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3.3

Wire Size and Circuit Breaker Selection

3.3.1 Circuit Breaker Selection

WARNING:

To guarantee the safety of equipment, circuit disconnecting means and branch circuit

protection between power source and inverter is necessary. The branch circuit protection can either

be in the form of thermal magnetic moulded case circuit breaker (MCCB) or current limiting time

delay fuse protection. Please follow all national and local electric codes.

Units rated for 240VAC input are suitable for use on a circuit capable of delivering not more than

5000RMS symmetrical amperes, 240V maximum. Units rated for 480VAC input are suitable for

use on a circuit capable of delivering not more than 5000RMS symmetrical amperes, 480V maxi-

mum.

CAUTION:

DO NOT connect power source to inverter output terminal (T1, T2, T3) otherwise the

unit will be damaged.

NEVER install Magnetic Contactor (MC) between inverter output terminal and motor. The tran-

sient de-energizing surge of magnetic contactor will destroy the unit or lead inverter to trip.

Tables 3.3a and 3.3b shown below provides the suggested rating of MCCB or MC for each of the

inverter ratings.

You should install RC surge absorbers across the coils of any control relays or contactors installed

within the system of the inverter. Metal Oxide Varistors (MOV's) alone are not acceptable. See

figure below for the proper surge absorbers.

3.3.2 Wire Size

The wire used in the main power circuit should be sized according to Tables 3.3a and 3.3b shown

below. Use copper conductors only, size field wiring based on 75°C wire only.

Diode ratings

Current >=

Coil VA

Coil Voltage

Voltage >= 4 x Coil Voltage

120V

Coils

Drivecon

KVFCC-2

Table 3.3a CC-2XX Series

Inverter type

CC-207

CC-215

CC-222

CC-237

CC-255

CC-275

CC-2110

CC-2150

CC-2220

MCCB/ fuse rating

10A

20A

30A

40A

50A

80A

100A

150A

MC (A/B IEC rated)

100A09ND3

100A12ND3

100A18ND3

100A30ND3

100A38ND3

100A60ND3

100A75ND3

100B110ND3

Wire Size *1

(minimum)

TM1

14 AWG

12 AWG

10 AWG

8 AWG

6 AWG

4 AWG

2 AWG

TM2/TB1

18 AWG

Screw *2

Terminal size

TM1 (torque)

M4 (10.5 in.-lbs.)

M6 (39 in.-lbs.)

M6 (22 in.-

lbs.)

M8 (53in.-

lbs.)

M8 (53in.-

lbs.)

TM2 (torque)

M3 (7 in.-lbs.)

TB1 (torque)

Wire clamp type captive screw (10 in. - lbs.)

Содержание Crane Commander ??-204

Страница 1: ...the Sine of Quality INSTRUCTION MANUAL Series AC Crane Hoist Drives RANE OMMANDER Rev 2 8 02 0 2 7 2 5 5 9 6 1 2 1 7 5 2 6...

Страница 2: ...n 5 Digital operator control 5 1 Introduction and configuration 32 5 2 Function parameter setting 35 5 3 Function code descriptions Fn00 Fn71 36 5 4 Factory default load Quick Set 57 Section 6 Test ru...

Страница 3: ...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...

Страница 4: ...connections or TB1 of D61530 for 120VAC connections refer to interconnection diagram on page 11 and 12 The following functions will be set using the Quick load feature Fn29 0 for hoist Fn29 1 for tra...

Страница 5: ...brakes The Crane Commander is suited for CMAA class A D use only WARRANTY Drivecon Corporation warrants that all products manufactured by it to be free from defects in mate rial and or workmanship un...

Страница 6: ...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...

Страница 7: ...C 207 215 222 237 CC 407 415 422 437 all rated protected chassis IP00 CC 255 2220 455 4220 all are NEMA1 IP20 Protected from rain and moisture Shielded from direct sunlight Free from metallic particle...

Страница 8: ...ODEL CC 204 7 48 7 09 7 60 CC 207 7 48 7 09 7 60 CC 215 9 06 8 66 9 20 CC 222 9 06 8 66 9 20 Fig 2 3a Mounting Dimension of CC 204 222 Please refer to Appendix E of this manual for dimension drawings...

Страница 9: ...07 415 422 CC 437 MODEL H CC 237 7 00 CC 407 415 422 6 00 Fig 2 3b Mounting Dimension of CC 237 407 437 Please refer to Appendix E of this manual for dimension drawings on disk Format is AutocadTM R13...

