Drivecon Crane Commander Series User manual

"the Sine of Quality"
INSTRUCTION MANUAL
Series AC Crane/Hoist Drives
RANE OMMANDER
Rev. 2-8-02
02725'5,9(6$1'&21752/6

Table of Contents
Section 1 Introduction
1.1 General 2
1.2 Receiving 2
Section 2 Installation
2.1 Location 3
2.2 Clearances 3
2.3 Mounting Dimensions 4
2.4 Standard drive ratings 8
2.5 Common speci ication 10
Section 3 Wiring
3.1 Interconnection 11
3.2 Hoist interconnection diagram 12
3.3 Wire size & circuit breaker selection 13
3.4 Grounding 14
3.5 Motor thermal overload relay 15
3.6 Brake motor magnetic contactor 15
3.7 Special cautions on wiring 15
Section 4 External connection layout
4.1 Component outline 17
4.2 Function description o main circuit terminal (TM1) 19
4.3 D61530 120V isolator instructions 23
4.4 Function description o control terminal (TM2) 26
Section 5 Digital operator control
5.1 Introduction and con iguration 32
5.2 Function parameter setting 35
5.3 Function code descriptions (Fn00-Fn71) 36
5.4 Factory de ault load 'Quick Set' 57
Section 6 Test run
6.1 Precautionary checks be ore test running 59
6.2 Test run 60
Section 7 Setting and adjust ent
7.1 General description o settings and adjustments 61
7.2 Example o digital operator control and requency command 62
Section 8 Fault indications 64
Section 9 Maintenance 68
Reference
a. Measurement o voltage and current 69
b. Troubleshooting procedure. 70
c. Electromagnetic compatibility (EMC) o inverter. 72
Appendix A Peripheral - Ground Fault Protection 76
Appendix B Peripheral - Digital Operator Extension 77
Appendix C - User Progra List 78
Appendix D - Ter inal Function List 80
Appendix E - D61530 (D61531) Input Isolator Instructions 81
Appendix F - 'B' size working sche atics i

ii
DANGER!
The Crane Commander inverter contains hazardous internal
voltages and should be serviced only by qualified ersonnel.
Most com onents are not user serviceable therefore, consult
Drivecon Cor oration if a roblem should arise.
Drivecon Corporation
820 Lakeside Drive
Gurnee, IL 60031 SA
Phone: [phone]
Fax: [phone]
Definitions:
Qualified Person:
For the purpose of this instruction manual and product labels, a QUALIFIED PERSO 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, DA GER 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, WAR I G indicates loss of life,
severe personal injury or substantial property damage CA result if proper
precautions are not taken.
CA TION: For the purpose of this manual and product labels, CAUTIO indicates minor
personal injury or property damage can result if precautions are not taken.
NOTE: For the purpose of this manual and product labels, OTES merely call attention to
information that is especially significant in understanding and operating the drive.

