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Instruction Manual

CCez Series Traveling 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. 5-16-02
CCEZ manual.p65
Table of Contents

Definitions i

Warranty 1

Introduction 2

Installation of CCez 3

Mounting dimensions of the CCez 4

Specifications 5

1 Description of the inverter 6

1.1 Connections 6
1.2 Normal operation 6
1.3 Status indication leds (green and red) 6
1.4 Compact brake motors 6
1.5 Wiring diagram 7

2 Programming 8

2.1 Minimum speed, maximum speed and ramp time 8


2.2 Control mode 8
2.3 Selection of the motor type 9

3 Fault codes, troubleshooting 10


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, adjust-
able 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
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:

Within ambient operating temperature range:

Enclosed type: -10° to 40°C (14° to 104°F)


Open chassis type: -10° to 50°C (14° to 122°F)
Rating of enclosure: Protected chassis IP00.
Protected from rain and moisture.
Shielded from direct sunlight.
Free from metallic particles and corrosive gas.
Free from excessive vibration. (Below 0.5G)

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 2.2) 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. 2.2 Location and Positioning of CCez.

3
Mounting dimensions of CCez

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Specifications:

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1. Description of the inverter

1. Terminal X1
2. Red led (fault)
3. Green led (ok)
4. Programming dip switches

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1.1 Connections
All connections are made to terminal block X1 as follows: 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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1.2 Normal operation
The inverter goes into the ready-to-run state within one second after the power supply is con-
nected. During running the inverter follows the operator’s speed reference according to the set
acceleration/deceleration ramp. When drive command is switched off the inverter decelerates
to zero according to the set ramp.

1.3 Status indication leds (green and red)


The inverter indicates its operating state by two leds. Red led indicates “fault state” (driving is
inhibited). Green led indicates “ok-state”. Blinking of green led indicates that fault state has
been active, but it has been recovered (see section 3). Normal driving is however possible also
when green led is blinking (in other words, blinking of green led does not indicate “warning-
state”).

1.4 Compact brake motors


This inverter is used with Compact brake motors, which have been especially designed for this
use. The Compact brake motors have the following special features:
- Compact brake, which is opened by the magnetic force of the motor. When the
magnetic force is removed (by cutting off the motor current) the brake is closed
by spring force.
- High nominal frequency (60Hz…120Hz)
6
1.5 Wiring diagram

* Supplied by customer.
Note: Line reactor is required for any power supply fed from 50 KVA transformer or larger.
Drivecon part # 103KLR2ATB.

7
2 Programming
The programming of the inverter is performed by dip-
switches. The state of each switch is either OFF (0) or
ON (1). There are five parameters that are possible to
set by the switches S1-S4.
S1 = Maximum speed
S2 = Minimum speed
S3 = Acceleration / deceleration time
S4 = Control mode and motor type

2.1 Minimum speed, maximum speed and ramp time


The adjustment ranges of maximum and minimum speed depend on the selected motor type
(i.e. motor nominal frequency). The speeds in the speed table A are used for the 100/120Hz
motors and the speeds in the speed table B for the 60Hz motors. The maximum speed,
minimum speed and ramp time are set as follows:
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EXAMPLE OF PARAMETER SETTING:
60Hz motor is connected to the inverter and 62Hz maxi-
mum speed is desired. That speed is located on the 5th row
in the speed table B. The corresponding setting for S1
switches is in the same row in the leftmost columns of the
table: 0-1-0-0 (off-on-off-off). Max speed set to 62Hz.

WARNING!!! 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.

2.2 Control mode


The signals from the controller (pendant, radio,…) control the inverter via the digital inputs (S1,
S2 ja SP2/AP). There are two possible control modes. The control mode is selected by switch
S4-1.
8
MS-control 2 preset speeds (S4-1 = OFF)

• S1 provides “minimum speed forward”


• S2 provides “minimum speed reverse”
• SP2 provides “maximum speed”
• When S1 and S2 are switched off the
inverter decelerates to zero

EP-control 2 step infinitely variable (S4-1 = ON)

• S1 provides “minimum speed forward”


• S2 provides “minimum speed reverse” or hold
• AP provides “acceleration”
• When starting S1 and S2 mean “accelerate
to minimum speed”
• When S1 and S2 are switched off the
inverter decelerates to zero
• During running S1 and S2 mean “hold
speed”

2.3 Selection of the motor type


The motor type is selected by switches S4-2, S4-3 and S4-4. There are several motor depen-
dant parameters which are set according to the selected motor (i.e. the operator selects a
parameter set). The motors are selected as follows:

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9
3 Fault codes, troubleshooting
When the inverter detects a fault situation it 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 below.

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

Inverter is not in a fault state, but operation is not possible:


• Check the supply voltage phases at terminal X1.
• Check the control 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 parameters (switch S4).
• Check that the motor(s) corresponds the selected motor parameters.
• Check that the microprocessor starts running. Both indication leds (green and red) blink
once as the inverter is powered up. After the one second initialising-time only the green led
should be lit.
• If motor is equipped, check that the brake opens and closes properly. Check the brake air
gap if necessary.

10
'ULYHFRQ
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