Pumps:
PD pumps require precise speed regulation to control the flow rate and high-starting torque to handle the initial load or pseudoplastic fluids. The i500 Series offers 200% starting torque and 0.3% speed accuracy open loop in vector mode (or 0.01% closed loop with an encoder). This reduces the motor size, simplifies system controls, and lowers application costs.

Typical applications:

• Metering pumps
• Dosing pumps
• Gentle fluid handling
• Pumping highly viscous fluids or highly frictional loads

Pressure limitation for protecting the piping system in PD pump applications can be achieved by setting the drive’s maximum motor current. The i500 can minimize shock from water hammer/pipe fill by programming longer acceleration and deceleration times.

Motor Control Mode for the Type of Pump Utilized:

For centrifugal pumps, set the “Motor control mode” (P300.000) = “V/f control (open loop) [6]” and set “V/f characteristic shape” (P302.000) = “Quadratic [1]” to maximize energy savings.

For positive displacement pumps, set the “Motor control mode” (P300.000) = “Sensorless Vector (SLVC) [4]” for accurate flow control and optimum starting torque. To trigger a fault for a pump runout/open flow condition, set “Maximum utilization (60s)” (P308.001) = 120% and configure the motor rated current (P323.000) to match the motor’s nameplate data.

To minimize water hammer or soften pipe fill:

• Use longer acceleration and deceleration times in non-PID applications.
• In PID applications, use longer times for “PID setpoint ramp” (P604.000), “Accel time of activation” (P607.001), and “Decel time for masking out” (P607.002).

To prevent cavitation, wire a pressure switch between “24V” and a digital input (e.g., DI3) and configure it to trigger either “Activate fault 1” (P400:043) or “Activate fault 2” (P400:044).

To limit pressure in PD pump applications, set “Max current” (P324:000) to a value that suits the application.

Basic PID Setup: PID applications are either "normal acting" or "reverse acting." Set the “Operating mode” (P600.001) for either "Normal operation" [1] or "Reverse operation" [2] as appropriate for the application.

Program the analog input used for the monitored process variable, set the “Default set point source” (P201.002) to “PID preset 1” [11], and adjust the PID loop settings for tuning.

For more detailed pump application notes, see the “i500 Pump Application Guide.”