Страница 10: ...6 CC 255 CC 455 CC 475 CC 275 Fig 2 3c Mounting Dimension of CC 255 275 455 475 Please refer to Appendix E of this manual for dimension drawings on disk Format is AutocadTM R13 DWG and DXF...

Страница 11: ...110 CC 2150 CC 2220 CC 4110 CC 4150 CC 4220 Fig 2 3d Mounting Dimension of CC 2110 2220 4110 4220 Please refer to Appendix E of this manual for dimension drawings on disk Format is AutocadTM R13 DWG a...

Страница 12: ...4110 CC 4150 CC 4220 Motor Rating KW 0 4 0 75 1 5 2 2 3 7 5 5 7 5 11 2 15 22 4 Constant Torque Motor Rating HP 2 0 5 1 2 3 5 7 5 10 15 20 30 Constant Torque Rated Current A 1 1 5 2 3 3 8 5 2 8 8 13 1...

Страница 13: ...venting 40 Amb t 10 C Model kW CC 204 CC 404 0 4 35 30 1 6 1 2 3 1 085 1 550 CC 207 CC 407 0 75 40 34 4 7 1 2 3 1 131 1 767 CC 215 CC 415 1 5 60 51 6 10 7 2 8 1 689 2 650 CC 222 CC 422 2 2 70 60 2 12...

Страница 14: ...z operationable from keypad pushbutton Operation modes Remote 120V terminal input or keypad FWD REV momentary V F Pattern 15 pre defined patterns One Curve programmable Braking torque or equal to 10HP...

Страница 15: ...age the inverter NOTE 2 Use jumper to short PIN1 and PIN2 when CON12 is not used 1 In single phase applications connect AC power supply to L1 and L2 of inverter 7 See page 13 14 for tightening torque...

Страница 16: ...disk with Autocad R13 DWG and DXF drawings for your use 1 In single phase applications connect AC power supply to L1 and L2 of inverter 7 See page 13 14 for tightening torque values of TM1 screw term...

Страница 17: ...y the unit or lead inverter to trip Tables 3 3a and 3 3b shown below provides the suggested rating of MCCB or MC for each of the inverter ratings You should install RC surge absorbers across the coils...

Страница 18: ...them should be directly grounded to a common point Please follow the grounding instructions shown in Fig 3 4 WARNING Never ground or connect terminal N of inverter to neutral Table 3 3b CC 4XX Series...

Страница 19: ...to inverter output This branch circuit should be fused in accordance with NEC regulations The coil of the brake contactor should be connected to the running relay output provided on the D61530 at ter...

Страница 20: ...etween motor and inverter Size festoon according to NEC standards based on inverter ampacity Table 3 7a Specification of reactor for constant torque use 5 impedance Inverter Type Current Amps Inductan...

Страница 21: ...Jumper 1 Ground TM1 Main terminal under D61530 1 D61530 120VAC D61531 24VAC isolator Shown detached from TM2 CON6 Connector of digital operator interface CON4 Connector of ground fault protection ZCT...

Страница 22: ...strip Caution Use screwdriver to dislodge Do not pull on wires D61530 TB1 D61531 All models F R 2 3 4 5 ACN RLA RLC RLB D61530 120VAC D61531 24VAC isolator Shown detached from TM2 CON4 Connector of gr...

Страница 23: ...of larger watt rating externally Replacement Procedures 2 Detach the built in resistor from P R terminal and insulate exposed ends Install external resistor with larger capacity watt The standard res...

Страница 24: ...ng torque CC 204 CC 207 CC 207 150 20 285 30 152 CC 215 75 40 103 CC 222 75 40 86 CC 237 CC 255 CC 275 62 100 84 63 52 CC 2110 Without braking resistor or module 15 20 CC 2150 CC 2220 CC 404 CC 407 CC...

Страница 25: ...amic brake option 1 2 10HP units require additional external resistor for all heavy duty applications and any CMAA class D uses Internal D B resistor must be disconnected when connecting external resi...

Страница 26: ...rake option 1 2 10HP units require additional external resistor for all heavy duty applications and any CMAA class D uses Internal D B resistor must be disconnected when connecting external resistor U...

Страница 27: ...N 4 3 3 MOUNTING INSTRUCTIONS 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 pe...

Страница 28: ...and connector may result Pry apart where both halves meet with a small flat blade screwdriver 4 3 4 CONNECTION Two directions including first speed 4 extra speeds special functions and reset can be co...