iii
Preliminary - 'Crane Commander' Series
Thank you for purchasing this Drivecon 'Crane Commander' variable frequency AC motor drive.
NOTE: Please read and understand this manual before operating the inverter.
DANGER: Make sure all sources of power are removed from inverter and internal capacitors
are discharged or personal injury may result.
This will ensure safe and reliable operation of the inverter.
Quick setup and operation procedure.
Warning: Insure only qualified personnel install and operate this inverter. Installation must
comply with NEC, CMAA and all appropriate local codes.
1. Connections:
AC mains power L1, L2, and L3 at TM1
Motor connections T1, T2, and T3 at TM1
Control wiring - Terminal strip TM2 - note numbering on page 11 and 12.
Select either keypad or remote terminal strip operation.
2. Keypad operation
The following functions must be set after loading the 'Quick-load' feature. This is used only
to verify operation. ot suited for normal operation. Fn29=0 for hoist Fn29= 1 for
traverse operation and then set Fn10, Fn11 = 0 and Fn25 = set operating frequency desired.
NOTE: Forward run and reverse run are limited to momentary operation only for increased
safety.
3. Remote input operation
Install forward, reverse, speed reference and other connections to terminal strips TM2 for
24VDC 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 traverse operation.
Fn10=1, Fn11 = as required for speed control method, default =2 (preset steps)
4. CA TION: The Crane Commander is equipped with the 'Quick-Set'TM function. These
pre-set parameters are tailored for either hoists or traverse motions. They are general
setpoints and not considered the final setpoints. Please consult the manual and program the
drives with specific parameters which maximize function and safety of the equipment.
5. CA TION: When connecting a potentiometer to terminals 12, 13, and 14 this should be in
strict compliance with wiring detail on page 11 and 12. Incorrect wiring will damage the
inverter.
6. CA TION: Control supply voltage
On CC-4110, CC-4150 and CC-4220 set the supply voltage by removing the front cover and
repositioning the link on the supply PCB. A caution label indicates this must be done
prior to operation of the inverter. ormal setting is 460VAC. Do not change if 460V
corresponds with your supply.
THE ABOVE ARE MINIMUM SETTINGS REQUIRED TO OPERATE THE INVERTER. MANY OTHER
OPERATING FEATURES ARE AVAILABLE AND ARE DETAILED IN THIS MANUAL. IT IS STRONGLY
RECOMMENDED THAT THIS MANUAL BE READ AND UNDERSTOOD TO OBTAIN OPTIMUM PER-
FORMANCE FROM YOUR INVERTER. SHOULD ANY QUESTIONS EXIST PLEASE FEEL FREE TO
CONTACT DRIVECON CORPORATION AT [phone].

1
Thank You!
We at Drivecon Corporation and affiliated dealer appreciate your purchase of this 'Crane Com-
mander' 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 oper-
ates, 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 installa-
tion, operation, and maintenance of the inverter adjustable frequency drive. If you require addi-
tional assistance please feel free to contact either your local supplier or Drivecon Corporation at
[phone].
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. You must wait until the red charge lamp
(LED 101) on the main control board goes out before servicing the inverter or any component of the
system. Typically 2 minutes.
DANGER: DO NOT make any contact with the circuit before inverter is disconnected from the AC
line and discharged. Failure to adhere to this warning could result in serious or personal injury.
Drivecon strongly suggests a complete OSHA approved load test of any hoist equipment
after installation of this equipment to overhead cranes or hoists. Drivecon Corporation is always
available for on-site commissioning of this equipment. The Crane Commander 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 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 under proper and normal use by the initial user. This warranty shall expire
eighteen (18) months following the date of shipment of such product to the purchaser or twelve (12)
months after such parts or products are first placed in service or operation, whichever shall first
expire. Drivecon Corporation 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.
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. llow capacitors to bleed off
prior to servicing.

Section 1: Introduction
1.1 General
Crane Commander series is a high performance 230V or 460V crane and hoist duty inverter
which incorporates a high efficiency 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 or properly modified wound rotor motor without the need of
special output filters. Please consult Drivecon Corporation if any question exists regarding the
motor planned to be connected to the inverter.
1.2 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.
ote: If any part of the inverter is damaged or lost, please notify the carrier and Drivecon
Corporation immediately.
CA TION: Should damage occur during transportation, installation and power
supply connection may lead to further damage.
2

Section 2: Installation of the Crane Commander.
2.1 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: CC- 204, 207, 215, 222 all rated at EMA1/IP20. CC-207, 215, 222, 237, CC-
407, 415, 422, 437 all rated protected chassis IP00. CC 255-2220, 455-4220 all are EMA1/IP20.
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.
2.2 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.
Fig. 2.2 Location and Positioning of Crane Commander.
3
(a) Front view (b) Side view

4
2.3 Mounting Dimensions
LE GTH
L1 L2 L3
MODEL
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 on disk.
Format is AutocadTM R13. (.DWG and .DXF)

5
CC-237
CC-407, 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. (.DWG and .DXF)

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)

