Drivecon Crane Commander ES Series User manual

rev. 11-13-02
cces-man.p65
Crane CommanderTM ES Series AC Drives
for Cranes and Hoists
InstructionManual

Table of Contents
Foreward 1
Examination before installation and purchase history 2
Chapter 1 Safety Precautions
1.1 Precautions of operation 3
1.2 Environmental precautions 6
Chapter 2 Hardware Instruction and Installation
2.1 Operation Environment 7
2.2 Sample model number identification 8
2.3 Specifications of CCES models 9
2.4 Wiring the inverter 10
2.5 Dimensions & location of terminal block 17
Chapter 3 Software Index
3.1 Keypad operating instructions 21
3.2 Parameter list 22
3.3 Parameter function description 24
3.4 Malfunction indication and countermeasure 35
3.5 General malfunction examination method 38
Chapter 4 Troubleshooting procedures
4.1 Troubleshooting Flow chart 39
4.2 Maintenance and examination 47
4.3 Voltage and current measurement 48
4.4 EMI filter, Din rail specification, and
Input AC reactor selection 49
4.5 Specifications of Braking Resistor 50
4.6 Field parameter table 51
Addendum 1: D61538 / D61539 isolator 54
Addendum 2: 11" x 17" drawings
i

1. Foreward
To fully employ all functions of the inverter, and to ensure the safety of users, please read
through this operating manual in detail. Should you have any further inquiry, please feel free
to contact your local distributor or Drivecon at 1-800-374-8266 toll free or 847--855-9150. Our
staff will be glad to serve whatever your need.
Precaution
Inverter is a power electronic device. For safety reason, please note paragraphs with
"WARNING" or "CAUTION" heading.
WARNING!: Personal injury may result with improper operation.
CAUTION!: The inverter or mechanical system may be damaged by improper
operation.
WARNING!
• Do not touch the PCB or components on the PCB while power is on or immediately
after turning off the power.
Wait for the charging indicator light to extinguish.
• Do not attempt to wire circuitry while power is on. Do not attempt to examine the
components and signals on the PCB while the inverter is running.
• Do not attempt to disassemble or modify internal circuitry, wiring, or components of the
inverter.
• The grounding terminal of the inverter must be grounded properly according to local
codes or NEC standards.
CAUTION!
• Do not attempt to conduct dielectric strength test to internal components of the inverter.
There are sensitive semiconductor devices vulnerable to high voltage in the inverter.
• Do not connect the output terminals T1(U), T2(V), T3(W) to AC line power.
• The CMOS IC on the primary PCB of the inverter is vulnerable to static discharge.
Do not touch the primary PCB of the inverter. If removal is required, follow
recommended guidelines for static discharge control.
1

2. Examination before installation and purchase history
Every Drivecon inverter has been fully tested and examined before shipment. Please carry
out the following examination procedure after unpacking your inverter.
• Verify that the inverter model number is the same as the one you ordered.
• Check to see if there is any damage that may have occured during transit. Do not
connect the inverter to the power supply if there is any sign of damage.
Report to regional sales representative or Driveconif you find any abnormal
conditions as mentioned above.
Caution! Failure to inspect the inverter may lead to damage of the system and avoidable
down time. Should you find any reason to suspect the unit itself or any aspects
of the system to be faulty please contact Drivecontoll free at 800-374-8266 or
847-855-9150.
Be prepared to provide model number of your controller and any other pertinant
information relative to the system.
Purchase history
Please take a moment and record the following information for future reference:
Model: _______________________
Serial number: _______________________
Date purchased: _______________________
Date installed: _______________________
Installed by: _______________________
Dealer: _______________________
2