Страница 29: ...ontrol operating direction of inverter and connected motor Each direc tion is interlocked electronically Should both directions become energized the inverter will stop according to the selected stoppi...

Страница 30: ...SP1 FWD SP1 FWD SP1 8 R REV REV REV SP1 REV SP1 REV SP1 5 2 x x SP2 ACC HOLD 6 3 x x SP3 x ACC 7 4 multi function terminal 1 multi function terminal 1 multi function terminal 1 multi function terminal...

Страница 31: ...ct keypad operator control setting see note Fig 4 4g Fn 1 TM2 analog input see note 4 4 5 Timing diagrams of speed command methods The following are timing diagrams explaining the various methods of s...

Страница 32: ...ast to stop Ramp to stop DC injection off Fn53 does not equal 0 X 0 Fn54 does not equal 0 0 does not equal 0 Fn55 does not equal 0 X X Table 4 4c Note Codes Fn53 and Fn54 control the method of deceler...

Страница 33: ...er or equal to Fn9 Please refer to Fig 4 4l D61530 D61531 is connected to the main PC board by a 2 wire jumper connected to header JP1 on the Crane Commander a Run mode output when Fn8 0 Level of term...

Страница 34: ...ing coil DC 1mA frequency meter or 0 10V digital frequency meter Terminal 16 Positive terminal of frequency meter See Figure 4 1a and 4 1b for furthur explanation NOTE Leave jumper pin connected to on...

Страница 35: ...V FWD JOG REMOTE STOP FWD RUN REV RUN STOP PRGM Fn JOG MODE RESET READ ENTER E Stop key orange E Stop command in digital operator control mode Red LED lights when motor is forward running Red LED ligh...

Страница 36: ...ec 0 1 sec 0 sec 0 5 sec Fn23 Smooth Operator curve Time 2 0 4 sec 0 1 sec 0 sec 0 5 sec Fn24 Jog Frequency 0 180Hz 0 1 Hz 5 Hz 5 Hz Fn25 Master Frequency 0 180Hz 0 1 Hz 5 Hz 5 Hz Fn26 BIAS of TM2 ana...

Страница 37: ...sec injection Fn54 DC Braking injection frequency 0 1 10Hz 0 1 Hz 0 2 Hz Fn55 DC Braking level 0 20 0 10 0 5 Fn56 Command Link Baud rate 0 3 2 2 Fn57 Command Link response mode 0 7 1 1 Fn58 Command L...

Страница 38: ...nt frequency QG 6 Repeat steps 1 5 Changing another function parameter 7 STOP Function parameter setting procedure ends Enter stopping mode Digital operator displays the current frequency 35 5 2 Funct...

Страница 39: ...er reference procedure ends Enter stopping mode Digital operator displays the current frequency XXXX DATA DATA If function parameters can t be changed and LOC is displayed this means function paramete...

Страница 40: ...on time will be reduced proportionately by the following Fn01 setting sec x set frequency maxf accel time sec The same holds true for calculating deceleration times but substitute Fn02 setting for Fn0...

Страница 41: ...if the standard patterns do not suit the application when Fn5 15 Refer to codes Fn37 42 Fn5 6 for hoist factory default Fn5 3 for traverse factory default Warning Observe that saturation frequency of...

Страница 42: ...Reference V F Pattern 50 Hz Saturation 0 60 Hz Saturation 1 50 Hz Saturation 2 60 Hz Saturation 3 Specifications Fn5 Reference V F Pattern 50 Hz Saturation 4 5 60 Hz Saturation 6 7 50 Hz Saturation 8...

Страница 43: ...40 Specifications Fn5 Reference V F Pattern 60 Hz High starting torque 11 12 13 14 Table 5 3c V F pattern for high starting torque Fig 5 3d Fn5 15 Custom V F pattern for special applications...

Страница 44: ...y output will be limited between the upper and lower limits Operation at the lower limit setpoint Fn7 begins immediately when forward or reverse command is received 180 Hz Frequency output Fn6 Fn7 Fre...

Страница 45: ...D is on Please refer to table 4 4a on page 26 Note Set Fn10 to 0 when using the KN232 link communication package Fn11 Frequency command method select This function selects the particular frequency com...

Страница 46: ...rease in frequency based on load condition and motor slip Range For hoists Fn29 0 up slip compensation down slip compensation from 0 5 addi tional or less frequency output Range For traverse Fn29 1 sl...

