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Instruction Manual

CCez+ Series Inverter


Instruction Manual

820 Lakeside Drive - Gurnee, IL 60031


Phone: (847) 855-9150 Fax: (847) 855-9650
1-800-DRIVCON (374-8266)
www.drivecon.com Email: drive.sales@drivecon.com

Rev. 6-12-02
CCEZ+ manual.p65
Table of Contents

Definitions i

Warranty 1

Introduction 2

1.0 CCez+ Frequency converter 3

1.1 Inspection and servicing of the frequency converter 3


1.2 Specifications 4

2.0 Installation of the CCez+ 5

2.1 Mounting locations and dimensions 6


2.2 Connections 7
2.2 Wiring diagram 8
2.3 Normal operation 9
2.4 Status indication leds (green and red) 9
2.5 Programming switches 9

3.0 Programming of the application parameters 10

3.1 Example of parameter setting 10


3.1.1 Minimum speed, maximum speed 10
3.1.2 Acceleration and deceleration ramp 12
3.2 Stopping method 13
3.3 Control mode 13
3.4 Slow down travel limits 14
3.5 Preset multi-speed settings 14
3.6 Stop limit 14

4.0 Programming of the motor parameters 15

4.1 Defining the motor parameters 15


4.1.1 Motor nominal voltage and frequency 15
4.1.2 Torque boost compensation 15

5.0 Description of control modes 17

5.1 2 preset speed control 17


5.2 2 step infinitely variable control 17
5.3 3 step infinitely variable control 18
5.4 4 preset speed control 18

6.0 Fault codes, troubleshooting 19


DANGER!

The CCez+ inverter contains hazardous internal voltages


and should be serviced only by qualified personnel. Most
components are not user serviceable therefore, consult
Drivecon Corporation if a problem should arise.

Drivecon Corporation
820 Lakeside Drive
Gurnee, IL 60031 USA

Phone: (847) 855-9150


Fax: (847) 855-9650

Definitions:

Qualified Person:
For the purpose of this instruction manual and product labels, a QUALIFIED PERSON is one
who is familiar with the installation, construction, operation and maintenance of the equipment,
and the hazards involved. In addition, the person must have the following qualifications:
1. Is trained and authorized to energize, de-energize, clear, ground and tag circuits and
equipment in accordance with established safety practices.
2. Is trained in the proper care and use of protective equipment such as rubber gloves,
hard hat, safety glasses or face shields, flash clothing, etc., in accordance with
established safety practices.
3. Is trained in rendering first aid.

DANGER: For the purpose of this manual and product labels, DANGER indicates loss of
life, severe personal injury or substantial property damage WILL result if proper
precautions are not taken.

WARNING: For the purpose of this manual and product labels, WARNING indicates loss of
life, severe personal injury or substantial property damage CAN result if proper
precautions are not taken.

CAUTION: For the purpose of this manual and product labels, CAUTION indicates minor
personal injury or property damage can result if precautions are not taken.

NOTE: For the purpose of this manual and product labels, NOTES merely call attention
to information that is especially significant in understanding and operating the
drive.

i
Thank You!
We at Drivecon and affiliated dealer appreciate your purchase of this 'CCez+' inverter or,
adjustable frequency drive. When properly installed, operated and maintained, the inverter will
provide a lifetime of reliable operation. It is mandatory that the person who operates, inspects,
and maintains this equipment thoroughly read and understand this manual.

This instruction manual has been designed to serve as a self-supporting guide for the proper
installation, operation, and maintenance of the inverter adjustable frequency drive. If you
require additional assistance please feel free to contact either your local supplier or Drivecon
at (847) 855-9150.

DANGER!
Hazardous voltage within can cause serious injury or death. Operating drive from keypad may
disable safety circuits and result in danger or injury. Only qualified personnel should work on this
equipment after familiarization with its operation. Turn OFF and lock out power at main panel.
Allow capacitors to bleed off prior to servicing.

DANGER: DO NOT touch any circuit components while AC main power is on or immediately
after the main AC power is disconnected from the unit. Please wait 3 minutes before perform-
ing any service work to inverter.

