STEPLESS CONTROL & VARIABLE

FREQUENCY DRIVES
Variable Frequency Drives (VFD) have become the motor speed control of choice for
many users of Overhead Cranes. For both new cranes and for upgrades of existing
equipment, VFD’s are frequently specified rather than the older Magnetic Contactor
Panels or Static Stepless Controls. The motor speed control is the interface between the
operator (using cab control, hard-wired pendant or remote control) and the crane motors
(bridge, trolley, and hoist).

VFD’s offer lower maintenance costs by utilizing solid state electronics, rather than a
series of contacts. The contacts in the older style panels are subject to wear through
arcing and can weld shut.

In addition to the maintenance benefits, VFD’s have the capacity to provide stepless,
proportional speed control. Unlike the other systems which gave the operators a preset
group of speed steps (typically 2, 3 or 5 speeds), VFD’s can potentially provide a smooth
speed range, in which the speed of the crane motion is directly proportional to the
amount of pressure applied to the control switch. A VFD controls the speed of an AC
electric motor by supplying the motor with pulsed current of variable frequency. The
pulsed current allows the motor to turn at a proportional range of speeds, rather than a
limited number of “steps” such as 2-speed or 3-speed.

Proportional speed control is important to the operator of Overhead Cranes because it

can give them better control of the load. Through improved control of acceleration, an
operator can decrease the amount of load swing and improve positioning. Enhanced
control and improved load positioning can directly improve productivity and enhance
workplace safety.

In order to utilize the smooth range of speeds a VFD can produce, the operator control
must supply a proportional range of voltages to the VFD. Hard-Wired Pendants do not
provide this interface. Telemotive Industrial Controls has introduced its SCS (Stepless
Control System) to provide the necessary interface. The operator uses a wireless
Pendant Style or Belly Box Transmitter in which the pressure applied to a button or lever
is converted to a DC output voltage for the VFD. Traditional crane controls, both wired
and wireless, control relay closures that allow for only “stepped” speed control.

Standard “Stepped” Controls require individual relay contacts for each speed. The SCS
design allows for just one set of relays to control the speed of each crane motion. With
fewer relays and circuit boards, the SCS radio remote controls are actually less
expensive than their traditional stepped counterparts. Crane operators who are utilizing
VFD’s can upgrade to the benefits of proportional, stepless control, in many cases at a
lower cost than an equivalent stepped control.

PO Box 13615 N49 W13650 Campbell Drive www.telemotive.com

Milwaukee, WI 53213 Menomonee Falls, WI 53051
Phone: 800-288-8178
Fax: 800-298-3503
 Another consideration in the control interface of the VFD is the capability to switch
between Radio and Hard-Wired Pendant Control. Some VFD’s are equipped with dual
inputs, which accept both the DC analog voltages of the SCS radio control and the
digital signal from the hard-wired pendant. For the VFD’s that do not have dual inputs,
the SCS radio control can be equipped with an optional Electronic Transfer Switch.
When the radio remote control is turned off, this transfer switch accepts the digital signal
from the hard-wired pendant and converts the signal to the analog voltage required by
the VFD.

As Variable Frequency Drives are specified to reduce maintenance costs, operator

controls should also be evaluated. The capability exists to improve productivity and
enhance safety by utilizing the proportional speed control that the VFD can provide. In
order to use this functionality, the operator control system must be able to provide
stepless rather than stepped control. The Telemotive SCS Radio Remote Control is
designed to interface with VFD’s in this manner.

PO Box 13615 N49 W13650 Campbell Drive www.telemotive.com

Milwaukee, WI 53213 Menomonee Falls, WI 53051
Phone: 800-288-8178
Fax: 800-298-3503