7
CC-2110, 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 and .DXF)

8
2. Standard Drive Ratings
Model CC-204 CC-207 CC-215 CC-222 CC-237 CC-255 CC-275 CC-2110 CC-2150 CC-2220
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) 3.1 4.5 7.5 10.5 17.5 26 35 52 70 105
Rated Output (KVA) 1.2 1.7 2.9 4.2 7 10.3 13.9 20 28 41.7
Weight (lbs) 4.8 4.8 4.8 12.1 12.8 20.7 22 42.9 47.3 49.5
Input Voltage 1/3 phase, 200-240VAC (+/- 10%), 50-60 Hz (+/- 5%) 3 phase, 200-240 VAC (+ / - 10%), 50/60 Hz (+ / - 5%)
Output Voltage 3 phase, 200-240 VAC
Model CC-404 CC-407 CC-415 CC-422 CC-437 CC-455 CC-475 CC-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 17.5 26 35 52
Rated Output (KVA) 1.2 1.7 2.9 4.2 7 10.3 13.9 20 28 41.7
Weight (lbs.) 9.2 9.2 9.2 9.2 18.5 22 22 45.1 47.3 49.5
Input Voltage 3 phase, 380-460 VAC (+ / - 10%), 50/60 Hz (+ / - 5%)
Output Voltage 3 phase, 380-460 VAC
(1) 150% overload for 120 seconds
(2) Horsepower and current ratings based on CMAA class A-D use for traverse or hoist
operation with a mechanical load brake. Consult Drivecon for other service classes. Always
choose inverters based on peak current draw of motor to be within the overload rating of the
drive.
Table 2.4a 230V Crane Commander Ratings
Table 2.4b 460V Crane Commander Ratings

9
∆∆
∆
Table 2.4c Inverter Thermal Characteristics
Heat loss of
inverter
(Watts) at
full load*
H: Calori-
Metric value
of heat
radiated by
inverter.*
(K cal/hr.)
Q:
Necessary
ventilation
volume t
= 10°C
(ft³/min.)
S: Vent port
area
(Minimum
value (in²))
Minimum
surface area
in² steel
enclosure
without
venting 40°
Amb.
t=10°C
Minimum
surface area
in² plastic
enclosure
without
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 12.5 3.4 1,968 3,100
CC-237
CC-437 4.0 135 116.1 23.6 11.5 3,782 5,983
CC-255
CC-455 5.5 190 163.4 37.6 15.3 5,349 8,418
CC-275
CC-475 7.5 240 206.4 42.5 20.0 6,760 10,620
CC-2110
CC-4110 11 310 266.6 54.6 25.6 9,612 13,736
CC-2150
CC-4150 15 453 389.6 80.0 37.5 14,050 20,062
CC-2220
CC-4220 22 673 578.8 118.9 55.8 20,868 29,813
∆
∆∆
* Approximate values.