DANGER: DO NOT make any contact with the circuit before inverter is disconnected from the
AC line and discharged. Failure to adhere t ent. The CCez is designed for operation of
traverse motions or hoist motions with properly operating mechanical load brakes. Consult
Drivecon for operating hoists without mechanical load brakes. The CCez is suited for CMAA
class A-D use only.

WARRANTY:
Drivecon warrants that all products manufactured by it to be free from defects in material and/
or workmanship under proper and normal use by the initial user. This warranty shall expire
twenty-four (24) months following the date of shipment of such product to the purchaser.
Drivecon is the sole determinant of all claims under warranty and no credit will be allowed for
damaged equipment resulting from improper installation or unauthorized repairs or alterations.
During this warranty period, Drivecon will repair or replace, FOB its plant, any parts reported to
and found to be defective by its inspection. Drivecon will not assume any expenses or liability
for any work done on its equipment outside of Drivecon plant without its written consent and
such unauthorized work will automatically void Drivecon's warranty. Equipment purchased
from others and resold by Drivecon, will carry the warranty of the manufacturer. This warranty
is in lieu of all other warranties expressed or implied including warranty of merchantability of
fitness for a particular use. Also Drivecon specifically does not warrant for any consequential
damages whatsoever. Drivecon does not assume or authorize any other person to assume for
it any obligation in connection with the sale of its products, except as herin expressly stated.

1
Introduction

General

CCez+ series is a high performance 460V crane duty inverter which incorporates a high effi-
ciency Pulse Width Modulated (PWM) design. The output closely approximates a sinusoidal
current waveform to allow variable speed control of any conventional 3 phase squirrel cage
induction motor. Please consult Drivecon if any question exists regarding the motor planned to
be connected to the inverter.

Receiving

This unit has been put through strict Q.C. tests at the factory prior to shipment.

Before unpacking please check the following:

Please compare the description of the product found on the name plate with your
purchase order.

Inspect for transport damage (serious damage of carton may lead to unit damage)

Please check the following after unpacking:

If the specifications (current and voltage) on the front cover name plate matches your
application requirements.

Check all the electrical connections and screws.

Verify that there is no visible damage to any of the components.

Note: If any part of the inverter is damaged or lost, please notify the carrier and
Drivecon immediately.

CAUTION: Should damage occur during transportation, installation and power


supply connection may lead to further damage.

2
1.0 CCez+ Frequency converter for travel

 ;  

  ;

1. Connector, Control terminal X1 and Power terminal X2


2. Fault LED (red)
3. Operating status LED (green)
4. Parameter switches

The frequency converter changes the speed and direction of rotation of the travelling motor
according to the commands given by the operator.
The frequency converter has a green LED (3) indicating its operating status and a red LED (2)
to indicate a malfunction. When the operating status LED (3) is lit, the frequency converter is
operating normally. When the operating status LED (3) is flashing, a malfunction has occured
but it has been reset, operation is possible. When the malfunction LED (2) is lit, a malfunction
has occurred that prevents operation of the inverter.
The settings for the frequency converter have been pre-set at the factory with the parameter
switches (4). All control signal connections to the frequency converter are made via connector
X1 (1). Power cabling connections to the frequency converter are made via connector X2 (1).

1.1 Inspection and servicing of the frequency converter

The frequency converter contains live parts at voltages that could cause death by electric
shock. Wait at least (3) three minutes after disconnecting the electricity supply before carrying
out any service procedures on the frequency converter.

Test the correct operation of the frequency converter by driving a motor via the use of the
operator controls.
Check the LED (3) for operational status and the LED (2) for any malfunction.

If the malfunction signal lamp (2) of the frequency converter is lit, contact Drivecon at 847-955-
9150, 800-374-8266 or on the web at www.drivecon.com or your authorized dealer.

3
1.2 Specifications:

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4
2.0 Installation of the CCez+

Location

Proper location of the inverter is imperative to achieve specified performance & normal
operation life expectancy. The inverter should always be installed in areas where the following
conditions exist:

Select a mounting location with adequate ventilation and clearance as shown in drawing be-
low. Insure location selected to include the following:

1) Ambient temperature of -10°-50°C


2) 0-95% RH, non condensing.
3) Enclosed within a suitable NEMA rated enclosure providing adequate protection from
the atmosphere.
4) 0.5G or less vibration in any direction.
5) Allows access to inverter for inspection.
6) Free from any aggressive content in the atmosphere. ie: caustic, explosive, metalic, oil,
fuel, direct sunlight, rain, moisture.