Chapter 1: Safety Precautions
1.1 Precautions of operation
Before turning ON power
CAUTION!
• Choose appropriate power source with correct voltage setting as the input voltage
specification of the inverter. Check line voltage phase to phase and phase to ground
for compliance.
WARNING!
• Special care must be taken while wiring the power circuit. The L1, L2 (and L3) terminal
must be connected to input power source and must not be connected to T1, T2, or T3
terminal by mistake. This will damage the inverter when the power is turned on.
CAUTION!
• Do not attempt to transport the inverter by the front cover. Securely hold the inverter by
the chassis to prevent the inverter from falling.
• Install the inverter onto firm metal base or other nonflammable material. Do not install
the inverter nearby any flammable material to avoid fire.
• Additional ventilation fan should be installed if several inverters are installed into one
control panel to lower the temperature inside to below 40°C to avoid overheating.
• Turn off power supply before proceeding removal or installation of operating panel.
Carry out installation procedure according to instructions given to avoid poor-contact
resulting in operating panel malfunction or display malfunction.
• The inverter can be easily operated over a wide speed range. Please reconfirm the
operating range of motor and machinery with respective manufacturers.
• Do not examine the signals on the PCB of the inverter when it is under operation.
• All inverters have been adjusted properly at the factory. If adjustment is required
consult manual and do not exceed normal operating values.
• Do not disassemble or examine before ensuring that the power is off and the charge
indicator (LED2) has been extinguished.
• Insure that all fail safe equipment on machine is operating correctly such as: limit
switches, brakes, etc.
3

When power is turned ON
WARNING!
• Do not attempt to install or remove the control panel connector to or from the inverter
when the power supply is turned on. Otherwise, the control panel may be damaged
due to surge peak caused by the insertion or removal.
Under Operation
WARNING!
• Do not switch motor ON with output side contactor while inverter is operating, otherwise
the inverter may be damaged.
• Do not remove the front cover of the inverter while the power is ON to avoid personal
injury caused by electrical shock.
• When the automatic restart function is enabled, the motor machinery will be restarted
automatically. Keep a safe distance to avoid personal injury. It is not advisable to
enable this function on any manually operated system.
• Do not use input contactor to cycle inverter ON and OFF. Repeated cycling may cause
inverter damage.
CAUTION!
• Do not touch the heatsink base.
• The inverter can be easily operated from a low-speed to high-speed range. Please
reconfirm the operating range of the motor and the machinery you are controlling with
their respective manufacturers.
• Do not examine the signals of the PCB of the inverter when it is under operation.
• All inverters are properly adjusted and set by the factory prior to delivery. However,
every system may require minor adjustments to be complete at time of installation.
Do not exceed the specified limits of the equipment or inverter.
• Do not proceed with disassembly or examination procedure before ensuring that the
power is off and the Power LED extinguished.
• Dangerous voltages are stored within the inverter for up to 2 minutes after removal of
line power.
• Use caution when operating from the direct keypad mode as safety travel limits will not
function.
• Do not suspend or handle loads directly over people. Refer to ANSI B30.16 as to safe
crane operating procedures.
4

5
During examination and maintenance
CAUTION!
• Inverter environment should be within -10°C and +40°C, humidity should be under 95%
RH non-condensing.
CAUTION!
• If operating without enclosure (chassis mount), the environment temperature should be
within -10°C and +50°C and the humidity should be under 95% RH non-condensing.
Also, the surrounding environment should be free from moisture or metal dust.
Typically the inverter requires no special maintenance. However, Drivecon suggests inspec-
tion of the inverter with special attention to loose wiring connections. Excessive accumulation
of dust or dirt will also shorten the expected life of the inverter. Periodic cleaning of the in-
verter with dry compressed air may be required.
WARNING!
• Insure power supply is switched OFF and the LED charge indicator has extinguished
prior to inspection or maintenance of inverter. Lock out all equipment under repair or
inspection.