10
2.5 Common Specifications
Model CC-204 CC-207 CC-215 CC-222 CC-237 CC-255 CC-275 CC-2110 CC-2150 CC-2220
Constant torque
motor rating (HP)(1) 0.5 1 2 3 5 7.5 10 15 20 30
Constant torque
rated current (A)(2) 3.1 4.5 7.5 10.5 17.5 26.0 35.0 52.0 70.0 105.0
Rated output
(KVA) 1.2 1.7 2.9 4.2 7.0 10.3 13.9 20.0 28.0 41.7
Weight (Lbs) 4.8 4.8 4.8 12.1 12.8 20.7 22 42.9 47.3 49.5
Input voltage SINGLE PHASE ( Below 3HP) or 3 PHASE, 200~230VAC +/- 10%, 50~60 Hz +/- 5%
Output voltage 3 PHASE, 0~200~230VAC
Model CC-404 CC-407 CC-415 CC-422 CC-437 CC-455 CC-475 CC-4110 CC-4150 CC-4220
Constant torque
motor rating (HP)(1) 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 13.0 17.5 26.0 35.0 52.0
Rated output
(KVA) 1.2 1.7 2.9 4.2 7.0 10.3 13.9 20.0 28.0 41.7
Weight (Lbs) 9.2 9.2 9.2 9.2 18.5 22.0 22.0 45.1 47.3 49.5
Input voltage 3 PHASE, 380~460VAC +/- 10%, 50~60Hz +/- 5%
Output voltage 3 PHASE, 0~380~460VAC
Control mode Sine Coded PWM Control
F
R
E
Q
U
E
N
C
Y
Accuracy +/- 0.5% (-10°C~40°C)
Resolution 0.1 Hz
Range 1~180 Hz
Start freq. 1 Hz
Adjustment Programmed speed presets, infinitely variable,(ramp and hold), external variable resistor 10K ohm; 1~5 VDC, 4~20mADC, 0~10VDC, menu
selectable.
Multi-speed Programmed speed presets 2-5 Steps (0-180 Hz)
Upper limit Programmable from 1~180 Hz
Lower limit Programmable from 0~180 Hz
Accel / Decel time 0.1~800 sec. accel, 1-30 sec. decel. independently programmable dual set points
JOG Frequency Programmable from 1-180 Hz 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; 100% with external D.B. resistor. > 10HP D.B. is optional.
DC Braking
injection Programmable 0.1 - 25.5 sec.; operation level 0 Hz-10Hz; Brake level 0-20%.
Alarm signal Fault Relay (250V / 1 Amp) Programmable NO or NC
Multi-function O/P Relay (250V / 1 Amp) Programmable for run mode, up to speed, at setting.
Frequency signal 0~10VDC, Digital Meter. 1mA Full scale moving coil meter
Stop mode Decelerate or Free Run to Stop Software Selectable
Reset Closed Contact Point or Pressing RESET on programming console
Display 4 Digits 7 Segments LED's & Status LED 1/2" high red digits.
Protection 22 total; Over Current, Over Voltage, Overtemperature, P.B. sequence error, travel limit,
Low Voltage, Stall Prevention, Ground Fault Protection, Microprocessor error, elapsed timer.
D.B. voltage 385 VDC on, 379 VDC off (200 series); 770 VDC on, 760 VDC off (400 series)
Communication RS232 standard RS485 (32 units maximum) optional.
Overload 150% for 2 minutes
Overcurrent 200% peak trip
Transient power
failure Over 15 msec.
Operation
temperature -10~+40°C +50°C chassis type enclosure.
Humidity 0~95% non-condensing
Vibration below 0.5G
Environment Dust free, dry, non-corrosive
(1) All horsepower data based on standard 4 pole motors.
(2) Horsepower and current ratings are based on CMAA class A-D use for traverse or hoist
operation with a mechanical load brake. Consult Drivecon for other service classes.
NOTE: Always size inverters based on the peak amp draw of the motor.
Table 2.5a CC Series Specifications

Section 3 Standard Wiring of Crane Commander
3.1 Typical Traverse
interconnection
diagram. (Some devices are optional and may not be required in all cases.)
Fig. 3.1
Please refer to Appendix E of this manual for
'B' size drawings of Fig. 3.1. Also provided
is a disk with Autocad™ R13 (.DWG and .DXF)
drawings for your use.
WARNING: Wiring diagrams differ per application.
Please consult system wiring diagrams or Drivecon Corporation.
Insure wiring conforms with all applicable industry and safety standards.
of inverter's control wiring or terminal ACN of D61530 120V isolator.
4. MC use is optional depending upon application, if not used: wire motor overload contacts in series with terminal 4 common
3. Do not connect wiper of frequency command potentiometer to terminal 12 or 14 of TM2. This will damage 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 values of TM1 screw terminals.
8. Use high temperature wire near resistor elements such as SRML.
9. Terminals SP2-SP5 are multi-function terminals which can be defined to use preferences.
10. All coils are to have suppressors.
11. Specify part number D61531 for 24VAC control voltage.
12. Terminations to inverter must be made with either listed
field wiring lug kits or listed crimp type ring terminals.
5. Built in brake unit not provided on units CC-211- or CC4110 and larger. Connect braking unit and resistors as shown.
Consult factory for details.
6. See page 15 section 3.5 on required motor thermal overload relay. NEC requires thermal overload protection for motor branch circuits.
13. Ground fault protection is standard on start only. Optional Ground Fault protection
while running is shown.