NOTE: Inverter life expectancy will be shortened if these points are not followed.

Clearances

For cooling and maintenance purpose, sufficient clearance (as shown in figure 2.0) around
inverter is necessary to keep effective ventilation. Inverter must be installed with heat sink fins
oriented vertically.

(a) Front view (b) Side view

Fig. 2.0 Location and Positioning of CCez+.

5
2.0 Installation of the CCez+

DANGER! There are high voltages inside the inverter (including the programming
switches). Wait for at least three minutes after the supply voltage has been switched off
before performing any service activities.

2.1 Mounting location and dimensions

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Fig. 2.1 Dimensions of CCez+

6
2.2 Connections
Control signals are connected to terminal block X1 located on top of inverter (dark gray) as
follows: Use 16 AWG MTW type copper wire for all connections to X1.
Note: Read terminal numbers from left to right looking down at top of inverter. See Fig. 2.1.
Note:
1) Do not connect any inductive loads in parallel with DI-DI5. Back emf surge will destroy
input circuit.
2) Install R-C suppressor across any inductive loads.
3) Do not exceed rated supply voltage of input supply.
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Power cabling is connected to terminal block X2 located on botton of inverter (green) as fol-
lows. Adhere to following Cautions. Note: Read terminal numbers from left to right looking at
front of inverter. See drawing Fig. 2.1.
Notes:
1) Crane power supply conductor rail must have double collectors.
2) Inverter and motor must be grounded.
3) Motor must be suited for inverter use. If not, an OLF motor protection filter must be
added between the motor and inverter.
4) If the line supply transformer is greater than 50KVA Drivecon recommends the addition
of a 3 phase line reactor on the input side.
5) Use 14 AWG MTW type copper wire for all connections to X2.
6) Install proper line fuses per NEC code for short circuit protection.
7) Add separate motor protection overload device if motor thermostats are not provided.
8) Wire in accordance with all local regulations and NEC codes.
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WARNING!!! Inverter must not be connected to following networks:
- isolated ground system (Delta or open delta supply systems)
- high-impedance grounded system
- phase grounded/grounded leg system. (Grounded B phase systems)
Note: An isolation transformer may be required if the user's power supply is any
one of the above systems. 7
2.2 Wiring diagram

Fig. 2.2

8
2.3 Normal operation
The inverter goes into the ready-to-run state within one second after the power supply is con-
nected. During operation the inverter follows the operator’s speed command according to the
set acceleration/deceleration ramp. During operation the brake relay (R01 and R02) is kept
closed. When drive command is switched off the inverter decelerates to zero according to the
set ramp and opens the brake relay.

Note: It is required to wire holding brake through brake contactor operated by relay terminals
R01 and R02.

2.4 Status indication leds (green and red)


The inverter indicates its condition by two leds. Red led indicates “fault state” (driving is inhib-
ited). Green led indicates “ok-state”. Blinking of green led indicates that fault state has been
active, but it has been reset (see section 6). Normal driving is however possible also when
green led is blinking.

2.5 Programming switches

The programming of the inverter is performed by dip-switches. The state of each switch is
either OFF (0) or ON (1). It is possible to set he following parameters by the switches S1-S6.
S1 = Maximum speed
S2 = Minimimum speed
S3 = Acceleration / deceleration time
S4 = Motor frequency and IR-compensation
S5 = Motor current, fast deceleration, stopping method
S6 = Control mode, slowdown limit speed, speed # 2, speed # 3

Turn to section 3 for additional details on programming the inverter via dip switches.

Note: The inverter is normally shipped with all dip switches in the off mode. The in-
verter will not operate in this mode until the switches are programmed accordingly.

9
3.0 Programming of the application parameters
Note: Check that the wiring and the desired performance of the
machinery is suitable for the selected application parameters.

3.1 Example of parameter setting


80Hz motor is connected to the inverter and 62Hz maximum speed is
desired. That speed is located on the 5th row in the speedtable B. The
corresponding setting for S1 switches is in the same row on the left col-
umns of the table: 0-1-0-0 (off-on-off-off).