1.2 Precautions of operation environment
Avoid direct sunlight
Keep away from corrosive gas or liquid
Keep away from oil, grease, and petroleum products
Avoid exposure to rain or dripping water
Avoid metal dust and dusty environments
Avoid areas of high vibration
Avoid extreme heat
Keep away from high electrical-magnetic wave or ultra-high wave. (such as electro-
soldering machine or other similar machinery)
Keep away from radioactive matter or environments
Keep away from flammable material
Keep surrounding area between -10 ~ +40°C for enclosed units or -10 ~ +50°C
for chassis type units
The choice of environments will directly influence the service life of the inverter. Please pro-
vide a suitable location.
6

7
Chapter 2: Hardware Instructions and Installation
2.1 Operating Environment
The installation site of the inverter poses direct impact to the full functionality and life expect-
ancy of your inverter. Please carefully choose an appropriate installation site based on the
following criteria:
• Environment temperature: -10°C to +40°C enclosed
without external casing: -10°C to +50°C chassis mount
• Avoid water dripping or humid environment
• Avoid direct sunlight
• Avoid oil atmospheres
• Avoid corrosive liquid or gas
• Prevent foreign dusts or metal scraps from entering interior
• Keep away from radioactive matter or flammable material
• Avoid electromagnetic interference (soldering or power machinery)
• Avoid vibration. If vibration can not be avoided, shock absorber should be installed to
reduce vibration.
• If there are several inverters installed in the same control panel, additional cooling fans
should be installed to lower the environment below 40°C for enclosed units. 50°C for
chassis mount units.
• Inverter should be installed facing forward and upright.
• Inverter must be installed as to leave room on all sides for proper heat dissipation. If
installed in an enclosure, the dust cover may be removed for better heat dissipation.
See diagram above. Remove dust cover to convert
from NEMA1 to chassis mount.

8
CCES- 2 - 07 - x - x - x
Series Voltage HP Power Supply Filter Enclosure
1: 110V 02: .25HP 1: 1 phase F: filter N4S: IP65/NEMA4
with switch
2: 220V 04: 1/2HP 3: 3 phase Blank: no filter N4: IP65/NEMA4
4: 440V 07: 1 HP Blank: 1 or 3 phase without switch
15: 2 HP
Blank: IP20-NEMA1
22: 3 HP
2.2 Sample Model No. Identification
Inverter model: CCES-207-xxx
Input power rating: AC, 1 ph 200~240V, 50/60 Hz
Output rating: AC, 3 ph 0~240V, 1HP, 4.2 Amps
Correct spacing of inverter relative to surroundings.
Ventilation and Installation
Direction
Front View
Ventilation and Installation
Direction
Front View