Страница 47: ...quency reference number 5 NOTE Fn17 21 are effective in remote command mode only The range of Fn17 21 is set from 0 to 180Hz Please refer to section 4 4 5 for timing diagrams of speed command methods...

Страница 48: ...Smooth operator curve time 1 acceleration Fn23 Smooth operator curve time 2 deceleration Smooth transition to ramp conditions for minimal load swing Fig 5 3j 120VAC connection to TB1 of D61530 24VAC c...

Страница 49: ...d down arrow buttons without the need to set the function code to Fn25 Example When JOG key is pressed inverter will run in jog mode no matter which frequency mode is in use If JOG key is pressed agai...

Страница 50: ...ximum frequency when the speed reference is at maximum Example of operation shown by line C Set Fn26 Fn28 x P Ref max P Where Fn28 is the maximum frequency when the speed reference is at maximum P is...

Страница 51: ...NTER and then press RESET and READ ENTER simultaneously RES will appear in display momentarily WARNING These Quick Set macro programs are designed to provide a basic starting point in which to start t...

Страница 52: ...n modes 1 Plugging Quick Change 2 First speed to stop transition Rapid Stop 3 Both plugging and first speed to stop Fn33 0 Normal operation not active Fn33 1 Quick Change reverse plugging enabled Fn33...

Страница 53: ...ations requiring fast response time we recommended not to change the factory setting to secure high electrical noise immunity level 2 AUTO RESTART Fn34 motor coast stop time Fn35 1 10 The inverter wil...

Страница 54: ...z When the inverter s output causes irregular motor noise a different carrier frequency may be set by changing Fn43 The carrier frequency is limited to 3600Hz to prevent damage to motor insulation Som...

Страница 55: ...operate until limit switch is once again opened TrL will be displayed on LED display while limit switch is closed and direction command is neutral or the direction that is locked out is selected Shou...

Страница 56: ...3 Fn50 Deceleration time 2 0 1 30 sec The operation method is the same as Fn2 Please refer to Fn46 and Fn33 Fn51 Display mode select Fn51 0 Inverter displays output frequency Hz Fn51 1 4 Inverter disp...

Страница 57: ...ake sure motor is at rest before inverter is restarted or damage may result Fn55 DC braking level Fn55 defines the percentage of DC injection braking voltage to the full input voltage For example set...

Страница 58: ...eration 4 LU C The first fault code is low voltage most recent fault Fn63 Elapsed time recorder This function serves as a running totalizer or hour meter The accumulated hours on the inverter can be v...

Страница 59: ...ically to 2 8 times When the condition of overvoltage disappears inverter will then decel erate from previous speed to new commanded speed Fig 5 3w Note The following diagram can only be applied to th...

Страница 60: ...y The point at which the Quick Pick function begins to operate if current detection is satisfied Adjustable from 2 to 120Hz Fn84 Quick Pick delay time once both conditions of current and frequency thr...

Страница 61: ...r to the first fault code DATA lamp lights 4 up key Refer to the second fault code DATA lamp lights 5 up key Refer to the third fault code DATA lamp lights 6 up key Refer to the fourth fault code DATA...

Страница 62: ...ly stopped Even with light loading never use a motor whose nameplate amperage exceeds the inverter rated current When starting and stopping the motor be sure to use the FWD REV keys or remote control...

Страница 63: ...operator display 1 Connect to power supply Inverter enters stopping mode 2 Set Fn10 0 Digital operator control mode 3 Set Fn11 0 Digital operator frequency command 4 Set Fn25 5 or press up or down ke...

Страница 64: ...nct preset speeds 1 3 Remote control terminal TM2 24VDC or TB1 120VAC 24VAC 2 step infinitely variable 1 4 Remote control terminal TM2 24VDC or TB1 120VAC 24VAC 3 step infinitely variable 1 In digital...

Страница 65: ...Reverse run is effective when Fn33 0 Must hold button in since both are momentary type 2 arrow key During stop mode frequency set increases 0 1Hz in 1 180 range by pressing arrow key once Set frequen...

Страница 66: ...0 Hz 2 If Fn7 0 FnSET goes to Fn7 Hz Hz Table 7 2 continued Digital operator control and frequency command NOTE Zero speed stop mode 0 00 is different from stop mode XX XX In zero speed mode FWD or RE...

Страница 67: ...Set Fn33 0 0 6W3 Remote operation error effective in remote control only Fn10 1 1 Problem is due to main power switched on and RUN switched on while direct start is prohibited Fn16 1 1 Set Fn16 0 2 R...