3.2 Typical Hoist
interconnection
diagram. (Some devices are optional and may not be required in all cases)
Fig. 3.2
of inverter's control wiring or terminal ACN of D61530 120V isolator.
4. MC use is optional depending upon application, if not used: wire motor overload contacts in series with terminal 4 common
3. Do not connect wiper of frequency command potentiometer to terminal 12 or 14 of TM2. This will damage the inverter.
NOTE:2. Use jumper to short PIN1 and PIN2 when CON12 is not used.
WARNING: Wiring diagrams differ per application.
Please consult system wiring diagrams or Drivecon Corporation.
Insure wiring conforms with all applicable industry and safety standards.
Please refer to Appendix E of this manual for
'B' size drawings of Fig. 3.2. Also provided
is a 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 terminals.
8. Use high temperature wire near resistor elements such as SRML.
9. Terminals SP2-SP5 are multi-function terminals which can be defined to use preferences.
10. All coils are to have suppressors.
11. Specify part number D61531 for 24VAC control voltage.
12. Terminations to inverter must be made with either listed
field wiring lug kits or listed crimp type ring terminals.
5. Built in brake unit not provided on units CC-211- or CC4110 and larger. Connect braking unit and resistors as shown.
Consult factory for details.
6. See page 15 section 3.5 on required motor thermal overload relay. NEC requires thermal overload protection for motor branch circuits.
13. Ground fault protection is standard on start only. Optional Ground Fault protection
while running is shown.

13
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.
CA TION: DO OT connect power source to inverter output terminal (T1, T2, T3) otherwise the
unit will be damaged.
EVER 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.)

14
Fig. 3.4a Grounding o Multiple inverters.
Good Good Bad
3.4 Grounding
Connect positive earth ground using terminal E on the Main Circuit terminal (TM1).
CAUTION: Ground wire size should be in accordance with NEC regulations or at least 14 AWG minimum. The lead
length should be kept as short as possible.
NOTE: Ground resistance to building earth should be below 100 ohm. Provide extra ground collector shoe i unsure
o ground on crane itsel .
NOTE: NEVER ground inverter along with welding machines, large current motors....etc.
NOTE: Where several inverter units are used together all o them should be directly grounded to a common point.
Please ollow the grounding instructions shown in Fig. 3.4.
WARNING: Never ground or connect terminal N o inverter to neutral.
Table 3.3b CC-4XX Series
Inverter type CC-407 CC-415 CC-422 CC-437 CC-455 CC-475 CC-4110 CC-4150 CC-4220
MCCB / fuse rating 10A 15A 20A 30A 40A 50A 75A
MC (A/B IEC rated) 100A09ND3 100A12ND3 100A18ND3 100A30ND3 100A38ND3 100A45ND3
Wire Size *1
(minimum)
TM1 14 AWG 12 AWG 10 AWG 8 AWG 4 AWG
TM2/TB1 18 AWG
Screw *2
Terminal size
TM1 (torque) M4 (16 in.-lbs) M6 (22 in.-lbs.)
TM2 (torque) M3 (7 in. - lbs.)
TB1 (torque) Wire clamp type captive screw. (10 in. - lbs.)
NOTE: *1 Use copper conductors only, minimum size listed, size ield wiring based on 75°C wire only.
*2 Use only U.L. listed ield wiring lug kits or U.L. listed ring terminals.