9
2.3 Specifications of CCES models
Inverter model CCES-
102
CCES-
104
CCES-
202
CCES-
204
CCES-
207
CCES-
215
CCES-
222
CCES-
407
CCES-
415
CCES-
422
Applicable Motor Output (KW) 0.2 0.4 0.2 0.4 0.75 1.5 2.2 0.75 1.5 2.2
Rated Horsepower (HP) 1/4 1/2 1/4 1/2 1 2 3 1 2 3
Rated Current (A) 1.4 2.3 1.4 2.3 4.2 7.5 10.5 2.3 3.8 5.2
Rated Capacity (KVA) 0.53 0.88 0.53 0.88 1.6 2.9 4 1.7 2.9 4
Weight (Lbs.) 1.5 1.5 1.7 1.7 1.8 3.7 3.9 3.5 3.5 3.6
Input Max. Voltage
Signal phase
100~120V (+10%, -
15%), 50/60 Hz
(+/-5%)
Single phase 200~240V *
(10%, -15%), 50/60 Hz (+/-5%)
Single or three phase
200~240V *
(+10%, -15%), 50/60
Hz (+/-5%)
3 phase 380~460V (+10%, -15%),
50/60 Hz (+/-5%)
Output Max. Voltage
3 phase 200~240V in
accordance with 2
times input
3 phase 200~240V in accordance with input 3 phase 380~480V
in accordance with input
Input signal state PNP type (source) input 12VDC provided; 120VAC with D61538 isolator; 24V with D61539 isolator standard.
Control Method Sinusoidal wave PWM contol
Frequency
control
Frequency control range 1~200Hz
Frequency setting
resolution
Digital: 0.01Hz (0~99.9Hz); 1Hz (100~200Hz)
Analog: 1.0Hz / 60 Hz
Keypad setting method Directly via up and down arrow keys for adjustment.
Frequency setting signal 1-3 preset speeds. Analog 0~10V, 0~20mA, 4-20mA, 2 step and 3 step infinitely variable.
Frequency limit Frequency upper / lower limit
Control
characteristics
Accel / Decel time 0.1~30 Seconds
V/F pattern 4 patterns for 50 or 60 Hz motors
Multifunction inputs 2 programmable inputs of the following : Ramp and hold,
Speed 2 and Speed 3 command, Emergency Stop, External base block, Reset command, Creep, Top Limit
Multifunction outputs 1 NO output contact of the following : fault, running output, frequency arrival, at current detect, at frequency detect.
Braking torque 20% standard. 100% with optional DB unit and resistor. 20% standard, 100% with external resistor
Built-in Function Deceleration or Free run to stop, Auto reset, DC injection frequency / time / level select. Analog 0-10VDC frequency
output.
Digital operator monitor 3-digit 7 segment display frequency / functi on constants / fault history / CPU version
Ambient temperature -10 ~ 40°C with cover. -10~50°C Chassis
Humidity 0 ~ 95% RH (non-condensing)
Vibration Under 0.5G
EMC Unfiltered Class A (Filter built-in) optional Class A (3 phases. Filter built-in)
optional
Enclosure Protected chassis, IP20
UL UL 508
Protective
Functions
Overload 150% 1 minute
Overvoltage DC bus exceeds 410V DC bus exceeds 800V
Undervoltage DC bus drop below 200V DC bus drop below 400V
Momentary power loss Ride through 0~2 seconds, depending on load.
Stall prevention During Acceleration / Deceleration / Constant speed
Output short circuit Provided by electronic circuit
Ground fault Provided by electronic circuit
Other protection Heat sink fin overheat, current limi t
Dimension (inches) H x W x D 5.2" x 2.8" x 4.6" 5.2" x 2.8" x 4.6" 5.63" x 4.65" x 6.8" 5.63" x 4.65" x 6.8"
Mounting Dimension (inches) H x W 4.6" x 2.4" 4.6" x 2.4" 5.01" x 4.25" 5.01" x 4.25"
Installation Panel mounted or usi ng DIN rail (Option)
* Single phase drives may be connected to three phase AC line voltages by connecting terminal L1/L to phase
A, L2/N to phase B and leave phase C disconnected and insulated. You may wish to rotate the phases in areas
where there are many single phase drives.