Acceleration/deceleration time of 3 seconds is selected


by setting switch S3=0-0-1-0

Fast deceleration (3 sec. is reduced to 2.1 sec.) is activated


by switch S5-3=1.

3.1.1 Maximum speed (S1) and Minimum speed (S2)


The adjustment ranges of maximum and minimum speed depend on the selected motor nomi-
nal frequency (see section 4.1). Table A is for 100 and 120Hz motors, Table B for 80Hz motors
and Table C for 50 and 60Hz motors. Maximum speed is set by the four switches of the switch-
package S1 and minimum frequency by the four switches of the switch-package S2.
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Table 3.1A 100/120 Hz motors


100Hz may be exceeded only if line voltage is 460-480V.
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Table 3.1C 50-60 Hz motors


50Hz may be exceeded only if line voltage is 460-480V.
11
3.1.2 Acceleration and deceleration ramp
Both acceleration and deceleration ramps are set by switch S3 as follows:
Note: Both acceleration and deceleration ramps are set to same time.

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Table 3.1D Ramp times

It is possible to reduce the deceleration ramp time by 30% if necessary. The fast deceleration
ramp is activated by switching S5-3 ON (1).

12
3.2 Stopping method
The motor can be stopped either by dynamic braking (by a ramp) or by mechanical brake.
When stopping by mechanical brake is selected and drive command is switched off the in-
verter immediately cuts off the motor current and opens the run status relay contact (R01 and
R02). The stopping method is selected by switch S5-4 as follows:

S5-4 = 0 Stopping by a ramp


S5-4 = 1 Immediate stopping by mechanical brake

3.3 Control mode


There are four different control modes available. The inverter operation in different control
modes is explained in section 5. The control mode is selected by switches S6-1 and S6-2
according to the table below.
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13
3.4 Slow down travel limits

Fig. 3.4
Slowdown frequency is activated in 2 and 3 step infinitely variable control modes when the
slowdown limit circuit is opened. In 2 step infinitely variable there are separate inputs for both
limit switch, therefore it is possible to drive high speed in the slowdown area in the safe direc-
tion. In 3 step infinitely variable there is only one input and therefore the speed is limited in
both directions in the slowdown area. There are two alternatives for the level of slowdown
speed which are selected by switch S6-3 as follows:

S6-3 = 0 Slowdown speed is 20% of the maximum speed (set by switch S1)
S6-3 = 1 Slowdown speed is 35% of the maximum speed (set by switch S1)

3.5 Speed # 2 and Speed # 3 multistep settings


In 4 speed preset control mode the lowest speed level speed #1 is set by switch S2 and the
highest level speed # 4 by switch S1. There are two alternative settings for the speed # 2 and
speed # 3, which are set as a percentage of the maximum speed by switch S6-3 as follows:

S6-3 = 0 Speed # 2 is 20% of maximum speed and speed # 3 is 40% of maximum


S6-3 = 1 Speed # 2 is 30% of maximum speed and speed # 3 is 50% of maximum

3.6 Stop limit


In operation mode of 2 speed, there is a provision for a programming or end of travel stop limit.
The stop mode will coincide with the setting of S5-4.

Fig. 3.6
14
4.0 Programming of the motor parameters

The motor parameters are set by switches S4 and S5 according to the following tables. Set-
tings for other motors can be defined when motor nominal frequency, voltage, current and the
torque boost are known. See section 3.1 for more details.

4.1 Defining the motor parameters

4.1.1 Motor nominal voltage and frequency

Motor nominal voltage and frequency are selected by switches S4-1 and S4-2 according to the
following table:

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4.1.2 Torque boost compensation

By the torque boost compensation the effect of the stator resistance at low frequencies is
compensated by increasing the V/f-ratio. Typically the necessary amount of compensation
(added voltage) is higher for small motors. The torque boost compensation is set by switches
S4-3 and S4-4. Estimation of the correct setting of torque boost compensation is made by
calculating the IR-rate of the motor.

Fig. 4.1
Note: Torque boost rate will vary from application to application. It is suggested to set the
torque boost so that the motor rotates at low speed under worst load conditions.