15
3.5 Motor Thermal Overload Relay
To prevent the motor from overheating and to adhere to UL and EC requirements, an external
thermal relay (MOL) should be mounted between the inverter output terminals (T1, T2, T3) and the
motor. (See Fig. 3.1 and 3.2)
NOTE: The thermal overload relay protection can be supplemented when using a motor with
thermal detectors embedded in the windings of the motor. TEFC fan cooled motors will overheat in
low speed operation. The use of thermal detectors in the motor is recommended when using TEFC
fan cooled motors. Thermal detectors will always provide a level of protection not possible with
conventional thermal overload relay.
NOTE: The thermal overload relay should be selected to match the motor's full load current rating.
NOTE: When multiple motors are being driven by a single inverter a separate thermal overload
relay should be provided for each motor sized to match each individual motor's full load current.
Motor thermal sensors should be wired in series.
3.6 Brake Motor Magnetic Contactor
Inverter generates a variable voltage output. For this reason, when using a brake motor with in-
verter, the brake power supply must be connected directly to the AC line power through a suitable
brake contactor (re: 100A09 D3)...DO OT connect to inverter output. This branch circuit should
be fused in accordance with EC regulations. The coil of the brake contactor should be connected
to the running relay output provided on the D61530 at terminals RLA, RLB, RLC. See page 11 and
12 or specific wiring diagrams.
NOTE: A suitable surge absorber is strongly recommended to be installed on line side of the brake
contactor to prevent transient voltage surge when the brake contactor is de-energized the brake
contactor coil should also be suppressed.
For single or three phase AC coil brakes, please use R-C supressor such as Drivecon number
KVFCC-3.
For DC coil brakes, please use diode type supressor.
See page 13 for connection details.
3.7 Special Cautions on Wiring
CA TION: DO OT connect AC power source to inverter output terminal (T1, T2, T3). This will
seriously damage the unit.
CA TION: DO OT install magnetic contactor (MC) between the inverter output terminal and
motor. Closing of such unit while inverter is in run mode will result in large transient current to
damage the unit or lead inverter to trip. Consult Drivecon if such a contactor is required.
CA TION: DO OT install power factor correction capacitor between inverter output terminal
(T1, T2, T3) and motor.
CA TION: DO OT megger the motor leads while inverter is connected to motor. The semicon-
ductor output module (TRM) will be destroyed by high test voltage.
CA TION: Source KVA must be limited to < 500 KVA to protect against premature rectifier
assembly

16
failure. If Source KVA exceeds 500 KVA, then installation of appropriate reactor is required. If
multiple inverters are used, installation of individual reactors is required - one reactor capable of
combined amperage is not recommended. (see Table 3.7) Drivecon also recommends the use of
line reactors in retrofit installations when the Crane Commander is driving an older vintage wound
rotor motor or EMA design D motor. Please consult Drivecon if any questions exist.
CA TION: DO OT connect output of inverter through bare copper wire, enclosed collectors or
any other sliding conductor system. It is recommended that festoon is used between motor and
inverter. Size festoon according to EC standards based on inverter ampacity.
Table 3.7a Speci ication o reactor or constant torque use, 5% impedance *
Inverter Type Current (Amps) Inductance (mH) Heat Loss (W) Drivecon Model #
CC-204 3 7.4 11 KLR3ATB
CC-207 4 5.5 11 KLR4ATB
CC-215 8 3.7 38 KLR8ATB
CC-222 12 1.8 44 KLR12ATB
CC-237 16 1.4 44 KLR16ATB
CC-255 25 0.88 94 KLR25ATB
CC-275 35 0.63 112 KLR35ATB
CC-2110 55 0.4 138 KLR55ATB
CC-2150 80 0.28 206 KLR80ATB
CC-2220 110 0.2 338 KLR110ATB
CC-404 2 18.3 12 KLR2CTB
CC-407 3 12.2 12 KLR2CTB
CC-415 4 9.2 12 KLR4CTB
CC-422 6 6.1 23 KLR6CTB
CC-437 8 4.6 75 KLR8CTB
CC-455 12 3.1 88 KLR12CTB
CC-475 16 2.3 88 KLR16CTB
CC-4110 25 1.5 118 KLR25CTB
CC-4150 35 1.1 130 KLR35CTB
CC-4220 55 0.82 162 KLR55CTB
* Use 5% impedence for maximum benefit and inverter protection.
Figure 3.7