10
2.4 Wiring Inverter
Suitable options and Wiring Specification
Molded-Case Circuit Breaker or fuse selection / Magnetic Contactor
Warranty does not apply to da age caused by the following situations:
(1) Damage to the inverter caused by the lack of appropriate moded-case circuit breaker or
fuses or when a circuit breaker or fuse with too large of capacity is installed between
the power supply and the inverter. See chart below.
( ) Damage to the inverter caused by the magnetic contactor, phase advancing capacitor,
or surge-protector installed between the inverter and the motor.
(3) Connecting line voltage to T1, T , T3 output.
Use copper conductors only. Size field wiring based on 75°C wire only.
CAUTION!
 Please utilize three-phase squirrel-cage induction otor with appropriate
capacity.
 If a inverter is used to drive ore than one otor, the total capacity ust be
s aller than the capacity of the inverter. Additional ther al relay ust be in
stalled in series with every otor. Set F_18 at 1.0 ti es of the rated value
specified on the otor na e plate at 50 Hz, 1.1 ti es of the rated value specified
on the otor na eplate at 60 Hz.
 Do not install phase advancing capacitor, LC, or RC co ponent between the
inverter and the otor.
 Use copper conductors only. Size field wiring based on 75°C wire only.
 Wire voltage rating ust be a ini u of 300V for 230VAC syste s and 600V for
460VAC syste s.
 Control wire should not run in sa e conduit as power or otor wiring.
 Follow NEC article 610 guidelines for installation of inverter.
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11
Application and precautions of Peripherals
Connection of single phase drives: You may connect a single phase input drive to 3 phase
power by connecting terminal L1/L to phase A, L2/N to phase B and insulate phase C.
From the Power Source: Apply the power source at the correct rated voltage to prevent from
damaging the inverter. Branch circuit protection (reference NEC article 610) must be installed
between the AC power supply and the inverter.
Molded-case circuit breaker and / or time delay fuses: Utilize an appropriate circuit
breaker that's suitable for the rated voltage and current ratings of the inverter to switch ON/
OFF the power supply to the inverter and as additional protection for the inverter.
Leakage circuit breaker: An earth leakage circuit breaker should be added to prevent false
operation caused by leakage current and to ensure personnel safety.
Magnetic contactor: A magnetic contactor on line side of inverter can normally be omitted in
lieu of a crane mainline contactor. To utilize external DB braking resistors the magnetic
contactor or mainline must be installed on the primary side of the inverter with DB overload
wired in series. The magnetic contactor is only a fault isolation means. Do not use the mag-
netic contactor to switch power ON or OFF the inverter in a repititious fashion. Constant
power cycling to inverter may damage the inverter. If the inverter is installed in a retrofit where
existing reversing contactors are still maintained, insure the inverter is connected to a con-
stant source of power.
Load side contactors or conductors: Any type of load side switch or load side sliding
conductors are strictly forbidden. The intermittent connection of the load will damage the
inverter.
Power feed conductors: Always use a high quality conductor bar system with tandem shoe
collectors. Avoid brass wheel pickups or open span wire systems. Poor input power conduc-
tion will be sure to cause intermittent operation and possible damage to the inverter.
Brake contactor: Select the proper contactor wired to primary of inverter to control motor
brake. Drivecon recommends the addition of a 3 phase AC suppressor across all brake
contactors.
Power improvement AC Reactor: If large capacity source is applied (over 500KVA) addi-
tional AC reactor may be added to improve power factor and reduce likelihood of damage to
inverter.
Inverter: Power supply input terminals L1, L2 and (L3) are not differentiated on phase se-
quence. They can be arbitrarily connected. Their connection may be interchanged.
Output terminal T1, T2, and T3 should be connected to T1, T2, and T3 terminals of motor
respectively. If motor turns in opposite direction of the inverter command, simply exchanging
two of the three wire connections will correct this problem.
Conductor length between drive and motor: Excessive wire length between drive and
motor can cause premature insulation failure of motor. Substantial voltage spikes can be
measured at the motor terminals with as little as 30 feet of distance between the motor and
VFD. Drivecon recommends the use of our OLF filter or inverter duty motors with 1600V
magnet wire.
CAUTION:
• Output terminal T1, T2, and T3 must not be connected to power source to prevent from
damaging the inverter.
Grounding terminal. Properly ground the grounding terminal in compliance with NEC or local
codes. Under most circumstances and extra 4th conductor rail is not required but highly recom-
mended for personal safety. External wiring should be carried out in accordance with the follow-
ing requirement. Check and reassure the wiring is correct after the wiring is complete.