Note: Do not turn torque boost higher than actually required since motor heat rise will in-
crease.
15
Calculation of IR-rate: IR-rate= INOM*RS*p*n

INOM Nominal current of the motor (one motor)


RS Stator resistance, measured between inverter terminals X2:4-5
P Numper of poles.
N Number of motors connected to inverter.

Settings:

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For conical brake motors it is recommended to set the torque boost compensation one step
higher than the IR-rate indicates. Reliable operation of the brake must be verified during start-
up.

4.1.3 Motor nominal current


Motor nominal current is set by switches S5-1 and S5-2 as follows:
• Check the nominal current of the motor from the rating plate
• Calculate the total current by multiplying the current by the number of the motors
• Select the settings according to the table below
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Example of motor current setting: there are two 1.5A motors. Setting is S5-1=0 and S5-2=1.

16
5.0 Description of control modes
5.1 2 preset speed control

Fig. 5.1

• S1 means "drive minimum speed forward"


• S2 means "drive minimum speed reverse"
• HSP means "maximum speed"
• When S1 and S2 are not active the inverter decelerates to zero or stops according to S5-4.

5.2 2 step infinitely variable control

Fig. 5.2
• S1 means "drive forward"
• S2 means "drive reverse"
• Accel means "accelerate"
• When starting, S1 and S2 mean "accelerate to minimum speed"
• When S1 and S2 are not active, the inverter decelerates to zero or stops
according to S5-4.
• During running of S1 and S2 means "hold speed"
• At maximum speed Accel will "hold speed", never allowing acceleration beyond
maximum speed.
17
5.3 3 step infinitely variable control

Fig. 5.3
• S1 means "drive minimum speed forward"
• S2 means "drive minimum speed reverse"
• Accel means "accelerate"
• HOLD means "hold speed"
• When starting, S1 and S2 mean "accelerate to minimum speed"
• When S1 and S2 are not active, the inverter decelerates to zero or stops according to S5-4.
• During running of S1 and S2 means "hold speed"
• At maximum speed Accel will "hold speed", never allowing acceleration beyond
maximum speed.
5.4 4 preset speed control

Fig. 5.4
• S1 means "drive minimum speed forward"
• S2 means "drive minimum speed reverse"
• SP2 means "drive speed 2"
• SP3 means "drive speed 3"
• HSP means "drive maximum speed"
• When S1 and S2 are not active, the inverter decelerates to zero or stops according to S5-4.
• The "highest" active input sets the speed reference (i.e. if HSP is active SP2 and SP3 are
ignored. If SP3 is active, SP2 is ignored).

18
6 Fault codes, troubleshooting

CAUTION! There are high voltages inside the inverter (including the programming
switches). Wait for at least three minutes after the supply voltage has been switched off
before any service actions.
When the inverter detects a fault situation it stops running and starts signalling the fault code
by blinking the indication leds (green and red). The blinking of the code is carried on until a
new fault occurs or until power is switched off. The fault codes are explained in the table be-
low.

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The latest active fault is removed from the memory always when power is switched off.

If inverter is not in a fault state, but driving is not possible:


· Motor will not start if dc-bus voltage too high (above 745V), this occurs if any of line-to-line
voltages exceeds 480V+10% = 528V. If line voltage cannot be reduced, install step-down
transformer
· Check the supply voltage phases at terminal X2.
· Check the drive command signal at terminal X1.
· Check the limit-switch signals at terminal X1.
· Check that the control voltage level is correct. Rating plate is located on the left side of the
inverter.
· Check all parameters, especially the motor dependent parameters.
· Check that the motor(s) corresponds the selected motor parameters.
· Check that the brake opens and closes properly. Check the brake airgap if necessary.
· Inverter starts and opens the brake, but motor does not rotate. Check motor current
parameter.
19
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0 2 7 2 5 ' 5 , 9 ( 6 $ 1 ' & 2 1 7 5 2 / 6
820 Lakeside Drive - Gurnee, IL 60031
Phone: (847) 855-9150 Fax: (847) 855-9650
1-800-DRIVCON (374-8266)
www.drivecon.com Email: drive.sales@drivecon.com