Страница 68: ...B resistor 28 Over voltage in stop mode 1 Input voltage fluctuation 2 Inverter is damaged 3 Insufficient D B resistor 4 D B unit is damaged 1 Check input voltage 2 Notify your supplier to check 3 Inst...

Страница 69: ...g or in run mode 1 Fn11 0 2 CPU version Fn64 can t be changed 3 Change those functions in function list with in Remark column in stop mode 0 UU Setting error 1 Fn6 frequency upper limit is set under F...

Страница 70: ...urrent OV Means all modes of over voltage LV Means all modes of low voltage In stop mode alarm LED extinguishes in run mode and zero speed stop mode alarm LED lights Fault code Alarm LED signal 1 2 2...

Страница 71: ...ing could result in serious or lethal injuries 1 Clean up internal dust and dirt 2 Check for tightness of electrical connection 3 Perform meggar test a Remove all connection wires from the complete un...

Страница 72: ...Measurement of Voltage and Current PFo Po x 100 3Vo Io PFi Pi x 100 3Vo Io DANGER Hazardous voltage within can cause serious injury or death Operating drive from keypad may disable safety circuits an...

Страница 73: ...r source Defective wiring Inverter damaged Short circuits Inverter damaged Inverter damaged Are parameters set correctly Correct param eters NO YES YES YES YES YES NO YES YES NO NO NO NO NO NO NO The...

Страница 74: ...motor cooling During accel decel Is accel decel time set properly Increase accel decel time Reduced load Use higher rating inverter and motors Inverter is damaged Install a flywheel Inverter is damage...

Страница 75: ...uppressed As EMI and RFI can involve very complex coupling modes not all solutions can be easily found EC Directives Inverters are able to comply with the EC Directives 89 336 EEC on limits to EMI and...

Страница 76: ...nt areas are also detailed below K1 4103 K1 4203 K1 4603 C1 C2 C3 0 47uF 500VAC 1 0uF 500VAC 3 3uF 500VAC C4 C5 C6 0 47uF 500VAC 1 0uF 500VAC 2 2uF 500VAC C7 C8 C9 0 0233uF 400VAC 0 0233uF 400VAC 0 07...

Страница 77: ...grounded to the same panel and as close as possible to the inverter If the connection exceeds 30cm a flat cable should be used for the earth connection between the filter and the inverter Interconnec...

Страница 78: ...2 The length of the cable between the inverter and motor must be kept as short as possible to limit cable capacitance If cable length exceeds 50m an output induc tor may be required 3 The connections...

Страница 79: ...sconnect and thread output line T1 T2 T3 through ZCT and connect ZCT to CON4 as shown on diagram Be sure to thread all T1 T2 T3 through ZCT Max cross section of T1 T2 T3 should be 10 AWG Please refer...

Страница 80: ...m CON 6 4 Remove KDOP 02 from inverter 5 Connect cable with grounding terminal to CON 6 and fix the grounding terminal on inverter as shown in the diagram 6 Clinch the rubber bushing to the hole on sh...

Страница 81: ...ec 0 1 sec 0 sec 0 5 sec Fn23 Smooth Operator curve Time 2 0 4 sec 0 1 sec 0 sec 0 5 sec Fn24 Jog Frequency 0 180Hz 0 1 Hz 5 Hz 5 Hz Fn25 Master Frequency 0 180Hz 0 1 Hz 5 Hz 5 Hz Fn26 BIAS of TM2 ana...

Страница 82: ...sec injection Fn54 DC Braking injection frequency 0 1 10Hz 0 1 Hz 0 2 Hz Fn55 DC Braking level 0 20 0 10 0 5 Fn56 Command Link Baud rate 0 3 2 2 Fn57 Command Link response mode 0 7 1 1 Fn58 Command L...

Страница 83: ...mode or when inverter reaches any preset frequency 11 Multi function 2 Programmable multi functions 12 Frequency command potentiometer positive Positive terminal of 10K ohm frequency command potentiom...

Страница 84: ...Appendix E D61530 D61531 Input Isolator Instructions...

Страница 85: ...Appendix F B Size working schematic connection drawings and 3 1 2 disk with Crane CommanderTM dimensional drawings and wiring diagrams in AutocadTM DWG and DXF formats Attach disk pocket here...

Страница 86: ...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 ULYHFRQ 0 2 7 2 5 5 9 6 1 2 1 7 5 2 6...

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