1
EMI connections:
It is very important that the connections between the inverter, the shielded motor cable, and
the EMI filters are tested as follows.
Use a metal grounding plate and place the frequency inverter and the EMI filter on the plate.
Use a shielded motor cable with 4 connectors (U, V, W, and Earth). Don't use the shielding as
safety earth (shield is high frequency earth)
Remove any paint around the two metal coupling nut holes so that the metal coupling nuts
(and the shielding) make contact with the frequency inverter and the motor.
Don't solder a conductor to the shielding.
Use a metal clamp to connect the shielding from the motor cable with the metal grounding
plate. Now there is a perfect high frequency earth connection between frequency inverter,
grounding plate, and EMI filter.
Keep the distance between the frequency inverter and the EMI filter as short as possible
(<30cm). If longer, use a shielded cable with a metal coupling nut and a metal clamp to con-
nect the shielded cable to the frequency inverter and metal grounding plate.
The only earth connection between the line and the test plate should be via the EMI filter. Use
a motor which equals the power rating or below of the inverter rating. Install a noise filter for
inverter onto the output side of the primary circuitry can suppress conducting noise.
'ULYH
'ULYH
Class B:
Class A:

13
When the distance between the inverter and the motor is longer than 100 meters, cable wires
should be carefully chosen to reduce the voltage loss due to wire resistance below 3%.
Voltage drop (V) = √3x Wire resistance (ohm/m) x wire length (m) x current.
(B) Control circuitry wiring must be separated, terminated, and away from the primary
power circuitry and other high-voltage or large-current power lines to avoid noise interference.
To reduce the noise interference and avoid possible operational problems, shielded twisted
pair cable should be used to wire the low voltage DC control circuitry. Please refer to the
following diagram. Connect the shielding wire onto the grounding terminal. Only connect one
end of the shield to ground.
(C) The grounding terminal of the inverter must be correctly grounded in compliance with
local codes or NEC requirements.
Grounding wire should be wired in accordance to electrical equipment (AWG) with the length
of the grounding wire as short as possible.
The grounding wire of the inverter must be grounded together with other large current loads
(such as soldering machines or large current motors). They should be grounded separately.
(D) Wire specification, apply appropriate wire with correct diameter for primary power
circuitry and control circuitry in accordance with electricity regulations.
Wiring distance must be under 50m.
To inverter terminal
Connnect Shield
Connect to system grounding terminal Wrapped with
insulating tape
Do not connect the shielding
wire at this end
To control machine
Insulation
Shielding
(a) good (b) good (c) not good

16
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Pri ary Circuitry Ter inal Block
(TM1) descriptions
Tightening torque for TM1 is 1 lb.-ft. or 12
lbs.in. (CCES-102, 104, 202, 204, 207)
Tightening torque for TM1 is 1.3 lb.-ft. or
1 lbs.in. (CCES-215, 222, 407, 415, 422)
* Wire voltage rating must be a minimum
of 300V (200V series) / 00V (400V
series)
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Control Circuitry Ter inal Block
(TM2) description:
Tightening torque for TM2 and TB1 is 0.42 lb.-ft. or 5.03 lbs.in.
* Wire voltage rating must be a minimum of 300V.
* Control wiring should not run in the same conduit or raceway with
power or motor wiring.
* Single input and Output Terminals (TM2) Ratings are ALL Class 2.
Inverter ter inal descriptions:
L1
(L)
CCES215, CCES222
CCES407, CCES415
CCES422
TB1
D61538 /
D61539
120V control
TM1 (power) L2
(N) T1 T2 T3
L1
CCES102, CCES104
CCES202, CCES204
CCES207
TM1 (power) L2 L3 P R T1 T2 T3
All models
12345678910 11
Trip relay Trip relay FWD REV +12V SP1 RESET +10V Vin 0V FM+
RA RC F R 2ND 3RD N P10 Vin 0V FM
All models
TM2
(low voltage
control)
Drive ter inal strip layouts
1234567891011

17
Models
CCES10
CCES104
CCES 0
CCES 04
CCES 07
2.5 Di ensions and location of ter inal block
Switch 1 External signal type
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SW1 function description
I
V

18
Di ensions and installation of class B filter
Models
CCES 15
CCES
CCES407
CCES415
CCES4